Teaching system for abnormal situations, teaching method for abnormal situations, and program product

Abstract

The present invention provides a teaching system for handling abnormalities, which infers the cause of an abnormality and teaches a handling operation for that cause. The teaching system for handling abnormalities includes: an operation parameter acquisition unit that acquires operation parameters measured during the operation of a device; a diagnostic information acquisition unit that acquires diagnostic information indicating the operation diagnostic results of instruments included in the device executed before the device is started; and a cause analysis unit that, when an abnormality occurs in the device, inputs the operation parameters and the diagnostic information into an FTA that has analyzed the cause of the abnormality to analyze the cause of the abnormality.

Description

Technical Field

[0001] The present disclosure relates to an abnormality response teaching system, an abnormality cause estimation method, an abnormality response teaching method, and a program. The present disclosure claims priority based on Japanese Patent Application No. 2020-188660 filed in Japan on November 12, 2020, the content of which is incorporated herein by reference. Background Art

[0002] Conventionally, when an abnormality occurs in a plant, a monitor performs an operation of estimating the cause of the abnormality by comparing the measured values measured by sensors at the time of the abnormality occurrence with a fault tree. Patent Document 1 discloses a technique for appropriately displaying a fault tree in such a situation.

[0003] Patent Document 2 discloses an abnormality diagnosis system in which an abnormality of a plant is detected based on data acquired from a plurality of sensors provided in the plant, and by combining maintenance history information associated with the detected abnormality, the diagnosis and disposal to be performed for the occurred abnormality are specified, and an operation instruction is given to service personnel. This abnormality diagnosis system presents an FTA showing a diagnosis process together with an abnormality diagnosis result to service personnel. Service personnel perform a diagnosis operation by comparing the diagnosis result performed by the abnormality diagnosis system with the FTA, and thus can quickly implement appropriate countermeasures.

[0004] Prior Art Documents

[0005] Patent Documents

[0006] Patent Document 1: Japanese Unexamined Patent Application Publication No. 03-213891

[0007] Patent Document 2: Japanese Unexamined Patent Application Publication No. 2012-137934 Summary of the Invention

[0008] Technical Problem to be Solved by the Invention

[0009] The operation cost for the operation of estimating the cause of an abnormality by comparing the data measured by sensors with an FTA is high, and a lot of time is required to accurately estimate the cause. Thus, a delay may occur in the response when an abnormality occurs.

[0010] The present disclosure provides an abnormality response teaching system, an abnormality cause estimation method, an abnormality response teaching method, and a program that can solve the above problems.

[0011] Means for Solving the Technical Problem

[0012] According to one aspect of the present disclosure, a teaching system corresponding to an abnormality includes: an operation parameter acquisition unit that acquires operation parameters measured during the operation of a device; a diagnosis information acquisition unit that acquires diagnosis information indicating a result of an operation diagnosis of an instrument included in the device performed before the device is started; and a cause analysis unit that, when an abnormality occurs in the device, inputs the operation parameters and the diagnosis information into an FTA that analyzes the cause of the abnormality to analyze the cause of the abnormality.

[0013] According to one aspect of the present disclosure, in a method for estimating the cause of an abnormality, operation parameters measured during the operation of a device are acquired, diagnosis information indicating a result of an operation diagnosis of an instrument included in the device performed before the device is started is acquired, and when an abnormality occurs in the device, the operation parameters and the diagnosis information are input into an FTA that analyzes the cause of the abnormality to analyze the cause of the abnormality.

[0014] According to one aspect of the present disclosure, in a teaching method corresponding to an abnormality, operation parameters measured during the operation of a device are acquired, diagnosis information indicating a result of an operation diagnosis of an instrument included in the device performed before the device is started is acquired, and when an abnormality occurs in the device, the operation parameters and the diagnosis information are input into an FTA that analyzes the cause of the abnormality to analyze the cause of the abnormality, and disposal operation instruction information for instructing a disposal operation corresponding to the cause is output.

[0015] According to one aspect of the present disclosure, a program causes a computer to perform the following processing: acquiring operation parameters measured during the operation of a device, acquiring diagnosis information indicating a result of an operation diagnosis of an instrument included in the device performed before the device is started, and when an abnormality occurs in the device, inputting the operation parameters and the diagnosis information into an FTA that analyzes the cause of the abnormality to analyze the cause of the abnormality.

[0016] Advantageous Effects of the Invention

[0017] According to the above-described teaching system corresponding to an abnormality, method for estimating the cause of an abnormality, teaching method corresponding to an abnormality, and program, when an abnormality occurs in a plant or the like, the cause of the abnormality can be estimated with high accuracy and in a short time. According to the teaching method corresponding to an abnormality of the present disclosure, when an abnormality occurs in a plant or the like, a method for dealing with the abnormality can be grasped. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 is a block diagram showing an example of a teaching system corresponding to an abnormality of an embodiment.

[0019] Figure 2 is a diagram showing an example of a fault tree of an embodiment.

[0020] Figure 3This is a diagram showing an example of the judgment conditions of the fault tree for the implementation mode.

[0021] Figure 4 This is a diagram showing an example of the analysis result of the fault tree based on the implementation mode.

[0022] Figure 5 This is a diagram showing an example of the notification of the disposal operation instruction information for the implementation mode.

[0023] Figure 6A This is the first diagram explaining an example of the disposal operation instruction information for the implementation mode.

[0024] Figure 6B This is the first diagram explaining an example of the disposal operation instruction information for the implementation mode.

[0025] Figure 7 This is a flowchart showing an example of the operation of the teaching system for handling abnormalities in the implementation mode.

[0026] Figure 8 This is a diagram showing an example of the hardware structure of the teaching system for handling abnormalities in the implementation mode. Specific implementation mode

[0027] <Implementation mode>

[0028] Hereinafter, with reference to Figures 1 to 8 The teaching system for handling abnormalities in the implementation mode will be described in detail.

[0029] (Structure)

[0030] Figure 1 This is a block diagram showing an example of the teaching system for handling abnormalities in the implementation mode.

[0031] The recovery management system 1 includes a teaching system 10 for handling abnormalities, a plant 20, a diagnostic system 30, and a terminal device 40. The teaching system 10 for handling abnormalities is communicably connected to the plant 20, the diagnostic system 30, and the terminal device 40.

[0032] The plant 20 is the equipment to be recovered. A plurality of sensors 21 are provided in the plant 20. The plant 20 includes a control device 22. The sensors 21 output the measured values (operating parameters) to the teaching system 10 for handling abnormalities. The control device 22 acquires the operating parameters measured by the sensors 21, judges the operating state of the plant 20, and outputs the judgment result to the teaching system 10 for handling abnormalities. For example, when the operating parameter exceeds the threshold value, the control device 22 outputs an alarm signal, and further outputs a trip signal when it becomes a value that requires the plant 20 to be stopped.

[0033] The diagnostic system 30 confirms the operation of the devices included in the equipment set 20 before starting the equipment set 20, and outputs the result as diagnostic information to the teaching system 10 for corresponding to abnormalities. For example, the diagnostic system 30 outputs an instruction signal to the valves included in the equipment set 20 to gradually change the opening degree of the valves from closed to open and from open to closed, and diagnoses the operation result of the valves in response to the instruction signal. For example, sensors capable of detecting the opening degree are installed on the valves, and the diagnostic system 30 acquires the opening degree detected by the sensors. For example, when the operation of the valves is completely normal, the diagnostic system 30 diagnoses that the operation of the valves is "normal", and outputs a value indicating normal to the teaching system 10 for corresponding to abnormalities. When the operation of the valves is not abnormal but there are still issues (for example, there is a delay in the opening operation in response to the opening degree instruction), the diagnostic system 30 diagnoses that the operation of the valves is "substantially normal", and outputs a value indicating substantially normal to the teaching system 10 for corresponding to abnormalities. For example, when the operation of the valves is abnormal, the diagnostic system 30 diagnoses that the operation of the valves is "abnormal", and outputs a value indicating abnormal to the teaching system 10 for corresponding to abnormalities.

[0034] When the equipment set 20 outputs an alarm signal or a trip signal, the teaching system 10 for corresponding to abnormalities infers the abnormal cause that led to the trip signal or the like based on the operation parameters, the diagnostic information obtained by the diagnostic system 30, etc., and teaches the handling operation for the abnormal cause. The teaching system 10 for corresponding to abnormalities includes an operation data acquisition unit 11, a diagnostic information acquisition unit 12, an inspection process information acquisition unit 13, a cause analysis unit 14, an analysis result output unit 15, a handling operation instruction unit 16, a handling operation completion reception unit 17, a restart preparation completion notification unit 18, and a storage unit 19.

[0035] The operation data acquisition unit 11 acquires the latest operation data output by the equipment set 20. The operation data includes the operation parameters measured by the sensors 21, the alarm signals and trip signals output by the control device 22. The alarm signal or the trip signal serves as a trigger for inferring the abnormal cause and teaching the handling operation. The operation parameters are used to judge the abnormal cause.

[0036] The diagnostic information acquisition unit 12 acquires the diagnostic results (diagnostic information) of the operation diagnosis performed by the diagnostic system 30 before the start-up of the plant 20. If the diagnostic system 30 diagnoses the operation as "abnormal", the plant 20 is started up after dealing with the abnormality. When the diagnostic system 30 diagnoses it as "normal" or "substantially normal", the plant 20 is started up, and then when the plant 20 stops due to an abnormality, the diagnostic results obtained by the diagnostic system 30 are used to presume the cause of the abnormality. For example, when the diagnostic system 30 diagnoses it as "normal", in the presumption of the cause of the abnormality, items related to the operation of the device diagnosed as "normal" can be excluded from the candidates for the cause of the abnormality. When the diagnostic system 30 diagnoses it as "substantially normal", in the presumption of the cause of the abnormality, items related to the device diagnosed as "substantially normal" can be excluded from the candidates with a high possibility of being the cause of the abnormality, and are treated as objects with a low possibility but whose possibility of being the cause of the abnormality cannot be completely denied.

[0037] The inspection process information acquisition unit 13 acquires inspection process information including the presence or absence of inspections and processes performed on the plant 20 and the results of subsequent operation confirmation, etc. For example, in a regular inspection, the devices or components of the plant 20 are disassembled, or valves that are closed during operation are opened. After the regular inspection, if there are operation errors when assembling the disassembled devices for restoration, or if the valves are forgotten to be restored to their original state after the regular inspection, this may become a cause of tripping, etc. during the operation of the plant 20 after the regular inspection. Thus, inspections or processes accompanied by the disassembly of devices, etc. may become the cause of an abnormality. When presuming the cause of the abnormality, in order to judge the possibility of the inspection or process having an impact, the inspection process information acquisition unit 13 acquires inspection process information indicating the presence or absence of inspections or processes before the start-up of the plant 20.

[0038] If an alarm signal or a trip signal is acquired from the plant 20, the cause analysis unit 14 inputs the operation parameters measured by the sensor 21, the diagnostic information output by the diagnostic system 30, and the inspection process information into an FTA (Fault Tree Analysis) to analyze the cause of the abnormality of the plant 20 that becomes the alarm signal or the trip signal. Inputting into the FTA means that in the judgment conditions set for each branch or each element of the fault tree used in the FTA, the operation parameters, diagnostic information, and inspection process information are applied to judge whether the judgment condition is satisfied. For example, the cause analysis unit 14 inputs sensor data, etc. into the FTA, and traces back sequentially while confirming the judgment conditions from the top of the tree to presume the cause of the abnormality.

[0039] The analysis result output unit 15 outputs the cause of the abnormality presumed by the cause analysis unit 14.

[0040] The countermeasure operation instruction unit 16 determines a countermeasure operation for the abnormal cause deduced by the cause analysis unit 14, and sends a countermeasure operation instruction indicating the implementation of the countermeasure operation to the terminal device 40. The countermeasure operation refers to an operation for eliminating the abnormal cause of the plant equipment 20 and enabling the plant equipment 20 to restart.

[0041] The countermeasure operation completion reception unit 17 acquires information indicating the completion of the countermeasure operation. For example, when the instructed countermeasure operation is completed, the staff inputs the completion of the countermeasure operation to the terminal device 40. When the completion of the countermeasure operation is input, the terminal device 40 notifies the abnormal situation corresponding teaching system 10 of the completion of the countermeasure operation, and the countermeasure operation completion reception unit 17 acquires this notification.

[0042] The restart preparation completion notification unit 18 notifies the terminal device 40 or the control room where the operator of the plant equipment 20 is performing operation monitoring that the plant equipment 20 can be restarted. When all the countermeasure operations are completed, the restart preparation completion notification unit 18 determines that the plant equipment 20 can be restarted.

[0043] The storage unit 19 stores the operation data acquired by the operation data acquisition unit 11, the diagnostic information acquired by the diagnostic information acquisition unit 12, the inspection process information acquired by the inspection process information acquisition unit 13, the fault tree of each event that causes an alarm signal or a trip signal, the information of the countermeasure operation corresponding to the abnormal cause, and the like.

[0044] The terminal device 40 is, for example, a portable terminal carried by the operator of the plant equipment 20. The terminal device 40 displays the countermeasure operation notified from the abnormal situation corresponding teaching system 10. The operator performs operations based on the information displayed on the terminal device 40 and responds to the abnormality of the plant equipment 20. When the countermeasure operation is completed, the completion of the countermeasure operation is input to the terminal device 40.

[0045] Next, Figures 2 to 3 the method for deducing the abnormal cause will be described.

[0046] Figure 2 An example of a fault tree is shown. Figure 2 A part of the fault tree obtained by analyzing the cause of the trip caused by burner misfire among various events that cause the gas turbine to trip is shown. For example, burner misfire is caused by improper air-fuel ratio or poor flame propagation (factor 1), etc. For example, improper air-fuel ratio is caused by inappropriate flow rate of ignition fuel or inappropriate air flow rate during ignition (factor 2). For example, inappropriate flow rate of ignition fuel is caused by malfunction of the flow control valve for adjusting the fuel flow rate, malfunction of the gas system, etc. (factor 3). For example, malfunction of the flow control valve is caused by malfunction of the flow control valve or error in the valve restoration operation during regular inspection, etc. (factor 4). In Figure 2In the example, if the events of the fault tree analysis can be traced to the level of factor 4, the cause of the trip caused by the burner misfire can be determined. The root cause analysis unit 14 searches for factor 4 determined by these data by using the operation parameters, diagnostic information, and inspection process information. In the storage unit 19, determination conditions for judging each branch on the tree are set together with the fault tree, and the root cause analysis unit 14 analyzes the abnormal cause according to the determination conditions.

[0047] Figure 3 An example of the determination conditions for determining factor 4 is shown. In the table, the items marked with ○ indicate the items used in the determination of the abnormal cause. For example, in the case of poor valve operation, the difference in response shown by the diagnostic information of the flow control valve, the opening command of the flow control valve at ignition, and the operation parameter 1 for the opening command (for example, the measured value of a flow sensor that measures the fuel flow downstream of the flow control valve or a pressure sensor that measures the fuel pressure) is used to judge whether there is an abnormality. For example, if the diagnostic information is "substantially normal" and the difference between the opening command of the flow control valve and the response is above a specified value, the root cause analysis unit 14 judges that the possibility of the abnormal cause being poor valve operation is high (○). Or, even if the difference between the opening command of the flow control valve and the response is normal, if the diagnostic information is "substantially normal", the root cause analysis unit 14 judges that the possibility of poor valve operation cannot be excluded (△). If the diagnostic information is "normal" and the difference between the opening command of the flow control valve and the response is within the specified value, the root cause analysis unit 14 judges that the possibility of the abnormal cause being poor valve operation is low (×).

[0048] For example, in the case of a valve recovery error during a regular inspection, the presence or absence of an abnormality is judged based on the inspection process information and the diagnostic information of the fuel system valve. For example, when the diagnostic information is "normal" and the inspection process information is "none", the root cause analysis unit 14 judges that the possibility of the abnormal cause being a valve recovery error during a regular inspection is low (×). For example, when the diagnostic information is "normal" and the inspection process information is "yes", it is judged that the possibility of poor valve operation is high (○), etc.

[0049] Similarly, in the case of poor gas replacement, the root cause analysis unit 14 judges the possibility that poor gas replacement is the cause of the burner misfire trip based on the inspection process information. In the case of poor IGV (Inlet Guide Vane) operation, the root cause analysis unit 14 judges the possibility that poor IGV operation is the cause of the burner misfire trip based on the operation parameter 2.

[0050] Figure 3 An example of the determination conditions for factor 4 is shown, but determination conditions related to factors 1 to 3 can also be set in the storage unit 19.

[0051] Generally, the operating parameters at the time of an abnormality occurrence are compared with the fault tree, and the monitor manually eliminates each factor of the fault tree and performs an operation to presume the cause of the abnormality. In contrast, in the present embodiment, based on the determination conditions of each factor and the operating parameters set in advance, the cause analysis unit 14 automatically determines the possibility of each factor being the cause of the abnormality. Thereby, it is possible to reduce the operation cost of cause presumption and the time required for presumption of the cause of the abnormality. In the present embodiment, in addition to the operating parameters, diagnostic information and inspection process information are also used for determination. Thereby, the possibility of a cause of an abnormality that cannot be determined based on the operating parameters can also be presumed (for example, Figure 3 'valve restoration error during periodic inspection', 'poor gas replacement'). For example, even in the case of Figure 3 'abnormal valve operation' where it can be determined based on the operating parameters, diagnostic information can also be used simultaneously for a more detailed determination. In this way, according to the present embodiment, the accuracy of presumption of the cause of the abnormality can be improved.

[0052] Next, Figures 4 to 5 an example of display of the analysis result of the cause of the abnormality and a process for instructing a disposal operation for the cause of the abnormality will be described. Figure 4 The result of the fault tree elimination by the cause analysis unit 14 based on the operating parameters, diagnostic information, inspection process information, and the determination conditions of each factor is shown. A cause with a high possibility of being the cause of the abnormality is marked with ○, a cause with a possibility of being the cause of the abnormality is marked with △, and a cause with a low possibility of being the cause of the abnormality is marked with ×. In the storage unit 19, appropriate disposal operations are registered in advance in correspondence with each factor representing the cause of the abnormality defined in the fault tree. For example, the analysis result output unit 15 may also Figure 4 output an image that displays the fault tree, the analysis result of the cause of the abnormality by the cause analysis unit 14, and the disposal operation in correspondence in a list to a display device or the like as exemplified. The analysis result output unit 15 may also display the cause of the abnormality considered to have the highest possibility in the most prominent manner ( Figure 4 in the example of 'poor gas replacement'), display the cause of the abnormality determined to be possible in a different manner from the cause of the abnormality considered to have a high possibility ( Figure 4 in the example of 'abnormal valve operation', 'abnormal combustion cylinder'), and gray out the cause of the abnormality determined to have a low possibility, etc., for display corresponding to the magnitude of the possibility. Thereby, the monitor can easily grasp the cause of the abnormality of the trip of the plant 20, the magnitude of its possibility, and the disposal operation required for each cause of the abnormality.

[0053] The troubleshooting operation instruction unit 16 instructs the staff to perform the troubleshooting operation based on the analysis result of the abnormal cause by the cause analysis unit 14 and the troubleshooting operations for the abnormal cause registered in the storage unit 19. For example, the troubleshooting operation instruction unit 16 determines the corresponding troubleshooting operations for all the abnormal causes (○ and △) judged as possible by the cause analysis unit 14, and sends the abnormal causes and the troubleshooting operation instructions to the terminal device 40. For example, assuming that the judgment result of the cause analysis unit 14 is "insufficient gas replacement", and "re-ignition" is registered in the storage unit 19 as the troubleshooting operation for "insufficient gas replacement". The troubleshooting operation instruction unit 16 sends the abnormal cause "insufficient gas replacement" and its troubleshooting operation "re-ignition" to the terminal device 40. Figure 5 An example of the troubleshooting operation instruction sent to the terminal device 40 is shown. As Figure 5 shown, a message "Ignition failure (burner misfire trip) is very likely due to insufficient gas replacement, so please perform the ignition operation" is displayed on the display screen of the terminal device 40. The staff performs the ignition operation with reference to this display. At this time, the troubleshooting operation instruction unit 16 can also send the troubleshooting operation step information for teaching the specific implementation method of the ignition operation. The troubleshooting operation step information includes not only articles but also diagrams, photos, videos, etc. Thereby, the cause of the burner misfire trip can be quickly identified and eliminated. In this way, by giving the troubleshooting operation instructions, the staff can clearly know what to do, quickly eliminate the abnormal cause, and restart the plant 20.

[0054] Figure 5 In the troubleshooting operation instruction exemplified above, the implementation of the ignition operation is instructed by a statement. The troubleshooting operation instruction unit 16 can not only use statements but also use diagrams or videos to instruct the staff to perform the troubleshooting operation.

[0055] Figure 6A and Figure 6B show a schematic structural diagram of the fuel system of a gas turbine. During the operation of the gas turbine, fuel flows from the left side to the right side of the paper and is supplied to the combustion chamber from the manifold M1 and the manifold M2. In the fuel system, a block valve V1, an exhaust valve V2, a stop valve V3, an exhaust valve V4, a stop valve V5, a pressure regulating valve V6, a flow regulating valve V7, and a flow regulating valve V8 are arranged in sequence from the upstream side in the fuel flow direction. The block valve V1 and the exhaust valve V2 are manually opened and closed valves. As Figure 6A shown, during the operation of the gas turbine, the block valve V1 is open and the exhaust valve V2 is closed. In contrast, during the regular inspection, as Figure 6B shown, the block valve V1 is closed and the exhaust valve V2 is open. If a regular inspection is performed before starting the plant 20 and a burner misfire trip occurs in the plant 20, the inspection process information "yes" is input, and as shown in Figure 3 and Figure 4As described above, the cause analysis unit 14 presumes that there is a possibility (or a high possibility) that the abnormal cause is "valve recovery error during regular inspection". Then, as a countermeasure against "valve recovery error during regular inspection", the disposal operation instruction unit 16 sends disposal operation information such as "confirm the isolation valve V1 and the exhaust valve V2" to the terminal device 40, for example. The disposal operation instruction unit 16 sends Figure 6A , and can also send messages such as "Please confirm whether the isolation valve V1 is open and the exhaust valve V2 is closed.", "If the isolation valve V1 is closed and the exhaust valve V2 is open, please open the isolation valve V1 and close the exhaust valve V2." In addition, the disposal operation instruction unit 16 can also send a video showing the positions of the isolation valve V1 and the exhaust valve V2 or the operation steps for opening the isolation valve V1 or closing the exhaust valve V2. Thus, even inexperienced staff can reliably perform the disposal operation.

[0056] As a general example, consider a case where the following series of disposal operations are performed during the disposal operation: operating an isolation valve for ensuring operation safety to isolate the instruments and components of the operation target, inspecting or repairing the instruments and components, and then operating a recovery valve to create a state for satisfying the restart conditions of the plant 20, and finally restoring the isolation valve to its original state. In this case, for example, the disposal operation instruction unit 16 can also output isolation valve instruction information indicating the operation of the isolation valve according to the operation steps, operation instruction information indicating the operation steps for the components and the position information of the components and the components existing at the position isolated by the isolation valve, and recovery valve instruction information indicating the operation of the recovery valve. In the operation instruction information, it is also possible to output the error-prone components existing near the components of the operation target and the position information of the components. Thus, by providing information that details the operation steps and operation positions, even in an emergency when an abnormality occurs, the staff can accurately perform the disposal operation.

[0057] (Operation)

[0058] Next, refer to Figure 7 to describe the operation of the abnormality response teaching system 10.

[0059] Figure 7 is a flowchart showing an example of the operation of the abnormality response teaching system according to the embodiment.

[0060] Before the start of the complete set of equipment 20. First, the operator inputs inspection project information indicating whether a regular inspection has been carried out, etc. into the abnormal situation corresponding teaching system 10. The inspection project information acquisition unit 13 acquires the input inspection project information and records it in the storage unit 19 (step S1). Next, the person in charge of the diagnostic system 30 operates the diagnostic system 30 before the start of the complete set of equipment 20 to perform action diagnosis on multiple instruments equipped with the complete set of equipment 20. The result of the action diagnosis is output to the display device of the diagnostic system 30, etc. If it is diagnosed as abnormal, appropriate measures are taken. If no abnormality is found in the action diagnosis, the diagnostic system 30 outputs the diagnostic information of each instrument that has been diagnosed to the abnormal situation corresponding teaching system 10. The diagnostic information acquisition unit 12 acquires the diagnostic information and records it in the storage unit 19 (step S2). Next, through the operation of the operator of the complete set of equipment 20, the complete set of equipment 20 starts (step S3). When the complete set of equipment 20 starts, the operation data acquisition unit 11 acquires operation parameters from the complete set of equipment 20 and records them in the storage unit 19 (step S4). The operation parameters include operation parameters measured by the sensor 21 of the complete set of equipment 20, various control signals output by the control device 22, etc. After that, the complete set of equipment 20 continues to operate, and the operation data acquisition unit 11 continues to acquire operation parameters. When the operation data acquisition unit 11 acquires an alarm signal or a trip signal from the complete set of equipment 20 (step S5; Yes), the abnormal situation corresponding teaching system 10 starts the analysis process of the abnormal cause. First, the cause analysis unit 14 reads the inspection project information, the diagnostic information of each instrument, the operation parameters before and after the occurrence of the abnormality, and the fault tree ([ Figure 2 ) of the FTA of the event indicated by the alarm signal or the trip signal, and the judgment conditions ([ Figure 3 ) for judging the branches or factors of the fault tree from the storage unit 19. Next, the cause analysis unit 14 analyzes the abnormal cause according to the fault tree (step S6). The cause analysis unit 14 eliminates the factors that do not meet the judgment conditions according to the inspection project information, the diagnostic information, the operation parameters, and the judgment conditions of each factor, and determines the factors that meet the judgment conditions, that is, the abnormal cause. The determined abnormal cause can be one or more. The cause analysis unit 14 can also perform grading corresponding to the size of the possibility, such as the abnormal cause with a high possibility ([ Figure 4 of ○), the abnormal cause with a medium possibility ([ Figure 3 of △), etc., according to the degree to which the operation parameters, etc. meet the judgment conditions. Next, the analysis result output unit 15 outputs the analysis result of the abnormal cause to the display device, etc. (step S7). For example, the analysis result output unit 15 can also display, as exemplified in [[ Figure 4 , the elimination result of the fault tree and the remaining abnormal cause together with its accuracy. The analysis result output unit 15 can also display, as exemplified in [[ Figure 4 , the disposal operation corresponding to the abnormal cause.

[0061] Next, the disposal operation instruction unit 16 determines a disposal operation corresponding to the abnormal cause deduced by the cause analysis unit 14 (step S8). The disposal operation instruction unit 16 reads, from the information in which disposal operations are set for each abnormal cause registered in advance in the storage unit 19, the disposal operation corresponding to the abnormal cause presumed to be possible ( Figure 4 ○ or △). Next, as Figure 5 illustrated, the disposal operation instruction unit 16 outputs a disposal operation instruction indicating the execution of the disposal operation determined in step S8 to the terminal device 40 (step S9). The staff member executes the indicated disposal operation. When executing the disposal operation, the staff member inputs the completion of the disposal operation to the terminal device 40. The terminal device 40 sends the completion information of the disposal operation to the abnormality corresponding teaching system 10. In the abnormality corresponding teaching system 10, the disposal operation completion receiving unit 17 acquires the completion information of the disposal operation (step S10). Alternatively, the staff member may use the terminal device 40 to take a photo or video of the work object part after the completion of the disposal operation, and the terminal device 40 may send this image data to the abnormality corresponding teaching system 10. The abnormality corresponding teaching system 10 acquires the image data. The operator confirms the content of the image data and confirms whether the disposal operation has been correctly executed. When it is confirmed that the execution is correct, the operator inputs to the abnormality corresponding teaching system 10 that the disposal operation has been completed. The disposal operation completion receiving unit 17 acquires the completion information of the disposal operation. The disposal operation completion receiving unit 17 may also display the acquisition status of the completion information of the disposal operation instructed by the disposal operation instruction unit 16. Thus, the recovery staff can confirm the progress of dealing with the abnormality. When the disposal operation completion receiving unit 17 acquires the completion information for all the disposal operation instructions, the restart preparation completion notification unit 18 notifies the terminal device 40 of the operator in charge of starting the plant 20, etc. that the restart preparation of the plant 20 has been completed (step S11). Thus, the plant 20 can be restarted.

[0062] (Effect)

[0063] As described above, according to the abnormality corresponding teaching system 10, it is possible to automatically perform the analysis process of abnormal causes using a fault tree. Since not only operating parameters but also diagnostic information and inspection process information are used to deduce abnormal causes, the accuracy of deducing abnormal causes can be improved. In the analysis process of abnormal causes by the cause analysis unit 14, inspection process information is not essential. For example, when the judgment conditions of the fault tree do not include inspection process information, the inspection process information can be omitted.

[0064] By pre-registering information on the handling operations corresponding to the presumed abnormal causes and providing it to the user side together with the presumed possible abnormal causes, it is possible to quickly respond to abnormalities. As a result, the plant 20 can be quickly restored to a normal operating state. By acquiring and managing the completion information of the handling operations, it is possible to determine whether the handling of abnormalities has been carried out without omission.

[0065] By notifying that the restart preparation is complete at the stage when the handling operations for all abnormal causes have been completed, the plant 20 can be restarted while ensuring that it can be restarted.

[0066] In the above embodiment, a plant including a gas turbine has been described as an example, but the object of the abnormality response teaching system 10, the abnormal cause presumption method, the abnormality response teaching method, and the program in the present embodiment is not limited to this, and can be applied to any machinery, equipment, and devices such as steam turbines, boilers, compressors, superchargers, and engines.

[0067] Figure 8 It is a diagram showing an example of the hardware configuration of the abnormality response teaching system according to the embodiment.

[0068] The computer 900 includes a CPU 901, a main storage device 902, an auxiliary storage device 903, an input / output interface 904, and a communication interface 905.

[0069] The above abnormality response teaching system 10 is installed in the computer 900. Moreover, each of the above functions is stored in the auxiliary storage device 903 in the form of a program. The CPU 901 reads the program from the auxiliary storage device 903 and expands it in the main storage device 902, and executes the above processing according to the program. The CPU 901 ensures a storage area in the main storage device 902 according to the program. The CPU 901 ensures a storage area for storing data in the storage process in the auxiliary storage device 903 according to the program.

[0070] It is also possible to record a program for implementing all or part of the functions of the teaching system 10 corresponding to an abnormality in a computer-readable recording medium, and perform the processing by each functional unit by causing a computer system to read and execute the program recorded in the recording medium. The "computer system" mentioned here includes hardware such as an OS and peripheral devices. In the case of using a WWW system, the "computer system" also includes a homepage providing environment (or display environment). The "computer-readable recording medium" refers to a removable medium such as a CD, DVD, USB, or a storage device such as a hard disk built into the computer system. When the program is distributed to the computer 900 via a communication line, the receiving computer 900 can also expand the program in the main storage device 902 and execute the above processing. The above program can be used to implement a part of the above functions, and can also be combined with a program already recorded in the computer system to implement the above functions. The teaching system 10 corresponding to an abnormality can be composed of a plurality of computers 900.

[0071] As described above, although several embodiments of the present disclosure have been described, all of these embodiments are exemplary and are not intended to limit the scope of the invention. These embodiments can be implemented in various other ways, and various omissions, substitutions, and changes can be made without departing from the gist of the invention. These embodiments and their modifications are included in the scope and gist of the invention in the same way as they are included in the invention described in the claims and its equivalents.

[0072] <Supplementary Note>

[0073] For example, the teaching system 10 corresponding to an abnormality, the abnormality cause estimation method, the teaching method corresponding to an abnormality, and the program described in the embodiments are grasped as follows.

[0074] (1) The teaching system 10 corresponding to an abnormality according to the first mode includes: an operation parameter acquisition unit (operation data acquisition unit 11) that acquires operation parameters measured during the operation of the device (plant 20); a diagnosis information acquisition unit 12 that acquires diagnosis information indicating the operation diagnosis result of the instruments included in the device executed before the start of the device; and a cause analysis unit 14 that, when an abnormality occurs in the device, inputs the operation parameters and the diagnosis information into an FTA (fault tree) that analyzes the cause of the abnormality to analyze the cause of the abnormality.

[0075] Thereby, it is possible to automate the operation of analyzing the cause of an abnormality according to FTA and shorten the time required to analyze the cause of an abnormality. Since the operation parameters and diagnosis information are used to analyze the cause of an abnormality, the analysis accuracy of the cause of an abnormality can be improved. Thereby, it is possible to quickly restore the plant to a normal operation state.

[0076] (2) The abnormality-corresponding teaching system 10 of the second mode is the abnormality-corresponding teaching system 10 of (1), and further includes an inspection process information acquisition unit 13 that acquires inspection process information indicating the actual results of inspections or processes performed on the device. The cause analysis unit 14 inputs the operating parameters, the diagnostic information, and the inspection process information into the FTA to analyze the cause.

[0077] By further using inspection process information in the analysis of the abnormality cause, the analysis accuracy of the abnormality cause can be further improved.

[0078] (3) The abnormality-corresponding teaching system 10 of the third mode is the abnormality-corresponding teaching system 10 of (1) to (2), and further includes a disposal operation instruction unit 16 that outputs disposal operation instruction information indicating the disposal operation for the cause analyzed by the cause analysis unit 14.

[0079] By presenting the disposal operation for confirming or eliminating the abnormality cause, the disposal for the abnormality can be carried out quickly. In addition to outputting the disposal operation instruction information, the disposal operation instruction unit 16 may also output disposal operation step information indicating the steps of the disposal operation.

[0080] (4) The abnormality-corresponding teaching system 10 of the fourth mode is the abnormality-corresponding teaching system 10 of (3). Among them, the disposal operation instruction unit 16 outputs isolation valve instruction information, operation instruction information, and restoration valve instruction information. The isolation valve instruction information instructs the operation of the isolation valve for ensuring operation safety. The operation instruction information is for the operation steps of the components located at the position isolated by the isolation valve and the position information of the components and the components. The restoration valve instruction information instructs the operation of the restoration valve for satisfying the restart condition of the device.

[0081] By outputting the isolation valve information, the operation instruction information, and the restoration valve instruction information, even inexperienced staff can perform a series of disposal operations including operating the isolation valve for ensuring operation safety, inspecting the specified components, etc., operating the restoration valve to create a restartable state, and restoring the isolation valve to its original state.

[0082] (5) The abnormality-corresponding teaching system 10 of the fifth mode is the abnormality-corresponding teaching system 10 of (3) to (4), and further includes: a disposal operation completion reception unit 17 that receives the input of the completion of the disposal operation; and a restart preparation completion notification unit 18 that notifies that the restart preparation is completed when all the disposal operations are completed.

[0083] By having a disposal operation completion reception unit, it is possible to grasp the implementation status of the disposal operation. By having a restart preparation completion notification unit, it is possible to execute the restart of the plant equipment 20 after all the disposal operations are completed.

[0084] (6) The abnormality-corresponding teaching system 10 of the sixth mode is the abnormality-corresponding teaching system 10 of (1) to (5), and further includes an analysis result output unit 15 that outputs the analysis result performed by the cause analysis unit 14 together with the fault tree of the FTA.

[0085] By outputting the analysis result together with the fault tree, it is possible to refer to the structure of the fault tree to confirm which abnormal cause defined in the fault tree is the cause of the abnormality that occurred this time and which abnormal cause is not the cause of the abnormality.

[0086] (7) In the abnormal cause estimation method of the seventh mode, operating parameters measured during the operation of the device (plant equipment 20) are acquired, diagnostic information indicating the operation diagnosis result of the instruments included in the device executed before the start of the device is acquired, and when the device has an abnormality, the operating parameters and the diagnostic information are input to the FTA that has analyzed the cause of the abnormality to analyze the cause of the abnormality.

[0087] (8) In the abnormality-corresponding teaching method of the eighth mode, operating parameters measured during the operation of the device (plant equipment 20) are acquired, diagnostic information indicating the operation diagnosis result of the instruments included in the device executed before the start of the device is acquired, and when the device has an abnormality, the operating parameters and the diagnostic information are input to the FTA that has analyzed the cause of the abnormality to analyze the cause of the abnormality, and disposal operation instruction information for instructing a disposal operation corresponding to the cause is output.

[0088] (9) The abnormality-corresponding teaching method of the ninth mode is the abnormality-corresponding teaching method of (8), and further receives the input of the completion of the disposal operation, and when all the disposal operations are completed, notifies that the restart preparation is completed.

[0089] (10) The program of the tenth mode causes a computer to execute the following processing: acquiring operating parameters measured during the operation of the device (plant equipment 20), acquiring diagnostic information indicating the operation diagnosis result of the instruments included in the device executed before the start of the device, and when the device has an abnormality, inputting the operating parameters and the diagnostic information to the FTA that has analyzed the cause of the abnormality to analyze the cause of the abnormality.

[0090] Industrial applicability

[0091] According to the above-described abnormality-corresponding teaching system, abnormality cause estimation method, abnormality-corresponding teaching method, and program, when an abnormality occurs in a plant or the like, the cause of the abnormality can be estimated with high accuracy and in a short time. According to the abnormality-corresponding teaching method of the present disclosure, when an abnormality occurs in a plant or the like, a coping method for the abnormality can be grasped.

[0092] Symbol Explanation

[0093] 1 - Recovery management system, 10 - Abnormality-corresponding teaching system, 11 - Operation data acquisition unit, 12 - Diagnostic information acquisition unit, 13 - Inspection process information acquisition unit, 14 - Cause analysis unit, 15 - Analysis result output unit, 16 - Disposal operation instruction unit, 17 - Disposal operation completion reception unit, 18 - Restart preparation completion notification unit, 19 - Storage unit, 20 - Plant, 30 - Diagnostic system, 40 - Terminal device, 900 - Computer, 901 - CPU, 902 - Main storage device, 903 - Auxiliary storage device, 904 - Input / output interface, 905 - Communication interface.

Claims

1. An abnormality-corresponding teaching system, comprising: An operating parameter acquisition unit that acquires operating parameters measured during the operation of the device; A diagnostic information acquisition unit that acquires diagnostic information indicating the operation diagnosis result of the instruments included in the device performed by the diagnostic system before the device is started; A cause analysis unit that, when an abnormality occurs in the device, inputs the operating parameters and the diagnostic information into an FTA that analyzes the cause of the abnormality to analyze the cause of the abnormality; A disposal operation instruction unit that outputs disposal operation instruction information indicating a disposal operation for the cause analyzed by the cause analysis unit; A disposal operation completion reception unit that receives an input indicating completion of the disposal operation; and A restart preparation completion notification unit that, when all the disposal operations are completed, notifies that the restart preparation of the device has been completed.

2. The abnormality-corresponding teaching system according to claim 1, further comprising an inspection process information acquisition unit that acquires inspection process information indicating the actual results of inspections or processes performed on the device, wherein the cause analysis unit inputs the operating parameters, the diagnostic information, and the inspection process information into the FTA to analyze the cause.

3. The abnormality-corresponding teaching system according to claim 1, wherein the disposal operation instruction unit outputs isolation valve instruction information, operation instruction information, and restoration valve instruction information, the isolation valve instruction information indicates the operation of an isolation valve for ensuring operation safety, the operation instruction information indicates the operation steps for components located at positions isolated by the isolation valve and the component and position information of the components, the restoration valve instruction information indicates the operation of a restoration valve for satisfying the restart conditions of the device.

4. An abnormality-corresponding teaching system, comprising: An operating parameter acquisition unit that acquires operating parameters measured during the operation of the device; A diagnostic information acquisition unit that acquires diagnostic information indicating the operation diagnosis result of the instruments included in the device performed by the diagnostic system before the device is started; A cause analysis unit that, when an abnormality occurs in the device, inputs the operating parameters and the diagnostic information into an FTA that analyzes the cause of the abnormality to analyze the cause of the abnormality; and A disposal operation instruction unit that outputs disposal operation instruction information indicating a disposal operation for the cause analyzed by the cause analysis unit, wherein the disposal operation instruction unit outputs isolation valve instruction information, operation instruction information, and restoration valve instruction information, the isolation valve instruction information indicates the operation of an isolation valve for ensuring operation safety, the operation instruction information indicates the operation steps for components located at positions isolated by the isolation valve and the component and position information of the components, the restoration valve instruction information indicates the operation of a restoration valve for satisfying the restart conditions of the device.

5. The abnormality-corresponding teaching system according to any one of claims 1 to 4, It also has an analysis result output unit that outputs the analysis result performed by the cause analysis unit together with the fault tree of the FTA.

6. An abnormal situation corresponding teaching method, wherein, Obtain the operation parameters measured during the operation of the device, Obtain diagnostic information indicating the operation diagnosis results of the instruments equipped in the device executed by the diagnostic system before the device is started, When an abnormality occurs in the device, input the operation parameters and the diagnostic information into an FTA that analyzes the cause of the abnormality to analyze the cause of the abnormality, Output disposal operation instruction information for instructing a disposal operation corresponding to the cause, Receive an input indicating that the disposal operation is completed, When all the disposal operations are completed, notify that the restart preparation of the device is completed.

7. A program product that causes a computer to execute the following processing: Obtain the operation parameters measured during the operation of the device, Obtain diagnostic information indicating the operation diagnosis results of the instruments equipped in the device executed by the diagnostic system before the device is started, When an abnormality occurs in the device, input the operation parameters and the diagnostic information into an FTA that analyzes the cause of the abnormality to analyze the cause of the abnormality, Output disposal operation instruction information for instructing a disposal operation corresponding to the cause, Receive an input indicating that the disposal operation is completed, When all the disposal operations are completed, notify that the restart preparation of the device is completed.

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