JP2012168799A - Plant monitoring device and plant monitoring method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve efficiency of a maintenance work by a worker.SOLUTION: When detecting an abnormality sign of a plant machine 1 based on actual data of device state data obtained from a measuring device 11 installed in the plant machine 1 and abnormality sign determination data preliminarily stored in an abnormality sign determination data storage section 32, a plant monitoring device 2: displays a three dimensional CAD machine layout image of the plant machine 1 where the abnormal sign is detected together with the surrounding plant machines 1 on a display device 50 by referring to a three dimensional CAD machine layout information storage 33; obtains maintenance guide information necessary for executing a maintenance work against the abnormality sign from a maintenance guide information storage section 35; and superimposes the obtained maintenance guide information on the three dimensional CAD machine layout image.

Description

  The present invention relates to a plant monitoring apparatus and a plant monitoring method for monitoring the health of a process plant.

  In a process plant, it may be necessary to stop the entire operation just because an abnormality or accident has occurred in some of the equipment. The failure to produce results in a decrease in sales.

  Therefore, in the process plant, in order to ensure the soundness of the operation, various measuring devices are provided in each plant equipment constituting the process plant, and the monitoring center is measured by the measuring device. A plant monitoring device is provided for collecting and monitoring data (for example, pressure, temperature, flow rate, etc.) representing the operating state of each plant device via a communication network or the like.

  When an abnormality is detected in any of the data representing the operating status of each plant device, the plant monitoring device displays that fact on a monitoring display device, etc., to prevent the operator from performing the abnormality avoidance or maintenance work. Encourage execution. At that time, the plant monitoring device of the monitoring center collects various data representing the operating state of each plant device, so even if an abnormality occurs in a certain plant device, the worker often Without going to the site where the plant equipment is installed, the abnormal state can be known while staying in the monitoring center.

  For example, Patent Document 1 displays a three-dimensional image of the entire plant equipment arrangement in the vicinity of the plant equipment in which an abnormality has been detected based on an image obtained from a design database or a monitoring camera of the three-dimensional arrangement of plant equipment. Furthermore, in the display image, technology that blinks the plant equipment in which an abnormality has been detected to stand out, and displays a graph of measurement data related to the abnormality or a diagnostic message that indicates the state of the abnormality. Is disclosed. Patent Document 2 discloses a technique for displaying the operation state and abnormal state of plant equipment as a three-dimensional virtual reality image.

  By using the techniques disclosed in Patent Literature 1 and Patent Literature 2, the worker grasps the abnormal state of the plant equipment in which the abnormality has occurred in a monitoring center, specifically and in detail. It becomes possible.

Japanese Patent Application Laid-Open No. 07-152984 JP 2000-259243 A

  However, although the above-mentioned prior art provides useful information for the worker to grasp the outline of the abnormality of the plant equipment, it is necessary to analyze the cause of the abnormality when the abnormality of the plant equipment is detected. And information on what actions the worker should take are not necessarily provided.

  Therefore, conventionally, maintenance work including analysis of the cause of abnormality of plant equipment can be performed only by skilled workers, and the work is troublesome and the work efficiency is never high. In particular, in the conventional plant monitoring device, since the viewpoint of detecting a sign of abnormality is not sufficient, the maintenance work is performed after the abnormality is detected. As a result, the maintenance work becomes complicated and takes a long time. It was a thing.

  In view of the problems of these prior arts, the present invention provides a plant monitoring apparatus capable of performing maintenance work before plant equipment reaches an abnormal state and capable of improving the efficiency of the maintenance work. An object is to provide a plant monitoring method.

  The plant monitoring device according to the present invention is connected to a measuring device provided in a plant device constituting the plant, and monitors a sign of abnormality in the plant device based on device state data of the plant device acquired from the measuring device. . For this purpose, the plant monitoring device includes a device status record data storage unit that accumulates device status data acquired from the measuring device as time-series device status record data, and an abnormal sign determination necessary for determining an abnormal sign of plant equipment. Pre-accumulation data storage unit that stores data in advance, and when a pre-failure of a plant device is detected, information required for maintenance work performed in response to the pre-failure is stored as maintenance guide information in advance A maintenance guide information storage unit; a three-dimensional CAD device arrangement information storage unit that pre-stores three-dimensional CAD device arrangement information of plant equipment in the plant; and device state data acquired from the measuring device; The device status record data stored in the data storage unit and the abnormality sign determination data storage unit The abnormality sign of the plant equipment is detected based on the abnormality sign determination data being detected, and for the plant equipment in which the abnormality sign is detected, the plant equipment and the surrounding plant equipment in which the plant equipment is arranged 3 Display a three-dimensional CAD equipment arrangement image on a display device, search the maintenance guide information storage unit, extract maintenance guide information about the plant equipment in which the abnormality sign is detected, and extract the extracted maintenance guide information It is characterized by being displayed superimposed on the displayed three-dimensional CAD device arrangement image.

  That is, in the plant monitoring apparatus of the present invention, a sign of abnormality before the plant equipment reaches an abnormal state is detected, and at that time, maintenance guide information useful for maintenance work is provided to the worker.

  According to the present invention, it is possible to provide a plant monitoring apparatus and a plant monitoring method capable of performing maintenance work before plant equipment reaches an abnormal state and improving the efficiency of the maintenance work. it can.

The figure which showed the example of the apparatus structure of the plant monitoring apparatus which concerns on embodiment of this invention, and the whole process plant. The figure which showed the specific example of the measuring apparatus which measures the mechanical soundness of plant equipment. The figure which showed the example of the structure of the apparatus state performance data memorize | stored in a memory | storage device, abnormality sign determination data, and maintenance guide information. The figure for demonstrating the determination method of the detection of the abnormality sign by the apparatus abnormality sign detection process part of an arithmetic processing unit. The figure which showed the example of how to determine the "predictive time" contained in the abnormal sign determination data. The figure which showed the example of the processing flow of the apparatus abnormality sign detection process in an apparatus abnormality sign detection process part. The figure which showed the example of the display screen which displayed the maintenance guide information on the plant equipment system diagram. The figure which showed the example of the display screen which displayed maintenance guide information on the three-dimensional CAD apparatus arrangement | positioning image. The figure which showed the other example of the display screen which displayed maintenance guide information on the three-dimensional CAD apparatus arrangement | positioning image.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  FIG. 1 is a diagram illustrating an example of a device configuration of a plant monitoring apparatus and an entire process plant according to an embodiment of the present invention. As shown in FIG. 1, the process plant 100 includes a plurality of plant devices 1, a plant monitoring device 2, and a design / maintenance information management device 6.

  The plant equipment 1 is a general term for equipment that directly constitutes the process plant 100, and refers to, for example, a reaction tank, a combustion furnace, a heater, a storage tank, a turbine, a generator, a pump, a cylinder, piping, a valve, and the like. . These plant devices 1 are provided with a measuring device 11 for measuring the operation state, and further, a control device 12 for controlling / changing the operation state of the plant device 1 and the adjacent plant device 1. Is provided.

  Here, in many cases, one plant device 1 is provided with at least one measuring device 11, but the control device 12 includes, for example, a passive tank device 1 such as a storage tank or a pipe. As in the plant equipment 1 (# 2) shown in FIG. 2, the control device 12 may not be provided. In the present embodiment, the valve is not an accessory of a storage tank or piping, but is regarded as an independent plant device 1.

  As the measuring device 11 provided in the plant equipment 1, for example, in addition to the one that directly measures the operating state of the plant equipment 1 such as the pressure and temperature in the reaction tank, for example, the thickness of a tank or a pipe There is a UT (Ultrasonic Testing) probe for measuring the vibration, an acceleration pickup for measuring the magnitude of the vibration, and the like. These latter measuring devices 11 mainly measure the external shape and mechanical strength of the plant equipment 1 and ensure the safety and environmental protection of the entire process plant 100 including the plant equipment 1. Is provided.

  In the present specification, not the direct operating state of the plant equipment 1 itself, but the measuring device 11 provided for safety, environmental conservation, etc. is used to measure “the mechanical health of the plant equipment 1. A specific example of the measuring device 11 will be described in detail separately with reference to FIG.

  Further, as shown in FIG. 1, the measurement device 11 and the control device 12 provided in the plant equipment 1 are connected to the plant monitoring device 2 via a communication network 7 (for example, a wired or wireless LAN (Local Area Network)). Usually, it operates according to the instruction information sent from the plant monitoring device 2.

  The plant monitoring device 2 is configured by a so-called computer, and includes an arithmetic processing device 20, a storage device 30, an input device 40 (for example, a keyboard, a mouse, a touch panel), a display device 50 (for example, an LCD (Liquid Crystal Display)), and the like. Is provided.

  The arithmetic processing unit 20 is configured by an arithmetic circuit, a program instruction processing circuit, and the like, and reads out and executes a program stored in advance in the storage device 30, thereby executing an apparatus state data acquisition unit 21 and a control arithmetic processing unit 22. The functions of functional blocks such as a device control data output unit 23, a device abnormality sign detection processing unit 24, a three-dimensional CAD (Computer Aided Design) device arrangement image display processing unit 25, and a maintenance guide information display processing unit 26 are realized.

  The storage device 30 is configured by a DRAM (Dynamic Random Access Memory), a flash memory, a hard disk device, and the like, and in that storage area, a device status record data storage unit 31, an abnormality sign determination data storage unit 32, and a three-dimensional CAD device arrangement An information storage unit 33, a plant equipment system diagram storage unit 34, a maintenance guide information storage unit 35, and the like are configured.

  Further, the plant monitoring device 2 is connected to the design / maintenance information management device 6 via the communication network 7. The design / maintenance information management device 6 includes a design drawing DB (Data Base) 61 in which design drawings for each plant device 1 (including the measuring device 11 and the control device 12) constituting the process plant 100 are accumulated, and each plant. A maintenance history DB 62 that stores maintenance history books in which the contents of maintenance of the device 1 are recorded, and is constituted by one or a plurality of computers.

  In addition, although operation | movement of each functional block contained in the arithmetic processing unit 20 is demonstrated in detail later on in order, in this specification, before the description, first, using FIG. An example of the measuring device 11 that measures mechanical soundness will be described. Further, with reference to FIG. 3, an example of the configuration of device state performance data, abnormality sign determination data, and maintenance guide information stored in the storage device 30 will be described. Let me explain.

  FIG. 2 is a diagram showing a specific example of the measuring device 11 that measures the mechanical soundness of the plant equipment 1. As shown in FIG. 2A, the main machine of the process plant 100 is provided with a strain gauge 115 for stress measurement and an acceleration pickup 114 for vibration measurement on its outer surface and the like. A moving image camera 111, an infrared camera 112, a microphone 113, and the like are installed in the periphery. The main machine of the process plant 100 is, for example, a steam turbine and a power generator in the case of a power plant, and a main reaction tank in the case of a chemical plant.

  As shown in FIGS. 2B to 2D, when the plant equipment 1 is a heater, a tank, a pump, a pipe, or the like, the strain gauge 115, the acceleration pickup 114, and the video camera 111 are also provided as in the main machine. An infrared camera 112, a microphone 113, and the like are installed. Further, a UT probe 116 for measuring the wall thickness is often installed on the pipe or the like.

  Here, the operator can know the deformation state or the damage state of the appearance of the plant device 1 from the video of the moving image camera 111. Moreover, the plant monitoring apparatus 2 can measure the deformation | transformation amount etc. by comparing the external appearance image of the said plant apparatus 1 acquired with the moving image camera 111 every day with the external appearance image at the time of the initial introduction, for example. . Therefore, the plant monitoring device 2 can detect an abnormality or a sign of abnormality of the plant equipment 1 based on the deformation amount of the external shape.

  In addition, the plant monitoring device 2 acquires the surface temperature of the plant device 1, the temperature distribution thereof, and the like from the video by the infrared camera 112 or the thermographic image thereof. Then, based on the acquired surface temperature, temperature distribution, etc., an alarm indicating that the plant equipment 1 is “high-temperature danger” may be displayed, or a prohibited entry area may be set around the site. It becomes possible. Further, based on the image representing the difference between the temperature distribution image on the appearance surface and the temperature distribution image in the steady state, and the data such as the change in temperature of a specific point on the appearance surface over time, an abnormality or a sign of abnormality of the plant equipment 1 is detected. Can be detected.

  Further, the plant monitoring device 2 analyzes the sound pressure level and frequency spectrum based on the acoustic data obtained from the microphone 113, and data such as the difference between the sound pressure level and the frequency spectrum from the steady state and the change with time. Based on the above, it is possible to detect an abnormality or a sign of abnormality of the plant equipment 1. Similarly, the plant monitoring device 2 analyzes the vibration amplitude and frequency spectrum of the plant equipment 1 based on the acceleration data obtained from the acceleration pickup 114, and the difference between the vibration amplitude and the frequency spectrum from the steady state, Based on the data such as the change over time, an abnormality of the plant equipment 1 or a sign of abnormality can be detected.

  Further, the plant monitoring device 2 compares the stress data obtained from the strain gauge 115 with a preset upper limit value or predicts a time when the upper limit value is reached based on a change in the stress data over time. One abnormality or a sign of abnormality can be detected. Similarly, the plant monitoring apparatus 2 compares the wall thickness data obtained from the UT probe 116 with a preset upper limit value or predicts the time when the wall thickness data reaches the lower limit value from the change over time. An abnormality or a sign of abnormality of the plant equipment 1 can be detected.

  FIG. 3 is a diagram illustrating an example of the configuration of the device status record data, the abnormality sign determination data, and the maintenance guide information stored in the storage device 30.

  The equipment state result data 31d is data in which the equipment state data measured by the measurement device 11 of each plant equipment 1 is associated with the measurement date and time, is created by the equipment state data acquisition unit 21, and is stored in the equipment state result data storage. Stored in the unit 31. The equipment state data referred to here is not only state data representing the operation of the plant equipment 1 itself (for example, the temperature and flow velocity of the fluid in the piping) but also state data representing the mechanical soundness of the plant equipment 1. (For example, vibration amplitude or distortion amount of piping).

  As shown in FIG. 3 (a), the device status record data 31d has “plant device name”, “device identification number”, and “measurement data name” as information at the beginning (hereinafter referred to as header information). Data in which “measurement date and time” and “measurement data” are associated with the header information, that is, time-series data of the device status data is followed.

  Here, the “plant device name” is the name of the plant device 1 in which the measuring device 11 in which the device state data is measured is installed, and the “device identification number” is identification information that uniquely identifies the plant device 1, “Measurement data name” is the name of the device status data.

  Next, the abnormality sign determination data 32d is knowledge data for determining an abnormality sign of the plant equipment 1 (hereinafter referred to as an abnormality sign), and is created based on the experience and knowledge of an operator in advance. The data is stored (accumulated) in the determination data storage unit 32.

  As shown in FIG. 3 (b), the abnormality sign determination data 32d has “plant device name” and “device identification number” as header information, and the header information includes “an abnormality sign identification number” and “measurement data name”. ”,“ Abnormal sign name ”,“ upper limit value ”or“ lower limit value ”, and“ predictive time ”, followed by abnormal sign determination data.

  Here, the “abnormal sign identification number” is uniquely identified by the abnormal sign detected from the equipment state data measured by the plant equipment 1 identified by the “equipment identification number” and designated by the “measurement data name”. It is information, and the “abnormal sign name” is a name that expresses the content of the abnormal sign in one word. The “upper limit value” or “lower limit value” is an upper limit or lower limit threshold value for determining whether or not the device state data specified by the “measurement data name” is normal.

  Further, the “predictive time” is a time in which the date and time when the device status data becomes an abnormal sign is set retroactively from the date and time when the device status data specified by the “measurement data name” is predicted to be abnormal. For example, when it is predicted that certain device status data will become abnormal at 21:00 on December 10 (this date and time will be referred to as an abnormal status prediction date and time as will be described later), the “predictive time” is 3 hours Is set, 3 hours before the abnormal state prediction date and time, that is, at 18:00 on December 10, an abnormal sign of the device state data is detected. Note that such an abnormality sign determination or detection method will be separately described in detail with reference to FIG.

  Next, the maintenance guide information 35d is knowledge data necessary for performing maintenance work on the abnormality sign when an abnormality sign is detected in the equipment state data of the plant equipment 1, and the experience of the operator or the like in advance. This is information created based on knowledge and stored (accumulated) in the maintenance guide information storage unit 35.

  As shown in FIG. 3C, the maintenance guide information 35d is composed of data such as “abnormal sign identification number”, “drawing number”, “history book information”, “site attention message”, “maintenance action message”, and the like. Is done.

  Here, “drawing number” is the drawing number of the design drawing required for performing maintenance work of the abnormal sign identified by “abnormal sign identification number”, and “history book information” is the same abnormal sign as the abnormal sign. The data indicating the location of the document that records the maintenance history and the like, “on-site caution message” is data of a message that warns or warns an operator at the installation site of the plant equipment 1 where the abnormality sign has occurred, “maintenance action” “Message” is data indicating the contents of maintenance work to be performed by the worker for the abnormality sign. Such a “maintenance action message” is set when the content of the maintenance work for the abnormality sign is known in light of the operator's experience or the like, and may be blank when unknown.

  Although explanation of the data structure is omitted in FIG. 3, the information stored in the three-dimensional CAD device arrangement information storage unit 33 and the plant device system diagram storage unit 34 is designed and constructed by the process plant 100. This is information that has already been created. Therefore, the data structure follows the data structure defined by the existing plant equipment system diagram editing CAD tool, three-dimensional CAD tool, or the like. In this case, the three-dimensional CAD may follow a standardized intermediate format such as IGES (Initial Graphics Exchange Specification).

  Next, the operation of the plant monitoring device 2 will be described in detail below. First, with reference to FIG. 1, FIG. 4, and FIG. 5, operation | movement until the plant monitoring apparatus 2 detects the abnormal sign of the plant apparatus 1 is demonstrated.

  The equipment state data acquisition unit 21 instructs the measuring device 11 provided in each plant equipment 1 to measure the equipment state data at each predetermined time, and measures the equipment state data measured according to the instruction. 11 from. The device state data acquisition unit 21 stores the acquired device state data in the device state result data storage unit 31 in association with the date and time at that time, and sends it to the control arithmetic processing unit 22 and the device abnormality sign detection processing unit 24. To do.

  The control arithmetic processing unit 22 performs various arithmetic processing such as feedback processing on the device state data sent from the device state data acquisition unit 21 to generate control data for controlling the operation state of the plant equipment 1. Then, the generated control data is sent to the device control data output unit 23. The equipment control data output unit 23 sends the generated control data to the control device 12 of each plant equipment 1. The operations of the control arithmetic processing unit 22 and the device control data output unit 23 are control operations for realizing a predetermined function assigned to each plant device 1 in the process plant 100.

  The device abnormality sign detection processing unit 24 is based on the device state data sent from the device state data acquisition unit 21 and the time series data of the device state data stored in the device state result data storage unit 31. The presence / absence of abnormal signs related to the status data is determined.

  FIG. 4 is a diagram for explaining a determination method of abnormality sign detection by the device abnormality sign detection processing unit 24 of the arithmetic processing unit 20, and (a) shows an example in which no abnormality sign is detected, (b). Shows an example when an abnormal sign is detected.

  In FIG. 4, the surface temperature of the pipe is taken as an example of the equipment state data to be determined as a sign of abnormality, and when the measured value of the equipment state data (surface temperature) exceeds the upper limit of 80 ° C., the pipe It is assumed that the surface temperature is abnormal. Performing such abnormality determination is knowledge data obtained empirically, and the knowledge data is stored in the abnormality sign determination data storage as described above in a part of the abnormality sign determination data 32d. It is accumulated in the unit 32 (see FIG. 3B).

  In the present embodiment, the plant monitoring device 2 does not detect an abnormality of the plant equipment 1 determined as described above, but detects an abnormality sign that is a sign of the abnormality. When an abnormality sign is detected, first, device status data to be targeted, that is, device status record data 31d for the device status data is designated. Therefore, the device abnormality sign detection processing unit 24 sets a recent predetermined number of data (for example, 10 sets of data) among the set data of “measurement date and time” and “measurement data” of the specified device status record data 31d. ) And a time-series change graph of “measurement data” (in this example, the surface temperature of the pipe) as shown in FIGS. 4A and 4B is created. In FIGS. 4A and 4B, the “measurement data” is represented by black dots.

  Next, the device abnormality sign detection processing unit 24 obtains a straight line that approximates the time series change of the “measurement data” by, for example, the least square method. In FIGS. 4A and 4B, the straight line is drawn as a solid line having an inclination near the black dot. The slope of the straight line represents the degree of tendency (time change rate) of the “measurement data” to rise or fall with time.

  Next, the device abnormality sign detection processing unit 24 stores the “plant device name”, “device identification number”, and “measurement data name” from the abnormality sign determination data storage unit 32 as the device state performance data 31d to be determined. The matched abnormality sign determination data 32d is read, and “upper limit value (or lower limit value)” (80 ° C.) and “prediction time” (2 hours) are extracted from the abnormality sign determination data 32d. In FIGS. 4A and 4B, the “upper limit value” is drawn as a horizontal straight line representing 80 ° C.

  Next, the equipment abnormality sign detection processing unit 24 extends a straight line approximating the time-series change of the previously obtained “measurement data” from the present to the future, and the straight line (the portion drawn by a broken line) A point reaching the value (80 ° C.) (a point represented by a white dot in FIGS. 4A and 4B) is obtained (hereinafter, this date and time will be referred to as an abnormal state prediction date and time).

  Next, the device abnormality sign detection processing unit 24 obtains a time obtained by subtracting the current date and time from the abnormal state prediction date and time (hereinafter, this time is referred to as a normal state remaining time). That is, when no maintenance work is performed and the measurement data of the equipment state data changes with the current inclination in the future, when the normal state remaining time obtained here elapses, the plant equipment 1 is in an abnormal state. It is predicted that

  Therefore, the device abnormality sign detection processing unit 24 compares the normal state remaining time with the “prediction time” set in the abnormality sign determination data 32d. As described above, the “predictive time” is a time that is determined to detect an abnormal predictor by going back to the predicted date and time of abnormality, and when the normal state remaining time becomes shorter than this “predictive time”, An abnormal sign is detected for the device status data. That is, as shown in FIG. 4A, when the normal state remaining time is longer than the “predictive time”, no abnormal sign is detected, but as shown in FIG. 4B, the normal state residual time is not detected. When it becomes shorter than the “predictive time”, an abnormal predictor is detected.

  Here, the “predictive time” is data that an operator sets in advance in the abnormal sign determination data 32d for each abnormality in the device state data of the plant equipment 1. Therefore, here, how to determine the “predictive time” will be described with reference to FIG. FIG. 5 is a diagram illustrating an example of how to determine the “predictive time” included in the abnormal sign determination data 32d.

  First, the “predictive time” is set longer than the maintenance work time (A) that is the time required for the maintenance work for the abnormal sign. This is because the effect of the maintenance work appears after the completion of the maintenance work, and that the “predictive time” is shorter than the maintenance work time (A) means that there is no effect of the predictive action. The maintenance work time (A) can be determined based on past maintenance work result data.

  By the way, even if maintenance work (for example, opening a certain valve and injecting cold water into a maintenance target pipe) is completed, the device status data (for example, the surface temperature of the pipe) is If it is in a phase that increases with time, it does not necessarily turn into a phase in which the device status data immediately decreases. Due to the heat capacity of the pipe itself and the fluid in the pipe, the surface temperature of the pipe rises for a while. Such a time (B) during which the trend (upward or downward) of the device state data until then can be obtained can be obtained based on, for example, a simulation or a theoretical model. Alternatively, it may be determined based on past maintenance work result data.

  Since the times (A) and (B) determined as described above usually include an error, a margin time (C) is set for the “predictive time” just in case. In other words, the margin time (C) sets the predictive time large in case the time (A) or (B) is estimated to be small.

  As described above, in the present embodiment, a time obtained by adding time (A), time (B), and time (C) is set as the “predictive time”. That is, when the abnormality sign is detected by the method described with reference to FIGS. 4 and 5, and the maintenance work is performed when the abnormality sign is detected, the abnormal state of the plant device 1 is avoided. Will be.

  Note that it is possible to detect an abnormal sign without setting the “predictive time”. In this case, it is assumed that no significant data is set in the “predictive time” included in the abnormality sign determination data 32d (instead, “Null” data is set), and the abnormality sign determination data 32d. The “upper limit value” or “lower limit value” included in is regarded as an “upper limit value” or “lower limit value” for detecting an abnormal sign.

  In other words, when a significant “predictive time” is not set for the device status data specified by “measurement data name data” of the abnormality sign determination data 32d, the device abnormality sign detection processing unit 24 determines that the device status data When the data measurement data exceeds the “upper limit value” or “lower limit value” included in the abnormality sign determination data 32d, it is immediately determined that an abnormality sign has been detected.

  For example, the plant equipment 1 is a pipe, and when the pipe is eroded by, for example, high-pressure steam and the thickness thereof becomes 18 mm, it may be determined that the plant equipment 1 is abnormal. In this case, the “lower limit value” of the abnormality sign determination data 32d is set to be larger than 18 mm, for example, 19 mm. By doing so, the equipment abnormality sign detection processing unit 24 can detect the abnormality sign of the pipe when the thickness of the pipe reaches 19 mm.

  FIG. 6 is a diagram illustrating an example of a processing flow of the device abnormality sign detection processing in the device abnormality sign detection processing unit 24. As illustrated in FIG. 6, the device abnormality sign detection processing unit 24 first acquires abnormality sign determination data 32 d corresponding to the device state data transmitted from the device state data acquisition unit 21 (step S <b> 21). The device status data sent from the device status data acquisition unit 21 includes “plant device name”, “device identification number”, and “measurement data name” in the device status record data 31d and the abnormality sign determination data 32d. It shall be assumed.

  Next, the device abnormality sign detection processing unit 24 determines whether or not a significant sign time is set in the acquired abnormality sign determination data 32d (step S22), and a significant sign time is set. (Yes in step S22), a recent predetermined number of pieces of measurement data of the device state data is acquired from the device state result data storage unit 31, and a straight line representing the time change tendency of the measurement data is obtained (step S23). : See also FIG.

  Next, the device abnormality sign detection processing unit 24 predicts an abnormal state prediction date and time (see FIG. 4) in which the obtained straight line exceeds the upper limit value or the lower limit value included in the abnormality sign determination data 32d (step S24), The normal state remaining time is calculated by subtracting the current date from the predicted state date (step S25). Then, the device abnormality sign detection processing unit 24 compares the calculated normal state remaining time with the aforementioned sign time (step S26), and when the normal state remaining time is larger than the sign time (in step S26). Yes), the device abnormality sign detection process is terminated as it is. On the other hand, when the normal state remaining time is equal to or shorter than the predictive time (No in step S26), the device abnormality sign detection processing unit 24 determines that an abnormality sign has been detected for the device state data (step S28). Then, the device abnormality sign detection process is terminated.

  If no significant sign time is set in step S22 (No in step S22), the device abnormality sign detection processing unit 24 sets the latest measurement data of the device state data to the abnormality sign determination data 32d. It is determined whether it is greater than the included upper limit value or smaller than the lower limit value (step S27). As a result of the determination, if the device status data is larger than the upper limit value or smaller than the lower limit value (Yes in step S27), the device abnormality predictor detection processing unit 24 has an error regarding the device status data. It is determined that a sign has been detected (step S28), and the device abnormality sign detection process is terminated. On the other hand, when the device status data is not larger than the upper limit value and smaller than the lower limit value (No in step S27), the device abnormality sign detection processing unit 24 performs the device abnormality sign detection processing as it is. finish.

  Next, the operation of the plant monitoring apparatus 2 when an abnormality sign is detected will be described with reference to FIGS. 7 is a diagram showing an example of a display screen displaying maintenance guide information on the plant equipment system diagram, and FIG. 8 is an example of a display screen displaying maintenance guide information on a three-dimensional CAD equipment layout image. FIG. 9 is a diagram showing another example of a display screen on which maintenance guide information is displayed on a three-dimensional CAD device layout image.

  When an abnormality sign is detected by the device abnormality sign detection processing unit 24, a notification including the abnormality sign identification number of the detected abnormality sign is sent to the three-dimensional CAD device arrangement image display processing unit 25 and the maintenance guide information display processing unit 26. Communicated.

  When the maintenance guide information display processing unit 26 receives the notification of the abnormality sign detection, the maintenance guide information display processing unit 26 refers to the abnormality sign determination data storage unit 32, acquires the abnormality sign determination data 32d corresponding to the abnormality sign identification number, and the abnormality sign. The plant equipment name and plant equipment identification number of the plant equipment 1 in which an abnormality sign has occurred are obtained from the determination data 32d. In addition, the maintenance guide information display processing unit 26 refers to the maintenance guide information storage unit 35 and acquires maintenance guide information 35d corresponding to the abnormality sign identification number.

  Next, the maintenance guide information display processing unit 26 refers to the plant equipment system diagram storage unit 34 and displays a plant equipment system diagram of a part including the plant equipment 1 having the acquired plant equipment name and plant equipment identification number. The extracted plant equipment system diagram is displayed on the display device 50, and maintenance guide information 35d is displayed on the plant equipment system diagram. At the time of the display, the latest data of the device status data is also displayed with reference to the device status record data storage unit 31.

  The display screen example 51 shown in FIG. 7 is displayed when the surface temperature of “HEATER-LP-NO3” becomes high and it is predicted that the upper limit value of 80 ° C. will be exceeded within the predictive time (for example, 2 hours). , "HEATER-LP-NO3" is displayed as "Surface temperature high: 73 ° C", and information such as drawing numbers and history books required for maintenance work is also displayed. ing. Further, information such as “attention to approach” is displayed as a caution message for the worker. The display information is information obtained from the maintenance guide information 35d.

  Note that the plant equipment system diagram displayed as the background of the display screen example 51 of FIG. 7 is extremely useful information for logically analyzing the cause of the abnormality or sign of abnormality of the plant equipment 1. However, it is not necessarily sufficient information for carrying out a specific maintenance work of the plant equipment 1. The worker goes to the site where the plant equipment 1 is installed, examines the state of the plant equipment 1 and the measuring device 11, or brings another measuring device to acquire other equipment state data. It may be necessary to do.

  In preparation for such a case, in the present embodiment, a three-dimensional CAD device arrangement image display processing unit 25 is provided. That is, when the three-dimensional CAD device arrangement image display processing unit 25 receives the notice of abnormality sign detection from the device abnormality sign detection processing unit 24, the three-dimensional CAD device arrangement image display processing unit 25 refers to the three-dimensional CAD device arrangement information storage unit 33 and The three-dimensional CAD device arrangement information of the peripheral devices is extracted, and a three-dimensional CAD device arrangement image based on the three-dimensional CAD device arrangement information is generated and displayed on the display device 50.

  When the three-dimensional CAD device arrangement image display processing unit 25 displays the three-dimensional CAD device arrangement images of the plant device 1 and the surrounding plant devices 1 in this way, the maintenance guide information display processing unit 26 displays the maintenance guide information storage unit. Maintenance guide information 35d corresponding to the abnormality sign identification number is acquired from 35, and the acquired maintenance guide information 35d is displayed on the displayed three-dimensional CAD device layout image (see FIGS. 8 and 9). Display screen examples 52 and 53).

  For example, as shown in a display screen example 52 in FIG. 8, when an on-site warning message such as “high surface temperature: 73 ° C.” or “attention to approach” is displayed superimposed on the 3D CAD device layout image, the operator In addition to knowing the actual arrangement status of the plant equipment 1 at the site, it is possible to obtain a caution message for performing maintenance work at the site. That is, the operator can easily identify which plant equipment 1 is the maintenance target by browsing the display screen examples 52 and 53 of FIGS. It is possible to know whether there is no safety problem even if the plant equipment 1 is approached. Therefore, the worker can perform maintenance work safely and efficiently.

  In the display of the maintenance guide information 35d in the display screen examples 51, 52, and 53 in FIGS. 7 to 9, the drawing number and the number portion of the history book are underlined. This number is associated with the drawing number designated by the number or the location of the history book (for example, the design drawing DB 61 and the maintenance history DB 62 in the design / maintenance information management device 6). When the underlined number is clicked, the design drawing or history book designated by the number is displayed. Therefore, the worker can easily access the history book in which the design drawings of the plant equipment 1 and the history information of the past maintenance are described from the display screen examples 51, 52, and 53.

  Further, when the maintenance work for the abnormal sign is known from past experience, the information indicating the content of the maintenance work is a maintenance action message of the maintenance guide information 35d (for example, “increase the opening of the valve AA twice. Etc.) in advance in the maintenance guide information storage unit 35 (see FIG. 3C), the maintenance guide information display processing unit 26 displays the action message in FIG. 7 when the abnormal sign is detected. Displayed in display screen examples 51, 52, and 53 in FIG. In the present embodiment, since the specific contents of such maintenance work are displayed, it is possible to easily perform the maintenance work even if it is not a skilled worker.

  As described above, according to the embodiment of the present invention, the abnormality sign determination data 32d for determining the abnormality sign of the plant equipment 1 is stored in the abnormality sign determination data storage unit 32 in advance. Based on the device status record data 31d of the device 1 and the abnormality sign determination data 32d, the abnormality sign of the plant device 1 can be easily detected. Furthermore, since the information necessary for performing the maintenance work for the detected abnormality sign is stored in advance in the maintenance guide information storage unit 35 as the maintenance guide information 35d, the plant monitoring apparatus 2 stores the maintenance guide information 35d. By superimposing and displaying the plant equipment system diagram and the three-dimensional CAD equipment arrangement image of the plant equipment 1, information useful for maintenance work can be provided to the worker. As a result, the efficiency of maintenance work can be improved.

DESCRIPTION OF SYMBOLS 1 Plant equipment 2 Plant monitoring apparatus 6 Design / maintenance information management apparatus 7 Communication network 11 Measuring apparatus 12 Control apparatus 20 Arithmetic processing apparatus 21 Equipment state data acquisition part 22 Control arithmetic processing part 23 Equipment control data output part 24 Equipment abnormality sign detection process Unit 25 3D CAD device arrangement image display processing unit 26 maintenance guide information display processing unit 30 storage device 31 device state result data storage unit 31d device state result data 32 abnormality sign determination data storage unit 32d abnormality sign determination data 33 3D CAD device Arrangement information storage unit 34 Plant equipment system diagram storage unit 35 Maintenance guide information storage unit 35d Maintenance guide information 40 Input device 50 Display device 61 Design drawing DB
62 Maintenance history DB
100 Process Plant 111 Video Camera 112 Infrared Camera 113 Microphone 114 Acceleration Pickup 115 Strain Gauge 116 UT Probe

Claims (6)

A plant monitoring device that is connected to a measurement device provided in a plant device constituting the plant, includes an arithmetic processing device, a storage device, and a display device, and monitors a sign of abnormality of the plant device,
The storage device
A device status record data storage unit for storing device status data acquired from the measurement device as time-series device status record data;
An abnormality sign determination data storage unit that accumulates in advance an abnormality sign determination data necessary for determining an abnormality sign of the plant equipment;
When a sign of abnormality of the plant equipment is detected, a maintenance guide information storage unit that stores information necessary for maintenance work corresponding to the sign of abnormality in advance as maintenance guide information;
A three-dimensional CAD device arrangement information storage unit that pre-stores three-dimensional CAD device arrangement information of plant equipment in the plant;
Comprising
The arithmetic processing unit includes:
A device state data acquisition processing unit for acquiring device state data measured by the measurement device from the measurement device;
Based on the device status data acquired from the measurement device, the device status record data stored in the device status record data storage unit, and the abnormality sign determination data stored in the abnormality sign determination data storage unit, An equipment abnormality sign detection processing unit for detecting a sign of abnormality of the plant equipment;
Three-dimensional CAD device arrangement image display processing for displaying on the display device a three-dimensional CAD device arrangement image of the plant equipment and the surrounding plant equipment in which the plant equipment is arranged for the plant equipment in which the abnormality sign is detected And
The maintenance guide information storage unit is searched to extract maintenance guide information about the plant device in which the abnormality sign is detected, and the extracted maintenance guide information is overlaid on the displayed three-dimensional CAD device arrangement image. Maintenance guide information display processing section to be displayed,
A plant monitoring device comprising: The abnormality sign determination data is
At least one of upper limit data and lower limit data of the equipment state data of the plant equipment,
An equipment abnormality predicting time which is a time during which it is possible to avoid the equipment state data of the plant equipment from reaching the upper limit data or the lower limit data by maintenance work,
The plant monitoring apparatus according to claim 1, comprising: The maintenance guide information is
An on-site caution message regarding the installation site of the plant equipment based on the latest equipment status data acquired from the measuring device provided in the plant equipment in which the abnormality sign is detected, and the operation for the sign of the abnormality The plant monitoring apparatus according to claim 1, further comprising at least one message among maintenance action messages representing contents of known maintenance work to be performed by a person. A plant monitoring method that is connected to a measuring device provided in a plant equipment constituting a plant, and that monitors a sign of abnormality of the plant equipment by a plant monitoring device that includes an arithmetic processing device, a storage device, and a display device. ,
The storage device
A device status record data storage unit for storing device status data acquired from the measurement device as time-series device status record data;
An abnormality sign determination data storage unit that accumulates in advance an abnormality sign determination data necessary for determining an abnormality sign of the plant equipment;
When a sign of abnormality of the plant equipment is detected, a maintenance guide information storage unit that stores information necessary for maintenance work corresponding to the sign of abnormality in advance as maintenance guide information;
A three-dimensional CAD device arrangement information storage unit that pre-stores three-dimensional CAD device arrangement information of plant equipment in the plant;
Comprising
The arithmetic processing unit includes:
Device status data acquisition processing for acquiring device status data measured by the measurement device from the measurement device;
Based on the device status data acquired from the measurement device, the device status record data stored in the device status record data storage unit, and the abnormality sign determination data stored in the abnormality sign determination data storage unit, Equipment abnormality sign detection processing for detecting a sign of plant equipment abnormality,
Three-dimensional CAD device arrangement image display processing for displaying on the display device a three-dimensional CAD device arrangement image of the plant equipment and the surrounding plant equipment in which the plant equipment is arranged for the plant equipment in which the abnormality sign is detected When,
The maintenance guide information storage unit is searched to extract maintenance guide information about the plant device in which the abnormality sign is detected, and the extracted maintenance guide information is overlaid on the displayed three-dimensional CAD device arrangement image. Maintenance guide information display processing to be displayed,
The plant monitoring method characterized by performing this. The abnormality sign determination data is
At least one of upper limit data and lower limit data of the equipment state data of the plant equipment,
An equipment abnormality predicting time which is a time during which it is possible to avoid the equipment state data of the plant equipment from reaching the upper limit data or the lower limit data by maintenance work,
The plant monitoring method according to claim 4, comprising: The maintenance guide information is
An on-site caution message regarding the installation site of the plant equipment based on the latest equipment status data acquired from the measuring device provided in the plant equipment in which the abnormality sign is detected, and the operation for the sign of the abnormality The plant monitoring method according to claim 4, further comprising at least one message among maintenance action messages representing contents of known maintenance work to be performed by a person.

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