JP2017224063A - Plant controller testing device and testing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To increase the efficiency of logic test and reduce the cost of a testing device.SOLUTION: In order to achieve the above objective, a test data storage unit has the function to store input signal data for test that is inputted to a digital controller before an update and output signal data for comparison that is outputted by the digital controller before an update, the input signal data for test and the output signal data for comparison being the one that was used by the digital controller before an update for control of an actual power generation plant. An emulator unit has the function to cause software logic to be tested that is the digital controller after an update to be stored and actuated, latch the input signal data for test and give it to the software logic to be tested, and output the processing result of the software logic to be tested, as output signal data to be tested. A comparison unit has the function to compare the output signal data for comparison and the output signal data to be tested, and determine the validity of the software logic to be tested.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a test apparatus and a test method for a plant control apparatus, and more particularly to a test apparatus for a plant control apparatus suitable for improving the efficiency of a soft logic test for a new control apparatus performed when a digital control apparatus for a power plant is updated. And a test method.

  A digital control device (hereinafter referred to as a control device) used for plant control of a power plant or the like takes an operation amount signal of an apparatus operated by an operator or a signal from a sensor that detects a process to be controlled as an input signal, and the control device The control logic (hereinafter referred to as soft logic) incorporated in the computer performs arithmetic processing and outputs a control command (hereinafter referred to as output signal) to the controlled device.

  Such a control device is updated when the service life is exceeded or production is discontinued. However, since the update interval of the control device is a long time of around a dozen years, the control device and system of a different model are usually adopted in the control device before and after the update, and the same software is used after the update. I can't use logic. Therefore, in order to confirm that the operation of the control device does not change before and after the update, a soft logic test (hereinafter referred to as a logic test) is performed to confirm the soundness of the new soft logic.

  The logic test includes a method that uses a simulator or an emulator that simulates the operation of the actual machine, in addition to a method that is executed by the updated control device itself (hereinafter, actual machine). If these are used, the logic test can be performed at the completion stage of the software design even if the actual machine is not manufactured.

  As a logic test method and test apparatus that does not require an actual machine, for example, as described in Japanese Patent Application Laid-Open No. 2013-168038, a pre-update soft logic (hereinafter referred to as an input signal pattern that is set in advance by an emulator) is used. , Old logic) and updated soft logic (hereinafter referred to as new logic) and automatically comparing the respective output signals to improve the efficiency of the logic test.

JP 2013-168038 A

In the logic test, a test input signal is given to each input point of the soft logic, and the processing result of the soft logic for the input is verified. Here, in the power plant control device, the input / output signals are several thousand points or more, and in the logic test, the efficiency of the test signal input work and the output signal verification work is required. In the technology, since the logic test is performed using both the old logic and the new logic, the operation of the old logic and the new logic for the same input signal can be automatically compared and the malfunction of the new logic can be automatically detected. Since an emulator for the control device is required, the cost of the test device increases. That is, when a logic test is performed with a simulator or an emulator, an apparatus is required only for the test, unlike when a test is performed with an actual product as a product.
In addition, since the old logic and the new logic to be compared do not necessarily have a one-to-one relationship, there is a possibility that extra manual work may occur and the test may become complicated. This is because in the control of power plants, a distributed control system that controls various systems of the plant with several to a dozen or more control devices is the mainstream. This is because aggregation is performed and the way of assigning signals to the control devices may be changed. In such a case, multiple old logics are required for testing one new logic, so manual logic switching and signal assignment changes occur, resulting in work mistakes such as test omissions and increased test man-hours. There is a risk of being connected.

  An object of the present invention is to provide a test apparatus and a test method for a plant control apparatus that can solve the above-described problems and can achieve both efficiency of a logic test and cost reduction of the test apparatus.

  In order to achieve the above object, the present invention is used for a soft logic test in updating a digital control device for a power plant, comprising a test data storage unit, an emulator unit, and a comparison unit, The test data storage unit has a function of storing the test input signal data input to the digital control device before the update and the comparison output signal data output from the digital control device before the update. The input signal data and the output signal data for comparison are those in which the digital controller before the update is used for controlling the actual power generation plant, and the emulator unit includes the soft logic to be tested which is the digital controller after the update. Store / operate, capture the input signal data for the test, and apply it to the soft logic under test to process the soft logic under test A function of outputting results as test target output signal data, and the comparison unit compares the comparison output signal data with the test target output signal data to determine the validity of the test target soft logic It comprised so that it might have.

  Specifically, this is a test device used for a logic test of a plant control device, and this personal computer (hereinafter, PC) type device includes all control devices being tested and in operation in a plant, including a control device to be updated. A test data storage unit that reads input / output signal data related to the corresponding control device from a plant data recording device that records input / output signals at the device, a soft logic storage unit that stores the soft logic to be tested, and a soft logic An emulator unit that reads input signal data stored in the test data storage unit, and the emulator unit receives an output signal that is a result of processing the read input signal, and imports it from the test data storage unit Compared with the output signal data, a comparison unit for determining the validity of the output signal to be tested is provided.

  According to the present invention, it is possible to achieve both efficiency improvement of the logic test and cost reduction of the test apparatus.

Overall configuration of test apparatus and related elements in the present invention Supplementary diagram of plant data recording device Supplementary diagram of soft logic diagram Logic test flow Output example to display unit 14

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1 shows a logic test apparatus 1 used for a logic test of a plant digital control apparatus, an update target control apparatus 2, a control target plant 3, and plant input / output signal data according to an embodiment of the present invention. This is an example of the overall configuration in which the plant data recording device 4 for recording and the external recording medium 5 are shown together.

  First, the control device 2, the plant 3, and the plant data recording device 4 will be described. Here, the plant 3 refers to the entire plant excluding the control device 2 to be updated, a control target device (electric valve, pump, etc.) of the control device 2, a detector for detecting the state of the control target device, Operation devices (such as push buttons) used by operators for plant operations, indicators for displaying the status of various processes and controlled devices, and the like are included. In the update work, the currently used control device 2 (before update) is replaced with a new control device 2 (after update).

  The control device 2 captures the process signal detected by the detector of the plant 3 and the operation amount signal from the operation device into the controller 22 via the input / output device 21. These input signals are processed by the soft logic unit 221 incorporated in the controller 22, and the resulting control command to the control target device and the display command to the status indicator are sent via the input / output device 21. It is output to the plant 3. The soft logic unit 221 is a control in which logic elements such as AND and OR, storage elements such as flip-flops, operators such as adders and subtractors, and input and output elements for exchanging signals with the outside are coupled by signal lines. Logic.

  The process signal detected by the detector of the plant 3 taken into the controller 22 via the input / output device 21, the operation amount signal from the operating device, and the soft logic output to the plant 3 via the input / output device 21 The control command to the device to be controlled and the display command to the status indicator, which are the results of the calculation processing by the unit 221, are stored in the RAS data storage unit 23.

  The plant data recording device 4 is provided in the plant so as to copy the data stored in the RAS data storage unit 23 for the purpose of, for example, cause analysis in case of trouble, and an input signal recorded in the plant data recording device 4 And the output signal are the operation results of the control apparatus having the correct operating relationship with validity.

  At this time, an input signal taken into the controller 22 and a signal output from the controller 22 are recorded in the plant data recording device 4 via the network. The plant data recording device 4 is a personal computer type information processing device that records all input / output signals of the control device 2 and other control devices connected to the same network as the control device 2 at a predetermined sampling period. Used for analysis in case of trouble. The input signal and output signal data recorded in the plant data recording device 4 are respectively stored in the input signal table 41 and the output signal table 42 shown in FIG. As information included in the stored input signal and output signal, the plant data recording device 4 has an input table 41 as a signal used for actual control of the control device 2 before update, as shown in FIG. , Identification number, control device, name, signal name, signal type, generation time, input value, unit, and related signal identification number are stored in association with each other. Similarly, as an output table 42 as signals used for actual control of the control device 2 before update, an identification number, control device, name, signal name, signal type, generation time, output value, unit, relation Signal identification numbers are stored in association with each other. It is also possible to record the generation time of the input / output signal and the identification number of the related signal.

  Here, the soft logic (example) of the soft logic of the control device 2 after the update is shown in FIG. On the other hand, the control device 2 before update and the control device 2 after update are composed of different logic as soft logic, but the control functions are exactly the same. The input signal table 41 and the output signal table 42 are configured to correspond to the relationship associated with the signal lines in the soft logic (example) 6 shown in FIG.

  The related signal here is a signal associated with a signal line, such as Output1 for Input1 (or Output1, Output2 for Input1, Input2, Input3, and Input4) in the soft logic (example) 6 shown in FIG. Point to.

  These tables can refer to each other by using the identification number of the related signal as a key. Therefore, using this table, for example, calculation of response time from input signal generation to output signal generation, and related input signal and output signal Can be confirmed. The data of these input / output signals can be taken out via the external recording medium 5 or a network. The above is the outline of the control device 2, the plant 3, and the plant data recording device 4.

  Next, the logic test apparatus 1 according to the present invention will be described.

  The logic test apparatus 1 is a personal computer type information processing apparatus, and includes a test data storage unit 11, an emulator unit 12, a comparison unit 13, a display unit 14, and an input device 15.

  The test data storage unit 11 takes in the input / output signal data of the control device to be updated in an arbitrary period, recorded in the plant data recording device 4 via the external recording medium 5 or the network. The plant data recording device 4 can capture input / output signal data of a plurality of plants and control devices, and the input device 15 can be used to select input / output signal data used for a logic test.

  The emulator unit 12 has a function of storing and operating the updated soft logic (soft logic (example 6) shown in FIG. 3). Similar to the plant data recording device 4, a plurality of soft logics can be stored, and the soft logic to be tested can be selected by the input device 15.

  The comparison unit 13 has a function of reading a plurality of output signal data from the control device and comparing / determining whether they match. When performing the comparison, test conditions are set in advance, such as whether to compare the value of the output signal at a certain time, or to compare the transition of an arbitrary output signal in a certain period.

  The display unit 14 is a display that displays an operation screen of each function of the logic test apparatus 1, behavior of soft logic operating in the emulator unit 12, comparison results of the comparison unit 13, and the like.

  Next, an actual logic test flow will be described with reference to FIG.

  In S401, input / output signal data (also referred to as test input signal data) of the control device 2 to be updated is read from the plant data recording device 4 into the test data storage unit 11 in advance. That is, each input signal data of identification numbers... 001 to 006... Shown in FIG. 2 and each output signal data of identification numbers 101 to 103 shown in FIG.

  In step S402, the test target soft logic (soft logic (example) 6 shown in FIG. 3) is loaded into the emulator unit 12. The soft logic (example) 6 shown in FIG. 3 is the soft logic of the control device 2 that will be updated and will be implemented in the future. Calculate and output Output1 (313) to Output2 (314). Also, input5 (305) to Input6 (306) are logically operated by the arithmetic element 311 and further controlled by the arithmetic element 312 to output Output3 (315). To do.

  When input signal data is selected from the test data storage unit 11 in S403, an input signal is given to the emulator unit 12. At this time, by using the information on the generation time included in the input signal data, it is possible to automatically reproduce the input signal from the plant 3 generated in an arbitrary period to the control device to be updated. For example, in the example of FIG. 2, the data “input value” of identification numbers 001 to 006 actually generated (and not updated) at the generation time 2015/09/07 20:18:30 is selected. In addition, you may select and give the arbitrary signals which an operator wants to test individually.

  In S404, the input signal data is given to the emulator unit 12, and simultaneously, the output signal data of the control device 2 (also referred to as comparison output signal data) for the input signal data is given to the comparison unit 13. . For example, in the example of FIG. 2, the data “output value” of the identification numbers 101 to 103 actually generated (and not updated) at the generation time 2015/09/07 20:18:30 is selected.

  In S405, the test target soft logic executes arithmetic processing according to the input signal (data “input value” of identification numbers 001 to 006) (the execution result is also referred to as test target output signal data).

  In S406, the calculation processing result is output to the comparison unit 13. At this time, the output signal data of the emulator unit 12 is taken into the comparison unit 13 in the same format as the output signal table 42 of FIG.

  In step S <b> 407, the comparison unit 13 compares the fetched output signal data of the emulator unit 12 with the output signal data (data “output value” of the identification numbers 101 to 103) given from the test data storage unit 11.

  In S408, the comparison result is output to the display unit 14. At this time, as a display method of the comparison result, there are a method of displaying each output signal to be compared in a table format, a method of displaying and comparing a trend of an arbitrary output signal as a graph as shown in FIG. When analog signals are compared, an allowable error can be set in advance to determine and display whether the comparison result is within the error. In addition, by extracting the comparison items having different results from the comparison results and displaying them on the display unit 14, it is possible to check the error of the new control logic or the changed part.

In S409, does the emulator output signal match the plant data output signal? Judging.
If they do not match, the soft logic is corrected in S410. If they match, the flow ends.

  According to this method, since the operator can easily confirm the soundness of the new logic by looking at the result of the display unit 13, it can be expected to improve test efficiency and prevent human error. Further, since the logic test apparatus 1 can be implemented on a soft logic maintenance tool normally provided for the function of the control apparatus, it is not necessary to prepare a new test apparatus for the logic test as in the prior art.

  The above is an example of an embodiment of the present invention, but the embodiment is not necessarily limited. For example, the plant data recording device 4 may be a part of the control device 2 or the logic test device 1. Further, as means for transferring plant data from the plant data recording device 4 to the test data storage unit 11, there is a method using a wired or wireless network in addition to using the external recording medium 5. During actual operation, the most appropriate one is selected from these methods in consideration of security, specifications of component devices, and the like.

  In addition to the above-described logic test embodiment, when a test is to be performed with an arbitrary input signal not recorded in the plant recording device 4, a simulation signal is set from the input device 12 provided in the logic test device 1. It is also possible to give.

  As described above, the test data storage unit includes the control device to be updated included in the plant data which is data at the time of testing or operation of the actually operating plant as the test input signal data and the comparison output signal data. The input / output signal data is read from the operating plant control device or the dedicated plant data recording device.

  In addition, an actual plant has a function of performing a test in which a test time required according to the characteristics of each hardware device is determined faster than the actual one by increasing the calculation speed of the emulator unit.

  Moreover, the display apparatus for confirming the test result, progress, and test conditions is provided.

  The display unit has a function of receiving output signal data within a predetermined time from the plant data recording device and / or emulator unit, and displaying the trend as a graph.

  As described above, it is possible to realize a test apparatus and a test method capable of performing a logic test of a new logic performed at the time of updating a control apparatus efficiently and at low cost. The plant data recording device described above is provided in the plant for the purpose of analyzing the cause of troubles, and the input and output signals recorded in the device are already in operation. It is the operation results of the control device, and the relationship is correct. Therefore, the recorded input signal is given to the test target soft logic operated by the emulator, and the output signal of the soft logic is compared with the output signal of the update target control device recorded in the plant data recording device. You can check the soundness of the new soft logic. If this method is adopted, the test signal input operation and the output signal confirmation operation can be automated, and the emulator for the control device before the update is not required, so that the cost of the test device can be reduced. Furthermore, since the test apparatus and function of the present invention can be realized on a maintenance tool normally provided in a plant for maintenance of the control apparatus, a logic test can be performed on the maintenance tool, and a new apparatus is prepared for the test. You can also eliminate the need to do.

1 Logic test equipment
2 Control device
3 plants
4 Plant data recording device
5 External recording media
6 Control logic diagram (example)
7 Output example to display unit 14

Claims (6)

Used for soft logic testing when updating a digital control device for a power plant, comprising a test data storage unit, an emulator unit, and a comparison unit,
The test data storage unit has a function of storing test input signal data input to the digital control device before update and comparison output signal data output from the digital control device before update, The input signal data for comparison and the output signal data for comparison are those used in the control of the actual power plant by the digital controller before the update,
The emulator unit stores and operates a test target soft logic which is an updated digital control device, takes in the test input signal data, and assigns the test target soft logic to the test target soft logic. It has a function to output the processing result as test target output signal data,
The comparison unit has a function of comparing the output signal data for comparison with the output signal data to be tested to determine the validity of the soft logic to be tested.   The test apparatus for a plant control apparatus according to claim 1, wherein the test data storage unit is used as a test input signal data and a comparison output signal data when testing or operating a plant that is actually operating. A test apparatus having a function of reading input / output signal data of a control device to be updated included in plant data, which is data, from a control device of a working plant or a dedicated plant data recording device.   3. A test apparatus for a plant control apparatus according to claim 1 or 2, wherein in an actual plant, a test in which a test time required according to characteristics of each hardware device is determined, the calculation speed of the emulator unit is increased. Thus, a test apparatus for a plant control apparatus, which has a function of performing faster than actual.   The test apparatus for a plant control apparatus according to claim 3, comprising a display device for confirming a test result, an intermediate process, and test conditions.   5. The plant control apparatus testing apparatus according to claim 4, wherein the display unit receives output signal data within a predetermined time from the plant data recording device or the emulator unit, or both, and the trend is graphed. A test apparatus for a plant control apparatus having a display function. In the test data storage unit, the test input signal data input to the digital controller for the power plant before the update, and the comparison output signal output by the digital controller before the update according to the test input signal data Save the data,
Processing and processing of the test target soft logic by storing and operating the test target soft logic which is the updated digital control device in the emulator unit, capturing the input signal data for the test, and applying it to the test target soft logic The result is output as test target output signal data,
A test method for a plant control apparatus, wherein the comparison unit compares the comparison output signal data with the test target output signal data to determine the validity of the test target soft logic.

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