JPH09330118A - Preventive maintenance device for control equipment - Google Patents

Abstract

PROBLEM TO BE SOLVED: To select a process alarm, a system alarm, an internal error, etc., as objects of alarm monitoring by providing a maintenance information display part which edits the system alarm and an equipment internal state into abnormal symptom information on control equipment and displays the information. SOLUTION: A system alarm monitor part 30 monitors communication errors occurring in a plant control part 10 and a man-machine interface pat 20 and the system alarm in case of an equipment stop. An equipment internal state monitor part 40 monitors the equipment internal operation states of the plant part 10 and man-machine interface part 20. A maintenance information transmission part 50 sends the system alarm gathered by the system alarm monitor part 30 and the equipment internal state gathered by the equipment internal state monitor part 40 to the maintenance information display part 60. The maintenance information display part 60 edits the system alarm and equipment internal state, sent from the maintenance information transmission part 50, into the abnormality symptom information on the control equipment and displays it.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a preventive maintenance device for control equipment used for a control device in the process industry such as petrochemical industry and nuclear power plant, and in particular, a customer can easily set an alarm monitoring target and an alarm report destination. Regarding improvements that can be sorted out.

[0002]

2. Description of the Related Art An apparatus for monitoring the operating state of a plant includes:
For example, as disclosed in Japanese Patent Application Laid-Open No. 5-166086, when an alarm occurs in a running process, an alarm and detailed information are displayed on a display device to notify an operator. Such a process alarm is an alarm generated in an operation mode for controlling a plant, for example, an HI alarm generated when an input value from a process exceeds a set value, and an output value to the process. There is an operation amount HI alarm or the like generated when the value exceeds a set value.

By the way, in recent years, from the viewpoint of preventive maintenance,
Before a failure occurs in a process control device, deterioration of the device is predicted in advance, and when the degree of deterioration reaches a certain level, the device is replaced. According to such preventive maintenance, there is an advantage that the customer does not have an unexpected failure of the control device and the operation plan can be easily established. For example, when there is a sign of functional deterioration in a certain valve controller, the number of operators is increased and manual control is performed to ensure plant operation while performing inspection and
Instrumentation engineers are performing repairs. In the current plant operation, the number of operators is smaller than in the past, so it is important to make a work plan in advance.

In order to perform preventive maintenance, it becomes necessary to detect system alarms and internal errors. here,
The system alarm is an alarm that occurs in the automatic control device, such as a communication error or equipment stoppage.The internal error is a read / write operation on the hard disk, which normally operates after several retries, and memory parity error recovery. It refers to non-surfaced system alarms that are stored inside the automatic controller, such as when a function is activated.

[0005]

However, according to the conventional device, when a process alarm is monitored, it is necessary to connect a dedicated alarm monitoring device to the automatic control device via the gateway, which lacks versatility. There were challenges. In addition, system alarms and internal errors are alarms that are less urgent for operators, so they are not covered by the alarm monitoring device, making it difficult for facility managers to collect alarm information necessary for preventive maintenance. was there. The present invention solves such a problem, and an object of the present invention is to provide a preventive maintenance device for a control device capable of selecting a process alarm, a system alarm, an internal error or the like as an alarm monitoring target.

[0006]

Means for Solving the Problems The present invention for achieving the above object is a plant for controlling by inputting and outputting a measured value from a detection end installed in a plant to be controlled and an operation amount to the operation end. A preventive maintenance device used for a control device having a control unit (10) and a man-machine interface unit (20) for transmitting information input and output by the plant control unit to the operator. A means 30 for monitoring a system alarm such as a communication error or a stoppage of equipment, a means 40 for monitoring an operation state inside the equipment of the plant control unit or the man-machine interface, and a system collected by the system alarm monitoring means. An alarm and a maintenance information transmission unit 50 for transmitting the device internal state collected by the device internal state monitoring means, and the maintenance information transmitting unit 50. Using the system alarms and devices internal state sent from the information transmission unit, it is characterized by comprising a maintenance information presentation unit 60 to display and edit the abnormality indication information of the controlled device.

According to the configuration of the present invention, the system alarm monitoring section 30 monitors the system alarm generated in the plant control section and the man-machine interface section.
The device internal state monitoring unit 40 monitors the operating states inside the device such as the plant control unit and the man-machine interface unit. The maintenance information transmitting unit 50 transmits the system alarm collected by the system alarm monitoring unit and the device internal state collected by the device internal state monitoring unit to the maintenance information presenting unit. The maintenance information presenting unit 60 uses the system alarm and the device internal state sent from the maintenance information sending unit to edit and display the abnormality sign information of the control device. Man Machine
The interface section is monitored by an operator in charge of plant operation, whereas the maintenance information presentation section 60 is monitored by an instrumentation engineer in charge of control equipment such as a plant control section and a man-machine interface section. Data analysis necessary for preventive maintenance is performed.

[0008]

DETAILED DESCRIPTION OF THE INVENTION The present invention will be described below with reference to the drawings. FIG. 1 is a block diagram showing the configuration of an embodiment of the present invention. In the figure, a plant control unit 10 controls input and output of a measured value from a detection terminal and an operation amount to an operation terminal installed in a plant to be controlled, and includes a single-loop controller and a distributed field controller. It corresponds to the control device. The man-machine interface unit 20 includes the plant control unit 1
0 is used to convey information to be input / output to the operator. For example, a general-purpose workstation is used.

The system alarm monitoring section 30 monitors system alarms such as communication errors occurring in the plant control section 10 and the man-machine interface section 20 and equipment stoppages. The device internal state monitoring unit 40 includes the plant control unit 10
Also, the operating state inside the device of the man-machine interface unit 20 is monitored. This operating state includes the temperature inside the device, the operating state of the fan, the actual operating time since the last inspection, and the voltage of the battery for power failure backup. There is an internal error as the operating state to be monitored, which is unique to the man-machine interface unit 20. The internal error corresponds to the operation state of the error correction function (EDC) for the memory and the delay time and the number of retries for the disk. As an operation state to be monitored unique to the plant control unit 10, each printed circuit board is instructed to perform a mode transition to a ready mode or a self-diagnosis mode, and it is confirmed whether the printed circuit board complies with the mode transition command. Make sure there is no.

The maintenance information transmission unit 50 transmits the system alarm collected by the system alarm monitoring unit 30 and the device internal state collected by the device internal state monitoring unit 40 to the maintenance information presentation unit 60. These system alarm monitoring unit 30, device internal state monitoring unit 40, and maintenance information transmission unit 5
For example, when 0 is installed side by side with the man-machine interface unit 20, it is convenient to be able to use the monitoring function of the process alarm and the system alarm together.

The maintenance information presenting unit 60 uses the system alarm and the device internal state sent from the maintenance information sending unit,
Edit and display the error sign information of the control device. In the case of a large plant, the instrumentation engineer and the person in charge of operation may be in different buildings, so it may be configured with a workstation connected to the man-machine interface unit 20 using a communication line, for example.

FIG. 2 is an explanatory view of concrete instrumentation equipment for realizing the apparatus of FIG. A for large combinato
A plurality of factories, such as the factories and factories B, are connected using a general-purpose LAN. In the general-purpose LAN, in addition to the man-machine interface unit 20 of each factory, a PC equipped with the function of the maintenance information presenting unit 60, and which factory manufactures the ordered product and how to deliver it to the customer A production management computer or the like that manages is connected. L for instrumentation at each factory
When AN is installed, the plant control unit 10 and man-machine
The interface unit 20 is connected. Then, the instrumentation engineer only monitors the maintenance information presentation unit 60,
Information necessary for preventive maintenance of the equipment of each factory connected to the general-purpose LAN can be obtained. Then, the instrumentation engineer confirms the content of the preventive maintenance data, discusses the message details explaining the content of the event and the maintenance person in charge of the manufacturer, and examines the importance of the trouble to determine the optimum maintenance method. Derive. As a result, treatment can be performed before the system goes down, and stable operation of the plant can be ensured.

FIG. 3 is a diagram showing an example of signals monitored by the equipment internal state monitoring unit 40, where the vertical axis represents the equipment internal temperature [° C],
The horizontal axis represents the actual operation time [H]. Here, the internal temperature of the device fluctuates in the vicinity of room temperature of 14 to 23 [° C], and it is judged that the electronic device is not thermally abnormal. Preferably, for early detection of abnormal signs,
When the temperature rises rapidly such that the temperature gradient exceeds a predetermined threshold value, for example, 10 [° C / H], measures such as checking the operating state of the fan are taken.

Next, a case where the device internal state monitoring unit 40 monitors an internal error will be described. Regarding the memory error, since the system side of the man-machine interface unit 20 adopts an EDC (Error Detection & Correcting) function to improve reliability, a 1-bit error corresponding to a conventional parity error is internally generated. Since the correction is made, the user does not recognize the occurrence of the memory error. However, if the EDC function operates every time the same address is accessed, there is a high probability that an error of 2 bits or more will occur in the future, which is a problem.

Therefore, when the EDC function operates, attention is paid to the memory address, the content is accumulated for a certain period of time, and error monitoring is performed. This makes it possible to detect the continuous occurrence of memory errors in a short time. The user is notified when the continuous occurrence of the memory error exceeds the threshold value, and is used as the maintenance appearance data.

Regarding the disk error, man-machine /
The system side of the interface section 20 carries out an error check at the time of reading / writing, and when an error occurs, the spare area is to be used. Therefore, the occurrence of the disk error will not be noticed by the user.
However, the spare area is finite, and if the spare area is used frequently, the spare area may reach the bottom, which is a problem.

Therefore, by monitoring the usage amount of the spare area used within a fixed time from the time when the use of the spare area is detected, it is possible to detect the continuous occurrence of disk errors in a short time. In addition, a fixed monitoring cycle is set to monitor the free space in the spare area. The user is notified when the continuous occurrence of disk errors exceeds the threshold and when the free space falls below the threshold, so that the data can be used as preventive maintenance data.

FIG. 4 is a block diagram showing the configuration of another embodiment of the present invention. As for the iron, a preventive data definition unit 70 is added to the device of FIG. The preventive maintenance data definition unit 70
System alarm monitoring unit 30 and device internal state monitoring unit 40
This is a file that defines the data to be monitored in. When updating equipment, this preventive maintenance data definition unit 70
Also, by redefining to match the updated equipment, even if the equipment is updated or added, preventive maintenance can be reliably performed with simple engineering work.

[0019]

As described above, according to the present invention, the maintenance information presenting unit 60 collects the system alarms collected by the system alarm monitoring unit 30 by the maintenance information transmitting unit 50 and the device internal state monitoring unit 40. Since the instrumentation staff can monitor the data necessary for preventive maintenance of the plant control unit 10 and the man-machine interface unit 20 by presenting the operating state of the inside of the device, the control device of the control device can be displayed at the time when a sign of an abnormal state appears. This has the effect of being able to understand anomalies and being able to respond before a serious event such as a system down occurs, thus increasing the reliability of plant operation. Further, according to the second aspect of the present invention, the preventive maintenance data definition unit 70 redefines the preventive maintenance data in response to the update or extension of the equipment, so that the equipment can be updated or added. The effect is that preventive maintenance can be reliably performed with simple engineering work.

[Brief description of drawings]

FIG. 1 is a configuration block diagram showing an embodiment of the present invention.

FIG. 2 is an explanatory diagram of specific instrumentation equipment for realizing the apparatus of FIG.

FIG. 3 is a diagram showing an example of signals monitored by a device internal state monitoring unit 40.

FIG. 4 is a configuration block diagram showing another embodiment of the present invention.

[Explanation of symbols]

 10 plant control unit 20 man-machine interface unit 30 system alarm monitoring unit 40 equipment internal state monitoring unit 50 maintenance information transmission unit 60 maintenance information presentation unit 70 preventive maintenance data definition unit

Claims (2)

[Claims] 1. A plant control unit (10) for inputting and outputting a measured value from a detection end and an operation amount to an operation end installed in a plant to be controlled, and an input / output at this plant control unit. A preventive maintenance device used for a control device having a man-machine interface unit (20) for transmitting information to be transmitted to an operator, wherein a system alarm such as a communication error or a device stop occurring in the plant control unit or the man-machine interface unit. (30), a means (40) for monitoring the operating status inside the equipment of the plant control unit or the man-machine interface, a system alarm collected by the system alarm monitoring means, and an internal status of the equipment. A maintenance information transmitting means (50) for transmitting the internal state of the equipment collected by the monitoring means, and a transmission from the maintenance information transmitting means. A preventive maintenance device for a control device, comprising: a maintenance information presenting means (60) for editing and displaying abnormal sign information of the control device by using the system alarm and the internal state of the device. 2. A plant control unit (10) for inputting and outputting a measured value from a detection end installed in a plant to be controlled and an operation amount to the operation end, and an input / output at this plant control unit. A preventive maintenance device used for a control device having a man-machine interface unit (20) for transmitting information to be transmitted to an operator, wherein a system alarm such as a communication error or a device stop occurring in the plant control unit or the man-machine interface unit. (30), a means (40) for monitoring the operating status inside the equipment of the plant control unit or the man-machine interface, a system alarm collected by the system alarm monitoring means, and an internal status of the equipment. A maintenance information transmitting means (50) for transmitting the internal state of the equipment collected by the monitoring means, and a transmission from the maintenance information transmitting means. Maintenance information presenting means (60) for editing and displaying abnormal sign information of the control equipment by using the system alarm and the equipment internal status, a system alarm monitored by the system alarm monitoring means, and the equipment internal status monitoring A preventive maintenance device for a control device, comprising: a preventive maintenance data definition unit (70) for defining an internal state of the device monitored by means.