JP2951203B2 - Method and apparatus for creating system control program - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for creating a system control program in a factory plant system for executing a plurality of processes.

[0002]

2. Description of the Related Art In the operation of plant equipment such as a refinery, for example, continuous operation is required day and night to improve the efficiency.
Various automations have been performed. In particular, automation of control of each process during steady operation has been performed to a considerably high level, and as a result, the work of the operator has basically focused on monitoring for abnormalities during steady operation and responding to it. Is to be placed.

[0003]

In constructing a program for controlling the operation of such plant equipment,
In general, step-wise operation is performed while checking the operation of each device in the plant.Especially, there are many parameters that need to be changed for startup and shutdown of the device. It's getting very complicated. In other words, taking a refinery plant as an example, startup, shutdown,
Alternatively, the program of the driving operation at the time of switching the oil type should proceed each step according to a predetermined procedure while confirming the operation.

[0004] However, there are many types of operations for each step, and moreover, the ratio of items to be confirmed on site is large. At that time, when the condition is not satisfied, including which part should be checked, depending on the experience know-how of the veteran operator. Further, in some cases, the situation where the situation at the site is judged by the human sense is left. Therefore, in constructing a program for automating the entire operation of the plant apparatus with high reliability, it is necessary to ensure that the check mechanism including the know-how is executed while executing the check mechanism.

Further, when changing a program once assembled, it is difficult to ensure safety unless all the check conditions are confirmed. Therefore, the check conditions set in a complicated combination of program steps are newly added. There is a problem that it is necessary to reconfirm and rewrite the reconfigured program, which requires a great deal of trouble. Therefore, in view of the above, in the present invention, in particular, in the operation of the plant apparatus, the confirmation of the operation conditions of each process is surely executed, and a program capable of ensuring a reliable and safe operation is quickly constructed. It is an object of the present invention to provide a system control program creating method and apparatus which can effectively use operating conditions once set and examined even when a program configuration is changed.

[0006]

According to a first aspect of the present invention, there is provided a method for controlling a system in an automation system.
Is a method of creating a program for
To execute the unit program corresponding to the unit step in the
Step to hold in chronological order according to and input
For each unit step according to the screen request,
Start permission condition and operation in executing the step operation
End of the unit step after the end
Entering the start permission condition and the start permission entered
Confirmation program based on conditions and termination permission conditions
Creating a module and the unit program
Place the confirmation program module before and after
Creating a program set;
From the input of the permission condition and the termination permission condition,
Up to the creation of a unit step in the unit steps held in the system.
Repeat the unit program set for each execution procedure.
Next, the whole program was created by linking .

Further, the present invention according to claim 2, the self
Of System Control Program for Automated System
A unit program corresponding to a unit step, which is a device.
For arranging chronologically according to the execution procedure
The unit step name and the operation of the unit step.
Each check program based and operating condition inputting means for inputting the end permission condition in order to terminate the unit step after the start permission conditions and the operation ends in order to line the end permission condition as the start permission conditions input means for creating a module, the probability before and after the unit program
Unit program set by certifying program modules
And linking means for linking the unit program sets corresponding to the input order of the unit step names.

[0008] The above-mentioned operating condition input means is provided for inputting a single unit.
An input screen that switches for each step name is provided.
A start permission condition and an end permission condition of the unit step can be input on an input screen for each unit step name .

[0009]

According to the first aspect of the present invention, for each unit step, a confirmation program module for checking operating conditions such as a start permission condition and an end permission condition is created, and this is incorporated before and after the unit program. Since these are connected as a set, various operating conditions are examined in the system, and a highly reliable control program without oversight is quickly created. Since the confirmation program module includes an end permission condition as an operation condition, a unit step is completed only by the set and can be handled as completely independent.

According to the second aspect of the present invention, the operation condition input is performed.
By sequentially inputting unit step names by means,
The execution order of the unit programs held in advance is
The confirmation program module is created by inputting the start permission condition and the end permission condition for each unit step. The control program is created by linking the unit programs by the linking unit in the above order as a unit program set in which corresponding check program modules are arranged before and after the unit programs.

[0011]

FIG. 1 shows an embodiment in which the present invention is applied to an automatic system for operating a plant apparatus. This automation system is under the boardman 1 that performs integrated operation management.
A director 2 that performs step management, a manager 3 that performs unit operation management, and a unit operation execution module 4 that is responsible for executing unit operations on target devices 5 in the field such as on-off valves, control valves, and pumps are arranged. Is built on a computer system.

FIG. 2 shows the sharing relationship of each level. Assuming that a unit step is defined corresponding to a certain process, the director 2 holds, as knowledge, a step procedure of an operation to be instructed by a boardman, and describes the procedure as a start permission condition, an end permission condition for each unit step. Proceed while checking permission conditions. When an abnormality during the step execution is detected by the unit operation execution module, know-how on how to deal with the error is accumulated in the director.

The manager 3 holds, as knowledge, the unit operation methods required to execute one unit step together with the execution order in the form of a unit program, and also has the types of parameters required for execution as knowledge. I have. Then, upon receiving an instruction from the director 2, it outputs a unit operation execution command to the unit operation execution module 4 based on the unit program. The manager 3 manages the unit operation in this way, and the execution of the unit operation itself is performed by the unit operation execution module 4.

The director 2 has an operation screen as illustrated in FIG. The operation screen of FIG. 3 is used for both input and monitoring display. First, in formulating a certain operation control operation, the operation screen is used for inputting the execution order and operation conditions of a plurality of unit steps necessary for the operation. In the figure, a unit step name is input in a, a step start permission condition including a pre-operation confirmation item and its determination data in b, a setting parameter such as a processing amount target value in c, and an operation end determination item or d in d. A step termination permission condition including a post-operation confirmation item and its determination data is input.

The operation procedure is defined for the director 2 according to the order of the unit steps input in the above a. Thereby, as shown in FIG. 4, the unit programs x, y,... Corresponding to the respective unit steps X, Y, Z,.
.. are arranged in chronological order. At this time, the director 2 simply specifies the unit step name, and the specific unit program is developed by the manager 3. The manager 3 constitutes means for holding the unit program of the invention. At the same time, based on the step start permission condition and the step end permission condition input to b and d on the operation screen of one unit step, the director 2 creates a confirmation step of the operation condition of the unit step as a confirmation program module. .

Then, as shown in FIG. 4, this confirmation program module is inserted before the unit step (unit program) for the step start permission condition and after the unit step for the step end permission condition. At the same time, the director 2 stores set information indicating that the above-described confirmation program module is attached as a set to the unit step. This is repeated for each unit step required for operation, and the sets are connected to create an entire operation control program. The director 2 constitutes an operating condition input unit, a unit for creating a confirmation program module, and a connecting unit according to the present invention.

When the operation is performed after the entire program has been created, the operation screen displays a monitor display, and the step start permission condition and the processing amount target value set as described above are input together with the unit step name as in the case of input. Are displayed, and various items such as step end permission conditions are displayed. These are displayed while being automatically switched for each step in accordance with the progress of the operation. On the operation screen, for example, necessary setting parameters are displayed with the previous value as a default value so that they can be input. Note that the automation system has a simulation function, and can first check whether or not a check item or the like in the created whole program is overlooked.

During the operation, when it is confirmed that all the step start permitting conditions of b are satisfied, a status display indicating that the start permitting condition is "established" is displayed on e.
The unit program of the unit step is executed.
When the respective items displayed in d are confirmed and the termination permission condition is satisfied, the status display changes from “not completed” to “finished” in f. This makes it possible to move to the next unit step.

In addition, in the operation screen, in addition to the above, a column for displaying an automatic / manual mode is displayed for g, a column for displaying a current processing amount for h, and a column for displaying the operating status or an abnormal status if j is present. ing. In this field, the response at the time of abnormality detection may be further described. When the start permission condition is “unsatisfied” or when the “unfinished” state continues until after a predetermined time, the manual mode is set and j Can take the countermeasures described in the above.

Next, an operation control program for obtaining a product D by mixing and reacting a plurality of raw materials in a plant as shown in FIG. 5 will be specifically described as an example. In this plant, the raw material A is supplied at a ratio of 30% and the raw material B is supplied at a ratio of 70%.
Let react. When the reaction is performed, the raw material volume becomes 70%. After the reaction is completed, the product D is obtained by adding 10% of the raw material C and stirring.

Pumps 12A to 12C are individually provided in the storage layers 11A to 11C of the raw materials A to C, respectively, and are connected to a merging pipe 14 via valves 13A to 13C.
The merging pipe 14 is guided to a stirring / reaction tank 15, and a flow meter 16 and a supply valve 17 are provided on the way. The integration program integrates the supply amount AV1 of the raw material via the process value F1 of the flow meter 16. The storage level in the storage layers 11A to 11C is the process value L
The operating conditions of the pumps 12A to 12C are process values E1 to E3, the open / close status of the valves 13A to 13C are process values H1 to H3, and the open / close status of the supply valve 17 is a process value H6. Is represented.

The stirring / reaction tank 15 is provided with a stirrer 18 having a stirring screw driven by a motor M, and a heating device 19 using a steam STM as a heat source.
Is provided, and the steam supply valve 20 is controlled by a temperature raising / lowering program. The reaction product is discharged from the stirring / reaction tank 15 to the product tank 22 via the discharge valve 21. The volume level in the stirring / reaction tank 15 is represented by a process value L4, and the opening / closing state of the discharge valve 21 is represented by a process value H5. The process values of other devices are similarly obtained and used for control.

First, the director 2 arranges the unit step names necessary for the above-mentioned product in a time-series necessary order corresponding to the step numbers (order) as shown in FIG. The operation procedure is defined. That is, in the first step, a first unit step including the preparation of the raw material A is set in the first step, and then the preparation of the raw material B as the second unit step is set in the second step. Then, in the third step, the stirring of the charged raw materials A and B, which is the third unit step, is set. In the third step, the temperature is raised as a fourth unit step.

The stirring in the third unit step is continued until the fourth step, and thereafter, in the fifth step, the preparation of the raw material C, which is the fifth unit step, is set. And the sixth
In the step, agitation is performed as a sixth unit step, and in the seventh step, product discharge is set as a seventh unit step.

FIG. 7 shows raw material A as the first unit step.
Indicates the unit operation required for the preparation of. As described above, these unit operations are held and managed by the manager 3 as knowledge in the form of unit programs. In the charging of the raw material A, a first operation (unit operation) of opening the supply valve 17 of the merging pipe 14 is performed first, and the raw material A is attached to the raw material A storage tank 11A, as apparent from FIG. A second operation to open valve 13A follows. Then, a third operation for driving the pump 12A for the raw material A storage tank is performed, and when a predetermined amount of the raw material A is supplied, the pump 1A is operated.
A fourth operation for stopping the driving of 2A is performed. Thereafter, the fifth operation of closing the valve 13A in the reverse order and the supply valve 17
A sixth operation for closing is performed. That is, the unit step of charging the raw material A includes the first to sixth operations.

As shown in FIG. 8, the first unit operation of opening the supply valve 17 of the merging pipe 14 is the first operation of charging the raw material B, which is the second unit step.
3B, a third operation for driving the pump 12B for the raw material B storage tank, a fourth operation for stopping the driving of the pump, a fifth operation for closing the valve 13B, and a fifth operation for closing the supply valve 17. It consists of 6 operations. The charging of the raw material C is also configured by the same unit operation, except that the valves and pumps related to the storage tank are changed.

Further, as an example of the stirring in the third unit step, as shown in FIG. 9, a first operation for performing a start / stop process (here, a start) of the stirrer 18,
Similarly, the second operation includes a start / stop process (stop) of the stirrer. Each of the other unit steps also comprises the required unit operations.

Next, for each of these unit steps, a step start permission condition (that is, a pre-operation confirmation item and its judgment data) is input on the operation screen of FIG. Similarly, a step end permission condition (operation end judgment item and post-operation confirmation item and its judgment data) is also input. The step start permission condition confirms the state of each component which is a prerequisite for executing each of the above-described unit operations constituting the unit step, and the step end permission condition indicates that the unit step has been completed, in other words, the target thereof. It is to confirm that it has been achieved.

FIG. 10 shows the step start permission condition and the step end permission condition in the first unit step (the preparation of the raw material A) exemplified above. The first of the step start permission conditions is the storage level of the raw material A in the storage tank 11A, and the process value L1 is 30% or more of the storage tank capacity. This is to ensure that a necessary amount of raw material is supplied. Step start permission condition second
The third is a line check of the raw material B and C systems. Here, the pumps 12B and 12C are stopped (the process values E2 and E3 are STOP), respectively, and the valves 13B and 13C are closed (the process values H2 and H3 are the C values).
LOSE). This is to prevent the backflow into other storage tanks and the mixing of other raw materials, so that an accurate amount of raw material A can be supplied.

The fourth step start permission condition is a check of the discharge line.
Valve 21 is closed (process value H5 is CLOS
E) is being done. It is necessary to prevent the raw materials from being discharged without stirring / reaction treatment in the stirring / reaction tank 15. The fifth step start permission condition is a check of the charging line, and the supply valve 17 of the merging pipe 14 is closed (the process value H6 is CLOSE) so that the supply amount can be accurately measured. To

Next, the step end permission condition of the first unit step is a charged amount, and the AV1 obtained by integrating the process value F1 of the flow meter 16 is set to have an error of 1% or less with respect to the target charged amount TG1. Here, in addition to the step start permission condition and the step permission condition, setting parameters are also defined. In the first unit step, the target charging amount TG1 of the raw material A is set. In this way, if the step start permission condition is satisfied, each unit operation constituting the first unit step is performed under the management of the manager 3. Then, when the supply amount of the raw material A reaches an error within 1% of the target preparation amount, the first unit step is completed.

FIG. 11 shows a step start permission condition and a step end permission condition in the third unit step (stirring). The first of the step start permission conditions is a check of the preparation line, and the second of the start permission conditions is
Check the discharge line. These require that the supply valve 17 of the merging pipe 14 and the discharge valve 21 to the product tank 22, which are the inlet and outlet of the stirring / reaction tank 15, are closed (the process values H6 and H5 are closed). I have.

If these step start permission conditions are satisfied, the stirrer 1 as the first operation of the third unit step is executed.
8 starts. Then, the stirring / reaction tank 15
When it is measured by the process value L4 that the volume of the raw material in the inside becomes 70% or less of the time when the stirring is started, the stirrer 18 is stopped as the second operation, and the third unit step is completed. Similarly, in the other unit steps, the states of the related devices before and after the step necessary to execute the step are set as step start permission conditions, and depending on the characteristics of the steps, further end permission conditions are set.

As described above, in this embodiment, a manager is provided which holds a unit operation method necessary for executing a unit step and an execution order thereof as a unit program. Then, in the director having the operation screen as an interface, while sequentially inputting the unit step names of the operation on the operation screen to hold the execution procedure as knowledge, the start permission condition from the operation screen for each unit step, By inputting the termination permission condition, a confirmation program module for the unit step is created. This confirmation program module is inserted before and after the unit step to form the entire program.

According to this embodiment, since the start permission condition and the end permission condition are obtained on the operation screen for each unit step, necessary confirmation items are surely taken into the entire program as a confirmation program module, and The omission in consideration of creation is greatly reduced, and the speed of completing the program for system control is increased.

Then, the confirmation program module is stored as the set information of the unit step, and the unit step is completed only by the set by entering an end permission condition. Therefore, when another unit step is incorporated, or when itself functions in another control program, the start permission condition of the next succeeding unit step is already confirmed as the end permission condition of the previous step. Therefore, there is no need to write again, and the unit steps can be treated as completely independent.

[0037]

As described above, according to the method of the present invention, the unit program corresponding to the unit step is stored in the system in advance.
And keep it in chronological order according to the execution procedure ,
In addition, according to the request of the input screen,
To enter the end permission condition and its start permission conditions, to create a confirmation program module for checking the operating conditions for each unit step, and the unit program set by incorporating this into the front and rear of the unit program, connecting them Since the control program is generated by the system, various operating conditions are examined systematically, and a highly reliable control program with no oversight is quickly generated. Since the confirmation program module includes the termination permission condition as an operation condition, the unit step is completed only by the set, and has an advantage that it can be handled as completely independent.

Further, in the apparatus of the present invention, the unit step name and its
And operating conditions input means for inputting operating conditions, and means for creating a confirmation program modules based on the input operating conditions, the confirmation program modules before and after the unit program corresponding to the unit step in advance held The unit program sets are allocated to each other, and the unit program sets corresponding to the input order of the unit step names are connected by the connecting means. Therefore, the reliability can be obtained simply by inputting the unit step name, the start permission condition, and the end permission condition. , And a control program with a high level is easily and quickly created.
In addition, since the confirmation program module includes the termination permission condition, the created unit program set is made independent, and there is an effect that position change or addition in the control program can be easily performed.

[Brief description of the drawings]

FIG. 1 is a diagram showing an embodiment in which the present invention is applied to an automation system of a plant device.

FIG. 2 is a diagram showing an assignment relationship at each hierarchical level of the automation system.

FIG. 3 is a diagram showing an operation screen in a director.

FIG. 4 is an explanatory diagram showing assembly and connection of a program.

FIG. 5 is a diagram showing a configuration of a plant as an example of an application system.

FIG. 6 is a diagram showing a definition of an operation procedure in a director.

FIG. 7 is a view showing a unit operation in a unit step of charging the raw material A.

FIG. 8 is a diagram showing a unit operation in a unit step of charging the raw material B.

FIG. 9 is a diagram showing a unit operation in a unit step of stirring.

FIG. 10 is a diagram showing a step start permission condition and a step end permission condition in a unit step of charging the raw material A.

FIG. 11 is a diagram showing a step start permission condition and a step end permission condition in a unit step of agitation.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Boardman 2 Director 3 Manager 4 Unit operation execution module 5 Target device 11A-11C Storage layer 12A-12C Pump 13A-13C Valve 14 Merging pipe 15 Stirring / reactor 16 Flow meter 17 Supply valve 18 Stirrer 19 Heating device 20 Steam supply valve 21 Discharge valve 22 Product tank STM Steam M Motor

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-4-55903 (JP, A) JP-A-5-265516 (JP, A) JP-A-4-82702 (JP, U) (58) Field (Int.Cl. ⁶ , DB name) G05B 19/05 G05B 15/02

Claims (3)

(57) [Claims] 1. For system control in an automation system
A program generation method, a unit corresponding to the unit step in advance in the system-flop
Keep programs in chronological order according to the execution procedure
Steps and unit steps as required by the input screen.
Start permission conditions for executing the operation of the unit step and
To end the unit step after the operation ends
Inputting the end permission condition of the user, and inputting the start permission condition and the end permission condition based on the input permission condition.
Creating a confirmation program module, and before and after the unit program,
To create a unit program set by arranging rules
From the input of the start permission condition and the end permission condition.
Until the creation of the ram set, the unit scan held in the system
Repeat for each step execution procedure to
A system control program creating method, wherein the entire program is created by sequentially linking the programs . (2)For system control in automation systems
A program creating device, Make the unit program corresponding to the unit step an execution procedure
Therefore, means for holding in chronological order, Executes the unit step name and the operation of the unit step
And permission to start The unit after the operation ends
The action to enter the end permission condition for ending the step
Operation condition input means, and based on the input start permission condition and end permission conditionIt
EachMeans for creating a verification program module;Before and after the unit program, the confirmation program module
Means for creating a unit program set by arranging tools,  Unit program set corresponding to the input order of unit step names
Connection means for connecting the
System control program creation device. 3. An operation condition input means, comprising:
It has an input screen that switches for each
3. The system control program creating apparatus according to claim 2 , wherein a start permission condition and an end permission condition of the unit step are input on an input screen for each step name .