JPH11272323A - Plant control system - Google Patents

Abstract

(57) [Problem] To provide a plant control system that comprehensively considers the quality of products and the safety and efficiency of plant equipment from the viewpoints of pollution and environment, equipment life management and operator qualities. thing. [MEANS FOR SOLVING PROBLEMS] Input resources composed of external power resources such as public electric power, water and gas, and own resources by private power generation,
Resource supply unit 17 that selectively supplies equipment that constitutes the plant
And an information database unit 15 that stores information necessary for determining an operation schedule such as power rate information or weather information and production management schedule information, and estimates necessary times for inspection of plant facilities, replacement of parts, etc. Operation schedule management unit 11 for instructing and managing the review of inspection time
And an engineer / operator / advice providing unit 13 for announcing the selection and supply information of the resources from the operation schedule management unit 11 and the power supply unit 17 to the operator.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a series of equipment constituting a plant system related to product production, that is, electric and mechanical equipment and devices in the industrial fields such as steel, chemicals and foods.

[0002]

2. Description of the Related Art Conventionally, in a plant system of this kind, a so-called "quality data" for assuring the quality of a product is attached to a manufactured product.

[0003] As the "quality data", data that merely attaches factors that affect the production state of a product, for example, information such as the temperature of the product or the ambient temperature and humidity are usually used.

[0004]

However, in accordance with the recent social situation where the strictness is required in terms of energy situation and environmental problem, not only the quality information of the product but also how much the product is. It is strongly desired that the quality information of a product be made in a state of low energy consumption and how much it does not adversely affect the environment.

[0005] On the other hand, there is also a problem in terms of the life management of plant equipment.

That is, the equipment constituting this type of plant system naturally has an equipment life and deteriorates.

[0007] Accordingly, although the equipment is managed by performing repairs on a regular basis, the state of the equipment constituting the plant equipment changes over time as it operates, so that It is necessary to determine the appropriate time to carry out periodic repairs in consideration of the service life management.

For example, a fluid substance adheres to an inner wall of a pipe constituting a plant facility, and a diameter of the pipe is reduced, which affects a fluid speed in the pipe, which changes characteristics of a plant.

Therefore, it is necessary to operate the plant safely and efficiently in consideration of such a temporal change.

[0010] Furthermore, there is a problem of the quality of the operator which affects the quality of the product.

In other words, in operating a plant safely and efficiently and producing a product of better quality, the know-how of the operator also accounts for a considerable proportion,
Therefore, the quality of the operator is one of the major factors affecting the quality of the product, and this point must be considered.

[0012] The realization of a plant system that comprehensively solves these various problems has been rapidly desired recently.
At present, there is no complete plant control system that takes into account the relationship with the environment, pollution problems, and quality problems of operators.

Therefore, the object of the present invention is to reduce pollution and the environment, to manage the life of equipment and to qualify operators.
An object of the present invention is to provide a plant control system that comprehensively considers the quality of products and the safety and efficiency of plant equipment.

[0014]

According to the present invention, a resource for selectively supplying an input resource having at least one of an external supply resource such as public electric power, water supply, gas or the like or a self-resource by private power generation or the like to plant equipment is provided. A supply unit, an information database unit that stores information necessary for determining an operation schedule of the plant equipment, and an inspection of the plant equipment, estimating a necessary time for replacement of parts, etc., and a review of a periodic maintenance time. An operation schedule management unit for instruction management; and an engineer / engineer for announcing information from the operation schedule management unit and the resource supply unit to an operator.
A plant control system including an operator / advise providing unit is obtained.

Further, according to the present invention, the accuracy change due to aging of the equipment constituting the plant equipment including the sensor for detecting the state of combustion in the furnace and the components of the exhaust gas, the product life and the time for replacement of the installation, etc. A plant control system characterized by further having a facility equipment information section for storing and managing the information and transmitting the information to the operation schedule management section and the plant information management section is obtained.

Further, according to the present invention, the equipment information section includes means for grasping the equipment life of each equipment constituting the equipment and appropriately predicting and setting the periodic repair based on the information. Thus, a plant control system is obtained.

Further, according to the present invention, a resource supply unit for selectively supplying an input resource having at least one of an external supply resource such as public power or water or gas or a self resource by private power generation or the like to plant equipment; An information database unit that stores information necessary for determining an operation schedule of the plant equipment, and an operation that instructs and manages a review of the periodic maintenance time by estimating a necessary time for inspection of the plant equipment, replacement of parts, and the like. A schedule management unit, and an engineer / operator who announces information from the operation schedule management unit and the resource supply unit to an operator.
It is characterized by having an advice providing unit and a plant information management unit that accumulates operation information on similar plant equipment other than the plant equipment concerned, and predicts future changes in plant characteristics from these operation information and history data. Is obtained.

Further, according to the present invention, the plant information management unit includes a plant characteristic management unit having means for predicting a future change in plant characteristics from operation information and history data on another similar plant. When a change in the characteristics of the plant is detected from the data, a plant control system characterized by having a related variable prediction unit that sets a control constant optimal for plant control according to the predicted value of the change in characteristics is obtained.

Further, according to the present invention, a resource supply section for selectively supplying an input resource having at least one of an external supply resource such as public electric power, water, gas, or the like by self-generation to a plant facility; An information database for storing information necessary for determining the operation schedule of the plant equipment, and an operation schedule for estimating the necessary time for the inspection of the plant equipment, replacement of parts, etc., and instructing and managing the review of the periodic maintenance time. A management unit, an engineer / operator / advice providing unit that announces the operation schedule information and the information from the resource supply unit to an operator, and accumulates data relating to waste in the plant furnace to determine whether the plant operation status is appropriate or not. A waste data management unit having means for controlling and managing Manage over data as quality information, the plant control system being characterized in that a quality information creation management unit having an output unit determination result based on the information as the quality information is e.

[0020]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of a plant control system according to the present invention will be described below with reference to the drawings.

FIG. 1 is a block diagram showing an outline of a plant control system in which the basic structure of the present invention is applied to a continuous annealing furnace. A thick-line arrow indicates a movement line of information, and a thin-line arrow indicates energy and physical quantity. Are shown, respectively.

In the figure, a furnace 2 for rolling and manufacturing a steel sheet 1 is shown.
Inside, a furnace temperature sensor 3 for detecting the temperature in the furnace 2 and an induction blower 4 for inducing air blow into the furnace 2 are provided. The inside of the furnace 2 is heated by a heating burner 6. I have.

The burned gas in the furnace 2 is sucked by the induction blower 4 and discarded outside through the chimney 5.

A fuel control section 7 indicated by a dotted line controls the temperature in the furnace 2 and the temperature of the steel sheet 1, and includes a sheet temperature controller 7A for performing PID control and a furnace temperature controller for controlling the temperature in the furnace 2. 7B.

Usually, a constant value of the plate temperature is controlled by the plate temperature controller 7A. However, when the furnace temperature reaches the upper limit, the temperature is switched to the furnace temperature controller 7B in order to prevent the furnace 2 from being damaged. On the other hand, when the furnace temperature falls from the upper limit, the control is switched to the control by the sheet temperature controller 7A.

The waste data management unit 8 manages data relating to the waste in the furnace 2 and measures at least one of the amount of oxygen and the amount of carbon monoxide at the inlet and the outlet of the chimney 5 and measures them. The ratio of the air to the air is determined and stored as measurement data, and the suitability or unsuitability of the plant operation status is determined from the ratio, and the resulting data is sent to the quality information creation management unit 9.

The quality information creation management section 9 collects the sheet temperature data, which is the control amount of the sheet temperature controller 7A, stores it as data, and manages the data from the waste data management section 8 as quality information. Then, a determination result based on such information is output as quality information 9A. As the data of the sheet temperature, for example, the heating time of the sheet temperature, which is the quality information of the steel sheet 1 itself as the product, can be mentioned.

The equipment information section 10 stores and manages accuracy changes due to aging of the accuracy of the control valves and other equipment, such as sensors, product life, and installation replacement time, and one output 10A. Is sent to an operation schedule management unit described later, and the other output 10B is sent to a plant information management unit described later.

The above-mentioned operation schedule management unit 11
It manages the operation schedule of the plant, receives the output data 10A from the equipment information section 10, estimates the time required for replacement, inspection, etc., and reviews the periodic maintenance time.

The plant information management unit 12 includes a function variable prediction unit 12A and a plant characteristic management unit 12B. When the function variable prediction unit 12A detects a change in plant characteristics from history data, A control constant optimal for plant control is set according to a predicted value of a characteristic change in the characteristic management unit 12B.
The plant characteristic management unit 12B predicts future changes in plant characteristics from the history data and operation information on other similar plants.

The plant information management unit 12 collects data relating to the characteristics of the plant in a time series and accumulates the data as the history data. At the same time, the plant information management unit 12 includes not only information on its own equipment but also operation information on other similar plants. Are also input as data from the equipment information unit 10 and stored.

Here, regarding the characteristics of the plant,
For example, a pipe of a piping facility will be described as an example. As a component constituting the plant equipment, there are also components such as pipes of plumbing equipment, in addition to the above-described equipment. Inside the pipe, substances such as petroleum, cement, and chemicals, which are raw materials of the product, pass, and are also used to feed fuel and air from the heating burner 6. Therefore, in a pipe, when a substance passes through the pipe, the inside diameter of the pipe slightly changes due to the adhesion of a passing substance to the inner wall of the pipe, and the flow rate or the dead time is changed. Changes.

Returning to the description of the configuration, the set value predicted by the plant information management unit 12 is stored in the engineer / operator advice providing unit 13 by the operator via a human machine interface (HMI) 14 such as a display. Is to be provided.

The information database 15 stores electric power rate information, weather information, production management schedule information, and the like. These information are sent to the operation schedule management unit 11 as necessary. The operation schedule management unit 11 creates a schedule that can suppress the power charge at the lowest cost based on the power charge information and the production management schedule information.

The air amount control unit 16 sends the optimum air amount for plant control to the fuel control unit 7 based on the plant characteristic information from the plant information management unit 12.

The power supply unit 17 selectively supplies power to a power supply unit (not shown) of each of the devices and equipment constituting the plant, that is, a power generation unit 18 by private power generation and the like, and externally supplied power as public power. From the operating schedule management unit 1 described above.
1 based on the operation schedule information. This operation schedule information is also sent to the quality information creation management unit 9 and is stored as a part of the history information.

Next, the operation of the plant control system having the above configuration will be described with reference to FIG.

In FIG. 1, the inside of the furnace 2 is heated by a heating burner 6 and the heated furnace temperature is measured by a temperature sensor 3.
And is controlled by the furnace temperature controller 7B to a temperature suitable for the rolling production of the steel sheet 1. At this time, in the furnace 2, the combustion state is monitored by the oxygen O2 and the carbon monoxide CO generated by the combustion by the heating burner 6. This monitoring is performed in the vicinity of the flue inlet 5A and in the vicinity of the outlet 5B of the chimney 5, and at least one of the oxygen amount or the carbon monoxide amount of the air is measured by the sensors 5C and 5D, and the air is measured. Find the percentage that occupies,
The ratio is stored as measurement data in the waste data management unit 3, and at the same time, the suitability or unsuitability of the plant operation status for the product in the furnace 2 is determined from the ratio, and the data of the determination result is stored in the quality information creation management unit. 9 and stored and managed as quality information.

Next, the operation of the life management of the equipment constituting the plant equipment will be described.

In order to accurately measure the temperature, energy, and flow rate by controlling the operation of the plant equipment, it is essential that the accuracy of the equipment constituting the plant equipment is correct. However, as described above, these devices generally have a high frequency of being reduced in accuracy or broken down due to fatigue due to aging, and therefore, it is difficult to manage the life of these devices. It becomes important in driving management.

In FIG. 1, an operation schedule management unit 1
In 1, the operation schedule of the plant is managed. For that purpose, the data of the equipment information section 10 is received, and the necessary time for replacement and inspection is estimated. This estimation result is sent to the engineer / operator advice providing unit 13, where it is converted into advice information, and an announce is made to the operator via the human-machine interface (HMI) 14 to reconsider the periodic inspection period. .

A small sealed lead-acid battery is often used as a power supply backup battery for the fuel control device 7 and the air amount control device 16, but the life of the small sealed lead-acid battery varies greatly depending on the ambient temperature. Therefore, it is necessary to fully consider the influencing factors and estimate the appropriate replacement time of the life product and the repair / inspection time of the equipment from the characteristics of the constituent devices. For this purpose, equipment management information including information on the installation time of these equipment and information on the product life is input to the equipment information section 10.

In order to estimate the replacement time of the life product and the repair / inspection time of the equipment, the change in the characteristics of the plant is grasped. Data on the characteristics of this type of plant is collected in time series and the history is collected. The information is stored in the plant information management unit 12. The plant information management unit 12 receives not only information on its own equipment but also operation information and the like on other similar plants as information from the equipment information unit 10. From the data, the plant characteristic management unit 12B predicts future characteristic changes of the plant. When a change in plant characteristics is detected from the history data stored in the plant information management unit 12, an optimum control constant is set according to a predicted value of the change in characteristics.

Next, a description will be given of the countermeasure effect of the plant equipment from the external situation of the installation place.

In general, the equipment of a plant is not completely free from the influence of external conditions at the place where it is being built. For example,
When the outside air temperature is low, the heat loss to the outside increases, and when the set value is the same as usual, it takes longer than usual to reach a predetermined value. Conversely, when the outside air temperature rises, the temperature may transiently become higher than the set value, which affects the quality of the steel sheet 1.

Accordingly, in order to maintain the quality accuracy efficiently, it is necessary to appropriately grasp the relationship between the outside air temperature and the set value and to set the set value.

The plant information management section 12 stores this kind of correlation as data, and the related variable prediction section 12A appropriately predicts the setting of variables such as set values from the stored data. Is announced to the operator via the engineer / operator advice providing unit 13. In addition, production may be stopped at the end of the month due to monthly production volume. In this case, from the viewpoint of energy saving, it is necessary to set an operation schedule that minimizes the cost of supplied power. Therefore, according to the present invention, the operation schedule management unit 11 creates a schedule capable of suppressing the power rate to the lowest price from the power rate information or weather information stored in the information database unit 15. On the other hand, in operating the plant safely and efficiently, the part based on the know-how of the operator cannot be ignored. This is because the qualifications of the operator, a boiler operator, are divided into special grade, first grade and second grade, and the quality of the operators is not uniform. Therefore, in the present invention, tips and the like in plant operation are input to the plant information management unit 12 as related information, and are used for prediction of related variables, prediction of plant characteristics, and the like.・ Operator advice provider 1
3 and provided to the operator, thereby eliminating variations in the operator during plant operation.

Next, the control procedure of the plant control system according to the present invention, and further, the life management, the environment management and the quality management of the operator will be described.

Generally, as the quality information of the steel sheet 1, the following 2
Type information includes (1) steel sheet quality indicating a heating time (steel sheet speed) and a heating temperature, and (2) environmental quality indicating a ratio of oxygen, carbon monoxide, and Nox in air.
In the present invention, these two types of data are measured and collected by the sensors 5C and 5D and the like, input to the quality information creation management unit 9, and the quality information creation management unit 9 converts the data into a human interface as quality information according to a predetermined format. (HMI) 14 and announce to operator. Also, information on the installation time of the equipment constituting the equipment, for example, a hard disk device which is important as a storage device of a human interface (HMI) device 14 of a plant, and a small sealed lead-acid battery used as a backup of a power supply, and information on product life. The equipment management information composed of the above is input to the equipment information section 10. Then, the equipment information section 10 obtains a scheduled replacement date from the input information on the mounting time and the product life, and passes the information to the operation schedule management section 11.

The operation schedule management section 11 checks this data and the scheduled scheduled maintenance date, and corrects the scheduled maintenance date if the service life and the scheduled maintenance date deviate significantly. When the product life is correlated with the ambient temperature, as in the case of the small sealed lead-acid battery described above, the information is collected as external factor information in the plant information management unit 12.
The product replacement date is determined from the ambient temperature of the battery.

The plant characteristic management section 12B collects information such as set values, control amounts, and operation amounts, which are basic amounts of the plant, and information such as the outside air temperature, and manages the collected information as history data. These data and current plant settings,
The control amount and the operation amount are compared with controllability index data such as set value followability and robustness against disturbance. If the controllability deteriorates, the engineer / operator advice providing unit 13 is notified to that effect. Send a message to

On the other hand, as the related information, the correlation between the outside air temperature and the characteristic change and the method of adjusting the control constant are input in advance.
Based on the knowledge and the current state, the control constants, optimal set values, and the like are stored in the plant characteristic management unit 12B and the related variable prediction unit 1B.
In 2A, an estimate is made and an engineer / operator advice providing unit 13 makes an announcement to an operator.

In the power supply unit 17, when private power generation by utilizing non-polluting natural energy such as solar power generation is selected and power is supplied to the equipment, it is desirable from the viewpoint of protection of the earth resources and environmental protection. State. However, in the case of this solar power generation, the amount of power generation is closely related to the duration of sunshine, so weather information is indispensable for predicting the amount of power generation, and it is rare that power can be supplied only by private power generation. In this case, public electricity will be used, but the electricity rate fluctuates slightly depending on the season.

Therefore, the operation schedule management unit 11 adjusts the schedule based on the power rate information, the weather information, and the estimated annual production so as to achieve the annual production at the lowest cost.

Next, although the operating efficiency of the plant is greatly affected by the qualities of the operator, the present invention also solves this point by the following control procedure.

Due to the configuration of the plant equipment, there are important points to be noted, such as pans, which are particularly easily worn or fatigued. The control at the time of starting or stopping the plant is performed by the fuel control unit 1.
In many cases, the automatic control by the 2A and the air amount control unit 12B alone is not sufficient, and the manual operation of the operator is often used. As for these, the quality of the operator has a great influence on the controllability, and also has a great influence on the product quality and the operation efficiency of the plant. Therefore, the present invention uses the know-how of a skilled operator with excellent skills as related information,
The information is input to the plant information management unit 12, and the knowledge can be referred to the operator himself / herself as necessary through the engineer / operator advice providing unit 13.

[0057]

According to the present invention described above, information on the environment in which the product is made and the pollution aspects are incorporated into the plant operation control aspect, and detailed life management for each component of the plant and operator By implementing a comprehensive plant control system that incorporates qualities into plant operation control, it has become possible to grasp energy and other environmental and pollution-related qualities as previously impossible quality information. Operating efficiency can be greatly improved.

[Brief description of the drawings]

FIG. 1 is a configuration block diagram illustrating an embodiment of a plant control system according to the present invention.

[Explanation of symbols]

1 ………………… Steel plate 2 ……………………… Furnace 3, 5C, 5D …………………… Sensor 4 ………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… ……………………… Fuel control unit 7A …………………………………………………………………………. ……… Waste data management unit 9 ………………………… Quality information creation management unit 10 …………………………. …………………………………………………………………… ·································································································· ........... Plant characteristic management unit 13 ……………………………………………………………………………………………………………………………… ···················································· Information database unit 16 Air flow control unit 17 Power supply unit 18 Power supply unit 18 Electric power Generator

Claims (6)

[Claims] 1. A resource supply unit for selectively supplying an input resource having at least one of an external supply resource such as public electric power, water supply, gas or the like or a self-resource such as private power generation to a plant facility, and an operation schedule of the plant facility An information database unit that accumulates information necessary for determining the operation, an operation schedule management unit that estimates the necessary time for the inspection of the plant equipment, replaces parts, etc., and instructs and manages the review of the periodic maintenance time. A plant control system comprising: an operation schedule management unit; and an engineer / operator advice providing unit that announces information from the resource supply unit to an operator. 2. The apparatus stores and manages accuracy changes due to aging of equipment constituting a plant facility including a sensor for detecting a combustion state in a furnace and a component of exhaust gas, a product life, a mounting replacement time, and the like. The equipment information section that sends information to the operation schedule management section and the plant information management section
The plant control system according to claim 1, further comprising: 3. The facility equipment information section includes means for grasping the equipment life of each equipment constituting the equipment and appropriately predicting and setting a periodic repair based on the information. Item 3. The plant control system according to Item 2. 4. A resource supply unit for selectively supplying an input resource having at least one of an external supply resource such as public power or water or gas or a self-resource such as private power generation to a plant facility, and an operation schedule of the plant facility An information database unit that accumulates information necessary for determining the operation, an operation schedule management unit that estimates the necessary time for the inspection of the plant equipment, replaces parts, etc., and instructs and manages the review of the periodic maintenance time. An engineer / operator / advice providing unit that announces information from the operation schedule management unit and the resource supply unit to the operator,
A plant control system, comprising: a plant information management unit that accumulates operation information related to other similar plant equipment other than the plant equipment and predicts a future change in plant characteristics from the operation information and the history data. . 5. A plant characteristic management unit having means for predicting a future characteristic change of a plant from operation information and history data of another similar plant, and a plant characteristic change unit based on the history data. 5. The plant control system according to claim 4, further comprising: a related variable prediction unit that sets an optimum control constant for plant control in accordance with a predicted value of the characteristic change when the detection is performed. 6. A resource supply unit for selectively supplying an input resource having at least one of an external supply resource such as public power or water or gas, or an own resource by private power generation or the like to a plant facility, and an operation schedule of the plant facility An information database unit that accumulates information necessary for determining the operation, an operation schedule management unit that estimates the necessary time for the inspection of the plant equipment, replaces parts, etc., and instructs and manages the review of the periodic maintenance time. An engineer / operator / advice providing unit that announces operation schedule information and information from the resource supply unit to an operator, and a unit that accumulates data relating to waste in the plant furnace and controls and manages the suitability or unsuitability of the plant operation status. The waste data management unit with the data and the data from this waste data management unit as quality information And a quality information creation management unit having output means for outputting a determination result based on the information as quality information.