JP4826218B2 - Plant operation management support method - Google Patents

Description

  The present invention relates to a plant operation management support method. In particular, the present invention relates to a method for supporting operation management by estimating a material balance of a water treatment plant.

  Conventionally, in a plant facility (for example, a water treatment plant), the capacity of individual facilities (hereinafter referred to as “units”) constituting the plant is measured and measured based on the specifications of each unit or by simulation. It is known that each unit and the entire plant composed of each unit are evaluated by comparing the values.

  For example, in Patent Document 1, data is measured from all units constituting the plant at all times (short-time intervals), and the measured data and the calculated values of the simulation are used to calculate the entire plant that changes continuously in time. It has been shown to perform a capability diagnosis. Therefore, according to Patent Document 1, the capacity of the plant (specification) that the plant originally has the capacity of any unit that is operated continuously in time and the capacity of the entire plant in which new and old units are mixed and interrelated. It is possible to evaluate against

On the other hand, in Patent Document 2, a material balance and a heat balance are calculated from actual measurement values measured from a plant (or one unit), and the calculated material balance and heat balance are compared with steady values. It has been shown that monitoring, reducing the burden of monitoring by the operator, and preventing the operator from being confused during an operational error or abnormality.
JP 2004-54418 A JP-A 63-77537

  However, in Patent Document 1 and Patent Document 2 described above, based on the material balance of the plant, estimation of the replacement time of consumables used in the unit, unit capacity diagnosis and overall plant capacity diagnosis are performed for the following reasons. May not be able to be done accurately. Usually, when performing operation management support such as capability diagnosis of each unit constituting the plant and replacement time of consumables, the actual measurement value may include many errors. In this case, the reliability of the result is low for a material balance that is not valid based on actual measurement values with large errors. In particular, the values of the industrial instruments of the plant and the display instruments in which the plant is installed may contain many errors and abnormal values, etc. In order to calculate a reasonable material balance, the values from these industrial instruments and display instruments It is necessary to adjust the actual measurement value itself.

  The present invention is based on reasonable estimates calculated by taking into account the material balance of a water treatment plant, extracting abnormal instruments used in the plant unit, estimating the replacement time of consumables, and It is an object of the present invention to provide an operation management support method capable of appropriately performing the capability diagnosis of each constituent unit.

(1) An actual value management device (for example, an actual value measured for the amount of treated water flowing into and out of each unit (for example, unit A200, unit B250 described later) of the water treatment plant and storing the actual value) A measurement information storage unit 160) to be described later,
An arithmetic device (for example, a control unit 110 described later) that calculates an estimated value of the water treatment plant based on an actual function stored in the actual value management device and an objective function including a constraint condition of the water treatment plant. And comprising
An operation management support method for diagnosing each of the units based on the estimated value calculated by the arithmetic device.

According to the invention of (1), measured values of the amount of treated water flowing into and out of each unit of the water treatment plant are measured, the measured values are stored, the stored measured values, and the water treatment plant The estimated value of the water treatment plant is calculated based on the objective function including the constraint condition, and each of the units is diagnosed based on the calculated estimated value.
Therefore, it is possible to diagnose each unit constituting the water treatment plant based on the consistent estimated value calculated from the actual measurement value and the objective function, and taking into account the constraints of the water treatment plant. is there. Therefore, normally, it is possible to make a proper diagnosis using the estimated value without relying only on the actual measurement value from an industrial instrument or a display instrument that may include an error or an abnormal value.

  (2) Diagnosing each of the units includes executing at least one of extracting an abnormal meter, estimating a consumable replacement time, and diagnosing capability for each of the units. Driving management support method.

  According to the invention of (2), on the basis of the consistent estimated value calculated from the actual measurement value and the objective function, the extraction of the abnormal instrument used in the unit of the water treatment plant, the replacement time of the consumables Either estimation or unit capability diagnosis can be performed more accurately than in the past.

  (3) The arithmetic unit minimizes a value calculated from the objective function by using a sum of differences between the actual measurement value and the estimated value to be calculated as an objective function (for example, (Equation 1) described later). The operation management support method according to (1) or (2), wherein an estimated value is calculated, and each of the units is diagnosed based on the estimated value.

  (4) The arithmetic device uses the sum of the quotient obtained by dividing the difference between the actual measurement value and the estimated value to be calculated by the actual measurement value as an objective function (for example, (Expression 2) described later), and minimizes the quotient The operation management support method according to any one of (1) to (3), wherein an estimated value to be calculated is calculated, and each of the units is diagnosed based on the estimated value.

  According to the present invention, based on a reasonable estimate calculated by considering the material balance of the water treatment plant, the extraction of abnormal instruments used in the plant unit, the estimation of the replacement time of consumables, and It is possible to provide an operation management support method capable of appropriately performing the capacity diagnosis of each unit constituting the plant. Therefore, diagnosis should be performed properly using the estimated value calculated by the objective function without relying solely on the actual measurement value from industrial and display instruments that may contain errors or may be abnormal values. Is possible.

  FIG. 1 is a configuration diagram showing units (unit A200, unit B250) that constitute a plant and a plant operation management apparatus 100 that is connected to the plant and manages the operation of the plant. Although only the unit A 200 and the unit B 250 are illustrated in FIG. 1, other units may be managed by the plant operation management apparatus 100. The unit B250 is connected to the communication unit 150 by a broken line, but this indicates that the unit B250 may be connected to the communication unit 150 or may be not connected as described later. .

  The plant operation management apparatus 100 includes a unit information input unit 120, a control unit 110, a measurement information storage unit 160, a diagnosis information storage unit 170, and an output unit 180, and appropriately includes a communication unit 140. The plant operation management apparatus 100 may be a computer incorporating a CPU (Central Processing Unit), a memory, and the like.

  The unit information input unit 120 is a device to which information and data are input by a plant manager, and may be a keyboard, a mouse, or the like, for example. For example, the plant manager visually recognizes the inflow meter 210 (outflow meter 220) of the unit A200 and grasps the actual inflow value (outflow actual value), and the inflow actual value (outflow actual value) via the unit information input unit 120. Value) is input to the plant operation management apparatus 100. Further, the unit information input unit 120 is used by the plant manager to specify the capacity value (hereinafter referred to as “unit capacity value”) regarding the inflow and outflow of the unit A200, the life of the consumables of the unit A200, Data on the replacement time is entered.

  The control unit 110 is a device that controls and calculates information and data input to the plant operation management device 100, and may be a CPU, for example. The control unit 110 executes a main processing routine, an estimated value calculation processing routine, and a plant diagnosis processing routine which will be described later.

  The measurement information storage unit 160 is a device in which actual measurement values are stored by the control unit 110. Here, the actual measurement value stored in the measurement information storage unit 160 may be input via the unit information input unit 120 and stored in the measurement information storage unit 160. The actual measurement value transmitted from A200 may be received and stored in the measurement information storage unit 160.

  The diagnosis information storage unit 170 is a device in which information and data for diagnosis by the plant operation management apparatus 100 are stored by the control unit 110. Here, the information and data stored in the diagnostic information storage unit 170 may be input via the unit information input unit 120 and stored in the diagnostic information storage unit 170. As will be described later, the communication unit 140 By receiving information and data transmitted from the unit A200, the information may be stored in the diagnostic information storage unit 170. The specific information and data stored in the diagnostic information storage unit 170 are data relating to the unit capability value of each unit, the lifetime of consumables for each unit, and the replacement timing of replacement parts, as will be described later.

  The output unit 180 is a device that outputs information and data controlled by the plant operation management apparatus 100 by the control unit 110, and may be a monitor, a liquid crystal display, a printer, or the like, for example.

  The communication unit 140 is a device that receives data such as actually measured values from the inflow meters 210 and 260 and the outflow meters 220 and 270 such as the unit A200 and the unit B250. The communication unit 140 may be connected to the unit-side communication unit 150 via a general public line or may be connected via a dedicated line. Further, the plant operation management apparatus 100 may not include the communication unit 140, and all information and data controlled by the plant operation management apparatus 100 may be input via the unit information input unit 120.

  Units A200 and B250 are one unit that constitutes a plant, and are units that flow in substances such as water and fuel, and flow out all or a part of the predetermined amount of substances that have flowed in. In the following, in order to describe a preferred embodiment, as shown in FIG. 3, a configuration in which only one unit is directly connected to one unit will be described. That is, a mode will be described in which, when a predetermined amount of substance flows into one unit (unit A200), the total inflow amount in which the inflow has occurred flows out to the next unit (unit B250).

  The unit A200 includes an inflow meter 210 that measures the inflow amount of the substance that has flowed in, and an outflow meter 220 that measures the outflow amount of the substance that flows out. Similarly, the unit B250 includes an inflow meter 260 that measures the inflow amount of the substance that has flowed in, and an outflow meter 270 that measures the outflow amount of the substance that flows out. In FIG. 1, only one communication unit 150 is provided for a plurality of units. However, each unit includes one communication unit 150 and communicates with the plant operation management apparatus 100 via the communication unit 140. You may go.

  Next, based on FIG. 2, the main process routine which the control part 110 of the plant operation management apparatus 100 performs is demonstrated. First, the control unit 110 performs an input process in which the actual measurement value of each unit is input (step S01). In this input process, an actual measurement value may be automatically input via the communication unit 140, or may be input by a plant manager via the unit information input unit 120. Next, based on the inputted actual measurement value, the control unit 110 performs a calculation process of the estimated value of the material balance (step S02). And the control part 110 performs the diagnostic process of a plant based on the information memorize | stored in the diagnostic information storage part 170 based on the calculated estimated value (step S03). Details of these steps will be described below.

First, the material balance between units will be described with reference to FIG. For the unit A200, the measured inflow value (f1) is 100 m ³ / h, and the measured outflow value (f2) is 110 m ³ / h. Since (f2) flowing out from the unit A200 flows into the unit B250, the inflow actual measurement value is 110 m ³ / h, and the outflow actual measurement value (f3) is 80 m ³ / h.

  The inflow actual measurement value and the outflow actual measurement value are data measured by the inflow meters 210 and 260 and the outflow meters 220 and 270, and these data are transmitted to the measurement information storage unit 160 via the communication unit 140 and the communication unit 150. The plant manager visually recognizes the inflow meters 210 and 260, the outflow meters 220 and 270, and inputs the actual measured inflow value and the actual measured outflow value via the unit information input unit 120. May be stored in the measurement information storage unit 160.

As described above, a flow in which the control unit 110 executes the estimated value calculation process after the inflow actual measurement value and the outflow actual measurement value are input will be described with reference to FIG. First, the control unit 110 sets an objective function based on an input from the plant manager (step S11). Here, the objective function is a function for calculating an estimated value from an input actual measurement value. For example, as in (Equation 1) and (Equation 2), the difference between the estimated value and the actually measured value (the quotient obtained by dividing the difference between the estimated value and the actually measured value by the actually measured value) is calculated for each unit, and this sum is calculated as the objective function Set as.

Next, the control unit 110 receives the input from the plant manager and sets a constraint condition (step S12). For example, the constraint condition may be (Equation 3) according to the constraint on the inflow and outflow material balance.

The control unit 110 substitutes the actual measurement value for the objective function (step S13). For example, substituting the actual measurement values input to (Expression 1) yields (Expression 4).

When the restriction of (Expression 3) is added to (Expression 4), (Expression 5) is obtained, and (Expression 5) is shown on the graph as shown in FIG.

  The control unit 110 calculates f1 having the minimum F in (Expression 4) (step S14). As shown in FIG. 5, F in (Expression 5) has a minimum value of 30 when f1 is 100, and thus the estimated value of f1 is calculated as 100. Control unit 110 outputs the calculated estimated value to output unit 180 (step S15).

  Next, a plant diagnosis processing routine performed based on the calculated estimated value will be described with reference to FIG. The control unit 110 calculates an estimated value by the above-described estimated value calculation processing routine (step S21). The control unit 110 compares the calculated estimated value with the actually measured value of each unit (step S22). From the result of this comparison, the control unit 110 extracts an abnormal instrument (step S23). This extraction process will be described below.

  FIG. 7 shows an error between the measured inflow values and the measured outflow values of the units A200 and B250 and the estimated values f1, f2, and f3 = 100 calculated by (Equation 5). For example, the error of the inflow meters 210 and 260 and the outflow meters 220 and 270 is assumed to be an error of ± 10% from the specifications. Based on FIG. 7, the error in the inflow meter 210 is 0%, the error in the inflow meter 260 (outflow meter 220) is 10%, and the error in the outflow meter 270 is 20%. It is possible to extract the instrument 270 as an abnormal instrument.

  Next, the control unit 110 compares the calculated estimated value with the unit capability value (step S24). Here, the unit capability value is a value determined by the specifications of each unit, for example, data determined for the inflow amount and outflow amount that can be processed by one unit. The unit capability value is stored in the diagnostic information storage unit 170.

As shown in FIG. 7, the unit A200 has a unit capability value of 150 m ³ / h, and the unit B250 has a unit capability value of 100 m ³ / h. The control unit 110 compares the estimated value 100m ³ / h of f1 with the unit capability value 150m ³ / h of the unit A200, and the estimated value does not exceed the unit capability value. Determine what is not necessary.

Further, the control unit 110 compares the estimated value 100m ³ / h of f2 with the unit capacity value 100m ³ / h of the unit B250, and the estimated value does not exceed the treated water amount of the unit capacity value. It is determined that no additional installation is necessary. However, the unit B250 has a unit capacity value of 100 m ³ / h, which is the same as the estimated value. Therefore, when the amount of treated water increases, the control unit 110 needs to be added to the unit B250. Judge that there is. In this way, when the amount of treated water is expected to increase, the control unit 110 can perform a capability diagnosis such as determining a unit that needs to be added.

Next, based on the estimated value, the control unit 110 determines the timing for replacing parts such as consumables (step S25). For example, the actual measured outflow value of the unit A200 is 110 m ³ / h, but is calculated based on the estimated value 100 m ³ / h without being based on this value (for example, an amount obtained by integrating the estimated amount with time) is calculated. . Accordingly, it is possible to accurately predict the life of the consumables and the replacement time of the replacement parts from the estimated values without depending on the abnormal values or the actual measurement values of the spill meter 220 of the unit A 200 that may have a large error. .

  Here, in the case of a water treatment plant, the consumable to be replaced is, for example, an ion exchange resin, a membrane, or activated carbon. In the diagnostic information storage unit 170, the control unit 110 stores data relating to the lifetime of these consumables and parts.

  According to the above-described embodiment, diagnosis of each unit constituting the plant, extraction of abnormal instruments, replacement of consumables based on ideal estimated values rather than abnormal instruments and actual measured values that may have large errors Since it is possible to estimate the timing, it is possible to derive an appropriate judgment result that is consistent with respect to the mass balance.

  Functions and methods for realizing such an embodiment can be realized by a program for execution on a computer or server such as the plant operation management apparatus 100 described above. Examples of the storage medium for this program include an optical storage medium, a tape medium, and a semiconductor memory. Further, a storage device such as a hard disk or a RAM provided in a server system connected to a dedicated communication network or the Internet may be used as a storage medium, and the program may be provided via the network.

  As mentioned above, although embodiment of this invention was described, it only showed the specific example and does not specifically limit this invention. Further, the effects described in the embodiments of the present invention only list the most preferable effects resulting from the present invention, and the effects of the present invention are not limited to the effects described in the embodiments of the present invention.

It is a block diagram which shows each unit which comprises a plant operation management apparatus and a plant. It is a flowchart figure of the main process routine which a plant operation management apparatus performs. It is a conceptual diagram which shows the material balance between the units which comprise a plant. It is a flowchart figure of the calculation process routine of the estimated value which a plant operation management apparatus performs. It is a graph which shows the relationship between an objective function and an estimated value. It is a flowchart figure of the diagnostic process routine of the plant which a plant operation management apparatus performs. It is a figure which shows the material balance between the units which comprise a plant, and the unit capability value of each unit.

Explanation of symbols

100 Plant Operation Management Device 110 Control Unit 120 Unit Information Input Unit 140 Communication Unit 150 Communication Unit 160 Measurement Information Storage Unit 170 Diagnostic Information Storage Unit 180 Output Unit 200 Unit A
250 Unit B
210 Inflow meter 220 Outflow meter 260 Inflow meter 270 Outflow meter

Claims (3)

An actual value management step for measuring an actual value of the amount of treated water flowing into and out of each unit of the water treatment plant and storing the actual value;
A calculation step of calculating an estimated value of the water treatment plant based on an actual value stored in the actual value management step and an objective function including a constraint condition of the water treatment plant;
The calculation step is calculated from the objective function using a sum of quotients obtained by dividing the absolute value of the difference between the measured value and the estimated value to be calculated based on the constraint condition by the measured value as an objective function. An operation management support method for calculating an estimated value that minimizes a value to be measured and diagnosing each of the units based on the estimated value.   The operation management according to claim 1, wherein diagnosing each of the units includes executing at least one of extracting an abnormal meter, estimating a consumable replacement time, and diagnosing capacity for each of the units. Support method. The operation management support method according to claim 2, wherein extraction of abnormal equipment is executed based on a difference between the actual measurement value stored in the actual measurement value management step and the estimated value calculated in the calculation step.

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