JP3280703B2 - Plant monitoring method and plant monitoring system - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a plant monitoring method and a plant monitoring system for remotely monitoring, for example, a building or a factory plant.

[0002]

2. Description of the Related Art Conventionally, in a plant monitoring system for remotely monitoring a building or a factory plant, various data of a plant are collected by a data collection device on a monitoring target plant side, and the various data collected by the data collection device are remotely stored. The data is transmitted to a higher-level monitoring device via a transmission path and filed in a monitoring data file.
And in such a conventional plant monitoring system,
Even in an abnormal state in which a component of a plant has failed or some process value is abnormal, data is collected at the same fixed cycle as in the normal state, and the synchronization of related data is not taken into account.

[0003]

However, such a conventional plant monitoring system has the following problems because it does not consider the synchronization of related data in an abnormal state. In other words, even if a component of the plant breaks down or an abnormal state occurs in which an abnormality occurs in the process value, the data collection cycle related to the abnormal state is the same as in the normal state and is constant. If the collection cycle of the abnormal signal is 100 ms and the collection cycle of measured values such as flow rate, pressure, and temperature is 10 s, the maximum is 10 s
Data collected at a certain time interval was collected, and it was not possible to collect relevant data of the plant at the same time as the occurrence of the abnormality, and there was a problem that the state of the plant at the time of the occurrence of the abnormality could not be accurately grasped .

[0004] To explain this further, a complicated plant has a large amount of data, and if the collection is performed in a short cycle, the load on the entire system is affected. Therefore, the measurement value collection cycle is usually 5 to 10 s. The transmission of the data collected on the plant side to the higher-level monitoring device is usually performed by RS232C.
The transmission is performed by the serial transmission method as described above, but the upper-level monitoring device takes out the data in the text and files it into the monitoring data file every time the transmission text is received, whether the plant is normal or abnormal.

[0005] For this reason, even when a large amount of data related to the abnormal state must be transmitted in a plurality of texts when an abnormality occurs, the data is taken out and filed every time one text is received. In this case, a time lag occurs between the data, and the synchronization of the data cannot be guaranteed in processes such as abnormality and failure diagnosis.

The present invention has been made in view of such a conventional problem. When an abnormality occurs on the plant side, the data collection device operates in conjunction with the occurrence of the abnormality separately from the normal periodic data collection. Collect all relevant data, notify upper-level monitoring device that abnormality-related data is to be transmitted, and have the upper-level monitoring device receive all abnormality-related data before filing them in a monitoring data file at once. Accordingly, an object of the present invention is to provide a plant monitoring method and a plant monitoring system that can ensure the synchronization of abnormality related data and provide accurate related data for abnormality and failure diagnosis.

[0007]

According to a first aspect of the present invention, there is provided a plant monitoring method, wherein the plant monitors an occurrence of an abnormality in the plant.
When the abnormality is detected, the data collection device is linked to the occurrence of the abnormality, separately from the regular periodic data collection .
Collects all abnormality-related data associated in advance for each abnormality state, notifies that transmits abnormality-related data to the upper monitoring device, the abnormality-related data all
Continuously transmitted to the higher-level monitoring device, and the higher-level monitoring device transmits the abnormality-related data from the plant side.
When the plant is notified,
After receiving all the related data , filing is performed in a monitoring data file.

According to a second aspect of the present invention, there is provided a plant monitoring system comprising: a data collection device installed on a plant side; and a higher-level monitoring device for monitoring a plant state based on data transmitted from the data collection device. An apparatus for detecting an abnormality in the plant,
An abnormality-related data collection unit that collects abnormality-related data previously associated with the abnormal state when the abnormality detection unit detects an abnormality of the plant; and When the abnormality-related data collection unit collects the abnormality-related data, the transmission unit transmits the abnormality-related data to the upper-level monitoring device, and adds the abnormality identification data for identifying the presence of the abnormality-related data to the upper-level monitoring device. A data receiving unit that receives data transmitted from the data collection device; and a data receiving unit that receives the abnormality identification data. And an abnormality determining unit that determines whether or not the abnormality-related data is included. Part is received collectively abnormality-related data all are collecting those having an abnormality-related data files filing.

[0009]

In the plant monitoring method according to the first aspect of the present invention, when an abnormality on the plant side is detected, the data collection device may operate in conjunction with the occurrence of the abnormality, separately from the normal periodic data collection .
Collecting all the abnormality-related data that has been previously associated , notifying the upper-level monitoring device that the abnormality-related data is to be transmitted, and monitoring the data file for monitoring after the upper-level monitoring device has received all of the abnormality-related data. In the event of a plant failure, the data collection device collects all the data related to the abnormality in advance and transmits it to the higher-level monitoring device, and stores the data in the monitoring data file. By filing, data synchronization is ensured.

[0010] In the plant monitoring system according to the second aspect of the present invention, when the abnormality detection unit detects an abnormality in the plant on the data collection device side, the abnormality-related data collection unit is in an abnormal state.
Collects all the abnormality-related data previously associated with the data, and adds the abnormality identification data that identifies the existence of the abnormality-related data to the abnormality-related data collected by the abnormality-related data collection unit when the data is transmitted at a fixed period. And send them all at once. Therefore, in the higher-level monitoring device, the data receiving unit receives the data transmitted from the data collection device, and the abnormality determining unit determines whether the received data includes abnormality identification data. If the abnormality determination unit determines that there is no abnormality identification data, the monitoring data file is filed with various data in a normal state each time it is received, and if the abnormality determination unit determines that there is abnormality identification data, the abnormality is determined. The related data file collectively receives all the abnormal data collected by the abnormal data collecting unit on the plant side and files the data.

[0011] In this way, the plant abnormality occurs at the time of the different
By collecting all the abnormal data related to the normal state in advance and transmitting it to the higher-level monitoring device, and filing it in the monitoring data file,
Ensure data synchronization.

[0012]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the present invention will be described below in detail with reference to the drawings. FIG. 1 shows a hardware configuration of a system according to an embodiment of the present invention, which is roughly divided into a plant data collection device 10 that collects various data of a plant 1 and transmits the collected data to a host device, From
For example, it is configured by a higher-level monitoring device 20 that receives and files plant data through a transmission line 2 that performs serial transmission such as RS232C.

The plant data collection device 10 receives a plant data collection CPU 11 for inputting failures, abnormalities, and various data of the plant 1 to determine whether a failure or abnormality has occurred, and transmitting relevant data to a higher-level device. And a plant data input device 12. The upper monitoring device 20 also includes a plant monitoring CPU 21 for filing and monitoring plant data, and a CRT display device 22 for displaying and recording plant status.
And a printer 23.

FIG. 2 is a functional block diagram of data collection, transmission, and filing processing of the plant monitoring system having the above hardware configuration. Part 1
01, an abnormality-related data collection unit 102 that collects abnormality-related data related to the abnormal state when the abnormality detection unit 101 detects an abnormality in the plant 1, and an abnormality collected by the abnormality-related data collection unit 102. A data filing unit 103 for filing the related data while distinguishing various data when the plant is normal, a transmission unit 104 for transmitting the data of the data filing unit 103 to the higher-level monitoring device 20, and an abnormality-related data collection unit 102 When collecting data, the transmission unit 104 includes an abnormality identification data transmission unit 105 that transmits abnormality identification data for identifying the presence of abnormality-related data when transmitting the data to the host monitoring device 20.

The upper monitoring device 20 includes a data receiving unit 201 for receiving data transmitted from the transmitting unit 104 of the data collecting device 10, and a data receiving unit 201.
An abnormality determination unit 202 that determines whether or not the data received by the device includes abnormality identification data;
2, when it is determined that there is abnormality identification data, an abnormality-related data storage unit 203 that temporarily stores all the abnormality-related data collected by the abnormality-related data collection unit 102, A monitoring data file 20 for filing data each time it is received, and filing abnormal-related data in the abnormal-related data storage unit 203 after receiving all abnormal-related data.
4.

Next, the operation of the plant monitoring system having the above configuration will be described.

The abnormality detection unit 101 checks the presence or absence of a signal registered in the failure signal registration table 30 as shown in FIG. The failure signal registration table 30 includes a target failure signal number section 31 and a related data table number section 32. An abnormality-related data table 33 corresponding to each of the associated data table numbers registered in the associated data table number section 32 is prepared. 34, measured value signal area 35, signal number area 3
6, a spare area 37.

The abnormality detection unit 101 also checks whether there is any abnormality in the signals registered in the measurement signal registration table 40 registered in the CPU 11. The measurement signal registration table 40 includes a measurement signal number 41 and a related data table number 42.

Therefore, when the abnormality detecting unit 101 detects an abnormality of the plant 1, the abnormality-related data collecting unit 102 collects the abnormal-related data related to the abnormal state, and the data-filing unit 103 transmits the abnormal-related data. Filing is performed separately from various types of data when the plant is normal, and the transmission unit 104 transmits the data of the data filing unit 103 to the higher-level monitoring device 20 during data transmission at a fixed period. At the time of this transmission, the abnormality-related data collection unit 102
Has collected the abnormality-related data, the abnormality identification data transmission unit 105 transmits the transmission including the abnormality identification data for identifying the presence of the abnormality-related data.

Therefore, on the host monitoring device 20 side, the data receiving unit 201 receives the data transmitted from the transmitting unit 104 of the data collecting device 10 on the plant side, and checks whether the received data contains abnormality identification data. The determination is made by the abnormality determination unit 202. Then, the abnormality determination unit 202
If the abnormality determination unit 203 determines that there is no abnormality identification data, filing of various data at the time of reception is performed in the monitoring data file 204, and if the abnormality determination unit 203 determines that there is abnormality identification data, the abnormality-related data is stored. The unit 203 temporarily stores all the abnormality-related data collected by the abnormality-related data collection unit 102 of the data collection device 10 until the reception of all the abnormality-related data is completed. File to file 204.

In this way, when a plant abnormality occurs, the plant data collection device 10 collects all the abnormality-related data at that time, transmits the collected data to the upper-level monitoring device 20, and files it in the monitoring data file 204, so that the abnormality-related data is filed. Ensure data synchronization.

The above operation is shown in the operation flowchart of FIG.
7 will be described in more detail.

First, the data collection device 10 inputs various plant signals from the plant 1 via the plant data input device 12 (step S1). Then, the abnormality detecting unit 101 checks the presence / absence of a signal registered in the failure signal registration table 30 from the input signals (step S2).

If it is determined in step S2 that there is,
The abnormality-related data collection unit 102 performs the failure signal registration table 3
A related data table 3 in which a signal number related to a failure signal is registered from a related data table number 32 in 0
3 is taken out (step S3). Then, according to the signal number 36 in the related data table 33, the current data of the corresponding signal is input from the plant 1 via the plant data input device 12, and the failure related data file 50 of the data filing unit 103 as shown in FIG. (Step S6).

If the signal is not found in the failure signal registration table 30 in step S2, it is checked in step S4 whether the signal registered in the measurement signal registration table 40 is abnormal. Collection unit 102
Extracts the related data table 33 from the related data table number 42 in the measurement signal registration table 40 (step S5).

After the signal number 36 has been extracted from the related data table 33 in this way, the process of step S6 is performed to file the related data file 50.

If there is no abnormality in the signals registered in the measurement signal registration table 40 in step S4, the input data is filed in the general data file 51 of the data filing unit 103 shown in FIG. 4 (step S7). .

Thus, the abnormality-related data file 50 and the general data file 51 are created.

Next, a process of editing the related data file 50 and the general data file 51 into transmission text as shown in FIG. 4 and transmitting the edited text to the upper-level monitoring device 20 will be described. A data file 50 and a general data file 51 consisting of a, b, c,.
In order to transmit the data alternately in the order of A, B, B, C, C,..., The data filing unit 103 transmits the data A, A, B, C,. Is created (step S1 in FIG. 6).
1).

Then, the abnormality identification data transmitting section 105 checks whether or not there is data in the related data file 50 (step S12), and if so, checks whether or not the related data has been transmitted for the first time (step SS1).
3) In the case of the first time, in order to notify the upper-level monitoring device 20 that there is related data, the related data table number extracted in step S3 or S5 described above is transmitted to the transmission unit 1.
04 (step S1).
4).

Next, the data extracted from the general data file 51 and the related data file 50 is
3, and transmitted from the transmission unit 104 to the higher-level monitoring device 20 via the transmission path 2 (steps S15 and S16).
In this transmission, when there are a plurality of transmission texts 53, the transmission texts 53 are repeatedly transmitted.

Next, the data receiving operation on the host monitoring device 20 side will be described. As shown in the flowchart of FIG. 7, first, the transmission text 53 from the plant data collecting device 10 is transmitted to the data receiving unit 201 using the data. Upon reception (step S21), the reception file 54 is created from this, and the abnormality determination unit 202 determines whether abnormality identification data with related data is included (step S2).
2, S23).

If there is no related data, the process jumps to step S25. If there is related data, the abnormal data storage unit 203 retrieves a related data table from the related data table number (step S24). The related data table is the same as the related data table 33 provided on the data collection device 10 side, and is assumed to be registered in the CPU 21 in advance.

Next, it is checked whether or not the signal number in the data of the received file 54 is registered in the related data table (step S25). If not, the general data file of the monitoring data file 204 is used as general data. 56 is directly filed (step S29).

If the data in the reception file 54 is failure-related data in step S25, the data is temporarily stored in the abnormality-related data file 55 of the abnormality-related data storage unit 203 (step S26). Then, it is confirmed that the reception of all the related data has been completed (step S27),
When the reception of all data including A, B, C,.
The related data file 55 is converted to the monitoring data file 204
Is filed in the general data file 56 (step S28).

As described above, when a failure or abnormality occurs in the plant equipment during plant monitoring, the data related to the abnormal state is collected on the plant data collection device 10 side by the regular periodic data collection. Separately, all data are collected in conjunction with the occurrence of the abnormality, and a notification that the abnormality-related data is to be transmitted to the higher-level monitoring device 20.
On the side, after receiving all the abnormality-related data, the data is collectively filed in the monitoring data file 204, so that the synchronization of the abnormality-related data can be ensured, and accurate relevant data can be provided for abnormality / failure diagnosis. To do so.

[0037]

As described above, according to the present invention, when an abnormality occurs in a plant, the abnormal state is previously determined.
The data collection device associated with the plant collects all the related abnormality-related data, transmits the data collectively to the upper-level monitoring device, and the upper-level monitoring device collectively files this abnormality-related data in an abnormality-related data file. Even if the transmission text of normal plant data is divided into multiple parts and transmitted, the abnormality-related data at the time of the abnormality can be synchronized, and the reliability is useful for failure diagnosis and recovery processing. High data can be provided.

[Brief description of the drawings]

FIG. 1 is a configuration diagram of a hardware system according to an embodiment of the present invention.

FIG. 2 is a functional block diagram of the embodiment.

FIG. 3 is an explanatory diagram of a data structure of a failure signal registration table and a measurement signal registration table in the embodiment.

FIG. 4 is a flowchart of a data transmission operation of the embodiment.

FIG. 5 is a flowchart of a data collection and filing operation of the data collection device of the embodiment.

FIG. 6 is a flowchart of a transmission text creation operation of the embodiment.

FIG. 7 is a flowchart of a received data filing operation of the higher order monitoring device of the embodiment.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Plant 2 Transmission line 10 Data collection device 11 Data collection CPU 12 Data input device 20 Host monitoring device 21 Data monitoring CPU 22 CRT display device 23 Printer 101 Error detection unit 102 Error related data collection unit 103 Data filing unit 104 Transmission unit 105 abnormality identification data transmission unit 201 data reception unit 202 abnormality determination unit 203 abnormality related data storage unit 204 monitoring data file

Claims (2)

(57) [Claims] 1. The plant monitors the occurrence of an abnormality in the plant.
When the abnormality is detected, the data collection device is linked to the occurrence of the abnormality, separately from the regular periodic data collection .
Collects all abnormality-related data associated in advance for each abnormality state, notifies that transmits abnormality-related data to the upper monitoring device, the abnormality-related data all
The hand is continuously transmitted to the higher-level monitoring device, the host monitoring system, the abnormality-related from the plant side
When receiving a notice to send data, the plant
Receiving all of the abnormality-related data from the side and filing the data collectively in a monitoring data file. 2. A plant monitoring system comprising: a data collection device installed on a plant side; and a higher-level monitoring device that monitors a plant state based on data transmitted from the data collection device. An abnormality detection unit that detects an abnormality, and an abnormality-related data collection unit that collects abnormality-related data that is related to the abnormal state in advance when the abnormality detection unit detects an abnormality in the plant.
A transmission unit that transmits the data of the abnormality-related data collection unit to the higher-level monitoring device; and, if the abnormality-related data collection unit collects the abnormality-related data, the higher-level monitoring device generates an error in the abnormality-related data. An abnormality-related data transmission unit that adds abnormality identification data for identifying the presence of related data and transmits the data collectively, wherein the higher-level monitoring device receives a data transmitted from the data collection device; An abnormality determining unit that determines whether the data received by the data receiving unit includes the abnormality identification data; and an abnormality-related data collection unit that collects the abnormality-related data when the abnormality determination unit determines that the abnormality identification data is present. A plant monitoring system, comprising: an abnormality-related data file for collectively receiving and filing all of the abnormality-related data being processed. Tem.