Plant control monitoring system and plant control monitoring method

Abstract

To provide a plant control monitoring system and the like that can easily recognize the situation when an abnormality occurs within a plant.SOLUTION: A plant control monitoring system 100 is provided with a control device 1 having a controller 11 that controls equipment of a plant P1 and a maintenance system 2 connected to the control device 1 via a control network 4. When the maintenance system 2 outputs a predetermined alarm signal based on a processing result of the controller 11, input signals that may contribute to the output alarm signal are identified, among input signals associated with the alarm signal. The system then displays a simplified control logic diagram on a monitor 22. This diagram is a simplified control logic diagram illustrating a path from the identified input signals to the alarm signal.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a plant control and monitoring system and the like. [Background technology]

[0002] As a technique for allowing an operator to grasp the situation when an abnormality occurs in a plant, for example, the technique described in Patent Document 1 is known. That is, Patent Document 1 describes an analysis device that includes "a report generation means for generating an analysis report including expressions according to the analysis parameters based on the analysis results of each device detected as an abnormal device." [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2022-158226 Summary of the Invention [Problem to be solved by the invention]

[0004] For example, when an operator grasps the situation when an abnormality occurs in a plant (when an alarm signal is output), he or she often visually traces the control logic diagram, tracing back from the alarm signal toward the input side. The circuits in a control logic diagram often branch along the way, and the operator has to decide how to trace the circuit. Therefore, the accuracy and speed of tracing the circuits in a control logic diagram tends to depend on the operator's experience and judgment. There is a demand for a system that makes it easy for operators to grasp the situation when an abnormality occurs in a plant, but Patent Document 1 does not describe such technology.

[0005] Therefore, an object of the present disclosure is to provide a plant control and monitoring system etc. that makes it easy to grasp the situation when an abnormality occurs in the plant. [Means for solving the problem]

[0006] In order to solve the above-mentioned problems, the plant control and monitoring system according to the present disclosure includes a control device having a controller that controls equipment in a plant, and a maintenance system connected to the control device via a control network, and when the maintenance system outputs a predetermined alarm signal based on the processing result of the controller, it identifies, from among the input signals associated with the alarm signal, input signals that may contribute to the output of the alarm signal, and displays on a display device a simplified control logic diagram that is a simplified control logic diagram from the input signals to the alarm signal. [Effects of the Invention]

[0007] According to the present disclosure, it is possible to provide a plant control and monitoring system and the like that makes it easy to grasp the situation when an abnormality occurs in a plant. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is a configuration diagram of a plant control and monitoring system according to an embodiment. [Figure 2] FIG. 2 is an explanatory diagram relating to functions of a maintenance system and a controller included in the plant control and monitoring system according to the embodiment. [Figure 3] FIG. 2 is a control logic diagram as an example of a plant control and monitoring system according to an embodiment. [Figure 4] 10 is a diagram illustrating an example of a screen display of data related to a bit memory of the plant control and monitoring system according to the embodiment. [Figure 5] 10 is an example of a screen display showing data of input signals associated with each alarm signal of the plant control and monitoring system according to the embodiment; [Figure 6] 10 is an example of a screen display in a maintenance system included in the plant control and monitoring system according to the embodiment. [Figure 7] 3 is a flowchart showing the processing of the plant control and monitoring system according to the embodiment. [Figure 8] 1 is a screen display example of a simplified control logic diagram in a plant control and monitoring system according to an embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] <Embodiment> <Configuration of plant control and monitoring system> FIG. 1 is a configuration diagram of a plant control and monitoring system 100 according to an embodiment. 1 is a system for controlling each device in a plant P1 and monitoring the operating status of each device in the plant P1. Examples of the plant P1 to be controlled include a thermal power plant and a nuclear power plant, but the plant is not limited to these and may also be a chemical plant, a manufacturing plant, a water treatment plant, or the like.

[0010] As shown in Fig. 1, the plant control and monitoring system 100 is configured to include a control device 1, a maintenance system 2 (also referred to as a maintenance tool), and an operation and monitoring system 3. The control device 1, maintenance system 2, and operation and monitoring system 3 are connected via a control network 4. Note that the number of each of the control device 1, maintenance system 2, and operation and monitoring system 3 is not limited to one, and there may be more than one. For example, one or more other control devices (not shown) having predetermined functions different from those of the control device 1 may be connected to the control network 4.

[0011] The control device 1 is a device that acquires signals indicating the operating status from each device of the plant P1 and generates control signals for each device of the plant P1. As shown in Fig. 1, the control device 1 includes a controller 11 and a PI / O device 12.

[0012] The controller 11 has a function of controlling the devices of the plant P1. Although not shown in the figure, the hardware configuration of the controller 11 includes electronic circuits such as a CPU (Central Processing Unit), ROM (Read Only Memory), RAM (Random Access Memory), and various interfaces. The controller 11 reads out a program stored in the ROM and loads it into the RAM, and the CPU executes various processes.

[0013] The PI / O device 12 acquires signals indicating the moment-to-moment operating state of the plant P1. Note that "PI / O" is an abbreviation for Process Input / Output. The signals indicating the operating state of the plant P1 are input to the controller 11 via the PI / O device 12.

[0014] 1, the controller 11 is connected to a control network 4. The controller 11 performs predetermined calculations based on signals indicating the operating state of the plant P1 (i.e., signals acquired by the PI / O device 12) as well as signals from the maintenance system 2, the operation monitoring system 3, and other control devices (not shown). The calculation results of the controller 11 are output to each device of the plant P1 via the PI / O device 12, and are also transmitted appropriately to other control devices (not shown), the maintenance system 2, and the operation monitoring system 3 via the control network 4.

[0015] The maintenance system 2 is a system that monitors the calculation results of the controller 11 and outputs predetermined signals to the controller 11. The maintenance system 2 is connected to the control device 1 via a control network 4. As shown in FIG. 1, the maintenance system 2 includes a system device 21 and a monitor 22 (display device).

[0016] The system device 21 generates a predetermined control logic diagram (for example, a control logic diagram D1a as shown in FIG. 3) based on data input by operating an input device (not shown) such as a keyboard or a mouse. Here, a "control logic diagram" is a sequence diagram that represents processing based on digital signals or analog signals as a predetermined logic circuit. Incidentally, a signal that represents an analog signal discretely using n numerical values ​​(i.e., a digitized signal) may also be considered an analog signal. Details of the control logic diagram will be described later.

[0017] A monitor program 21b (see FIG. 2) is pre-stored in the system device 21. The monitor program 21b (see FIG. 2) acquires the calculation results of the controller 11 via the control network 4 and displays these calculation results in a predetermined manner on the monitor 22. The monitor 22 is a display for displaying the calculation results of the controller 11, etc.

[0018] The operation monitoring system 3 is a system that monitors the operating state of the plant P1. The operation monitoring system 3 includes a computer 31 connected to the control network 4 and a monitor 32 that displays the calculation results of the computer 31. Note that the operation monitoring system 3 has a well-known configuration, and therefore a description thereof will be omitted.

[0019] FIG. 2 is an explanatory diagram regarding the functions of the maintenance system 2 and the controller 11. As described above, the maintenance system 2 generates the control logic diagram D1 based on a predetermined input operation. Then, the system device 21 (see FIG. 1) compiles various control data including the control logic diagram D1 to generate the backup object 21a.

[0020] Here, an "object" is data that is a predetermined combination of variables, functions, and data structures and that has been converted into a format that can be read by a processor such as a CPU. The backup object 21a is backed up in the maintenance system 2 and is also downloaded to the controller 11 via the control network 4 (see FIG. 1). An object downloaded to the controller 11 in this way is called a controller object 11a.

[0021] 2 is a storage device for storing data such as input signals in the control logic diagram D1 (for example, the control logic diagram D1a in FIG. 3) from time to time. The analysis data storage unit 21d is a storage device for storing data of input signals associated with a predetermined alarm signal when the alarm signal is issued.

[0022] The monitor program 21b acquires the calculation results of the controller object 11a via the control network 4 (see FIG. 1). Then, the monitor program 21b displays a control logic diagram D1 reflecting the calculation results of the controller object 11a on a monitor screen 22a (the screen of the monitor 22 in FIG. 1) in a predetermined manner, based on the data in the input value storage unit 21c and the analysis data storage unit 21d. In addition to the backup object 21a and the monitor program 21b, the input value storage unit 21c and the analysis data storage unit 21d are included in the maintenance system 2 (see FIG. 1). The controller object 11a is included in the controller 11 (see FIG. 1).

[0023] FIG. 3 is an example of a control logic diagram D1a. As mentioned above, a "control logic diagram" is a sequence diagram that represents processing based on digital signals or analog signals as a predetermined logic circuit, and is displayed on the monitor 22 (see FIG. 1) of the maintenance system 2 (see FIG. 1). In the example of FIG. 3, the control logic diagram D1a is configured such that input signals A to F, arithmetic circuits 41 to 43, AND gate 44, OR gates 45 to 47, and alarm signals α and β are connected in a predetermined manner via wiring.

[0024] The input signals A to F are signals input from the plant P1 (see FIG. 1) or other control devices (not shown). Examples of such input signals A to F include, but are not limited to, detection values ​​from sensors (not shown) installed in equipment in the plant P1. The input signals A to F are in the form of analog signals or digital signals. Here, an "analog signal" is a signal whose value changes continuously. Note that an analog value input from the outside as a current or voltage and converted into a digital value for calculation is also considered to be an "analog signal." Furthermore, a "digital signal" is a signal that takes on discrete values. For example, a binary signal of 0 or 1 is a "digital signal."

[0025] The alarm signals α and β shown in Fig. 3 are alarm signals that indicate an abnormality in equipment in the plant P1 (see Fig. 1). The format of these alarm signals α and β is a digital signal. The output signals of the arithmetic circuits 41 to 43, AND gate 44, and OR gates 45 to 47 provided between the input signals A to F and the alarm signals α and β are also digital signals. The input signals to the arithmetic circuits 41 to 43 may be either analog signals or digital signals.

[0026] Although details will be described later, in this embodiment, a simplified control logic diagram (see, for example, FIG. 8) is generated by extracting from the control logic diagram D1a a portion related to an actually output alarm signal (for example, alarm signal β). Such a simplified control logic diagram is called a "simplified control logic diagram." The control logic diagram D1a shown in FIG. 3 is the original control logic diagram before simplification. This control logic diagram D1a includes predetermined "operators" such as arithmetic circuits 41 to 43, an AND gate 44, and OR gates 45 to 47.

[0027] As shown in FIG. 3, in the original control logic diagram D1a before simplification, bit memories 51 to 55 are provided on predetermined wiring over which digital signals are transmitted. The bit memories 51 to 55 are devices capable of storing 1 bit of information (0 or 1). These bit memories 51 to 55 are used when extracting portions of the control logic diagram D1a that relate to the output of an alarm signal. In the control logic diagram D1a, the character "X1" indicating the identification information of the bit memory 51 is displayed next to the rectangular symbol representing the bit memory 51 (the same applies to the other bit memories 52 to 55).

[0028] Although it is possible to provide a bit memory on any wiring that transmits digital signals, it is recommended to provide the bit memory as follows: In other words, in the control logic diagram D1a, the bit memory should be provided at a location where a predetermined alarm signal is output when the value of the digital signal transmitted via the wiring changes.

[0029] For example, if the alarm signal α is output based on the logical sum of the OR gate 45, it is advisable to provide one bit memory 51, one bit memory 52 on the input side of the OR gate 45. This makes it easier to identify the part directly related to the output of the alarm signal α. Also, if a specific alarm signal is output based on multiple calculation results, the operator can check the order in which these calculation results were input in chronological order. To give a specific example, suppose the value of the bit memory 51 changed from 0 to 1 immediately before the alarm signal α was output. In this case, the output of the alarm signal α can be identified based on the calculation result of the AND gate 44 on the input side of the bit memory 51.

[0030] It is also advisable to provide the bit memory as close as possible to one of the terminals for input signals A to F. This makes it easier to identify the input signal related to the output of a predetermined alarm signal when the alarm signal is output.

[0031] For example, when the value of bit memory 51 (i.e., the value of the digital signal transmitted via wiring K1) changes, data for identifying the change is recorded in input value storage unit 21c (see FIG. 2). That is, when the value of bit memory 51 changes from 0 to 1 or from 1 to 0, the values ​​before and after the change, the device position of bit memory 51, and the date and time when the value of bit memory 51 changed are recorded in input value storage unit 21c (see FIG. 2). The same applies to the other bit memories 52 to 55.

[0032] Figure 4 shows an example of a screen display of data related to bit memory. The data shown in Fig. 4 is recorded in the input value storage unit 21c (see Fig. 2), converted into a table format by the monitor program 21b (see Fig. 2), and displayed on the monitor 22 (see Fig. 1). In the example of Fig. 4, the "date and time" when the value of a specific bit memory changed, the "device position" of the bit memory, and the "value" of the bit memory before and after the change are associated with each other and displayed in a table format.

[0033] The "device position" of a bit memory is information for identifying that bit memory, and is composed of a "sheet number" and "identification information." The "sheet number" is a number assigned to the multiple sheets (not shown) that make up the control logic diagram D1a (see Figure 3). The "identification information" is a number or symbol assigned to the bit memory. By checking these "sheet numbers" and "identification information," the operator can determine which bit memory value changed and when.

[0034] For example, the first row of the table in Figure 4 shows that at 10:00 on a specific date, "yyyy / mm / dd", the value of bit memory 51 (see Figure 3) of identification information X1 contained in a sheet with a specific "Sheet No. **" changed from 0 to 1.

[0035] Next, the correspondence between the alarm signals and the input signals will be described. As described above, when the backup object 21a (see FIG. 2) is created, the data of the control logic diagram D1a (see FIG. 3) is compiled in the maintenance system 2. During this compilation process, all of the input signals corresponding to the alarm signals α and β of the control logic diagram D1a are extracted.

[0036] When compiling the data of the control logic diagram D1a, the maintenance system 2 (see FIG. 2) extracts input signals A to D that are connected to the alarm signal α via wiring or the like, and stores them in association with the alarm signal α. These input signals A to D are identified by tracing back from the alarm signal α to the input side via wiring or the like. Similarly, the maintenance system 2 extracts input signals C to F that are connected to another alarm signal β via wiring or the like, and stores them in association with the alarm signal β.

[0037] FIG. 5 is an example of a screen display showing data of input signals associated with the respective alarm signals α and β. The data shown in Fig. 5 is displayed on the monitor 22 (see Fig. 1) of the maintenance system 2 (see Fig. 1). Also, "α" and "β" in the upper left of each table indicate the alarm signals α and β. "*******" written to the right of "α" and "β" indicates the specified ID or signal name of the alarm signals α and β.

[0038] In the example of FIG. 5, the "sheet number," which is the number of a specific sheet (for example, the sheet containing input signal A), the "link ID" of the input signal, and the "signal name" of the input signal are associated and shown in a table format. Note that the "link ID" is information used to identify a signal within a specific sheet. In the example of FIG. 5, the link ID of input signal A is "A" (the same applies to input signals B to F).

[0039] For example, four input signals A to D are associated with an alarm signal α. This indicates that in the control logic diagram D1a (see FIG. 3), the terminals of the input signals A to D are connected to the terminal of the alarm signal α via wiring or the like. Similarly, four input signals C to F are associated with another alarm signal β. By displaying such data on the monitor 22 (see FIG. 1), the operator can grasp at a glance the correspondence between the alarm signals and the input signals.

[0040] It is not necessary to associate all of the input signals A to D with the alarm signal α; some of the input signals A to D may be associated with the alarm signal α, and the rest may not be associated with the alarm signal α. In other words, when the alarm signal α is output, the system designer or operator may select in advance the input signals that are to be displayed as output factors, and associate them with the alarm signal α. Furthermore, input signals that do not particularly need to be displayed as output factors may not be associated with the alarm signal α (the same applies to the other alarm signals β).

[0041] Next, the setting of threshold values ​​for input signals will be described. When the data of the control logic diagram D1a (see FIG. 3) is compiled in the maintenance system 2 (see FIG. 2), a threshold value that serves as a criterion for whether or not to store the values ​​of the input signals A to F (see FIG. 3) in the input value storage unit 21c is extracted for each alarm signal.

[0042] It should be noted that there may be multiple thresholds for a given input signal. In such a case, the maintenance system 2 sets the threshold for the input signal so that the normal range specified by the threshold (the range in which the input signal value is normal) is the narrowest. In other words, the maintenance system 2 sets the threshold for the input signal so that the abnormal range specified by the threshold (the range in which the input signal value is abnormal) is the widest. This makes it possible to prevent input signal values ​​related to the output of a given alarm signal from being omitted from recording.

[0043] FIG. 6 shows an example of a screen display in the maintenance system. For simplicity, the control logic diagram D1b shown in Fig. 6 shows a circuit that extracts the portion from the input signals D and E to the alarm signal β in the control logic diagram D1a of Fig. 3. Also, Fig. 6 omits the illustration of the OR gate 47 (see Fig. 3) and the bit memory 53 (see Fig. 3).

[0044] In the example of FIG. 6, a digital value indicating a predetermined plant state is input as input signal D within a range of 0 to 50°C. Furthermore, a digital value of 0 or 1 is input as input signal E. The controller object 11a (see FIG. 2) performs a predetermined calculation based on the values ​​of these input signals D and E. As shown in FIG. 6, the calculation circuit 43 is configured to include a logic macro 43a and an AND gate 43b.

[0045] The logic macro 43a is configured to output a value of 0 when the value of the input signal D is 30 or less, and to output a value of 1 when the value of the input signal D is greater than 30. The operation result of the logic macro 43a is output to the AND gate 43b via the wiring K2. The value of the input signal E is also output to the AND gate 43b.

[0046] The AND gate 43b performs a logical AND operation, and outputs a value of 1 if all of the signals input to it are 1, and outputs a value of 0 otherwise. In the example of FIG. 6, if the value of input signal D is greater than 30 and the value of input signal E is 1, an alarm signal β is output. Therefore, the threshold value of input signal D is set to 30. Also, the threshold value of input signal E is set to 1. In this way, the threshold value of the input signal is set based on whether or not an alarm signal β is output when that input signal (e.g., input signal D) reaches a predetermined threshold value.

[0047] The controller object 11a (see FIG. 2) reads the value of each input signal at a predetermined time interval (sampling period). When the value of an input signal exceeds a predetermined threshold, the controller object 11a records the value ("input value" shown in FIG. 6) and the acquisition date and time ("date and time" shown in FIG. 6) in the input value storage unit 21c (see FIG. 2). Of the data recorded in the input value storage unit 21c, the data transferred to the analysis data storage unit 21d (see FIG. 2) is organized in a table format or a graph format by the monitor program 21b (see FIG. 2) and displayed as a table T1 or a graph G1 as shown in FIG. 6.

[0048] In the example of Figure 6, for a specific input signal that exceeded the threshold immediately before an alarm signal was output, the "date and time" when this input signal was acquired and its "input value" are displayed as table T1. The "Sheet No.", "Link ID," and "Signal Name" of the input signal are displayed above table T1.

[0049] Furthermore, the time-series change in the input value of the input signal is displayed as graph G1. Specifically, the time-series change in the input value of the input signal that exceeds the threshold indicated by the dashed line L1 (i.e., falls within the abnormal range) from moment to moment is displayed as graph G1. This allows the operator to easily understand how the input signal changed when it exceeded the threshold and entered the abnormal range. Incidentally, when an abnormality occurs in plant P1, in addition to the case where the input signal value exceeds the threshold and increases, the input signal value may also become smaller than the threshold.

[0050] <Plant control and monitoring system processing> FIG. 7 is a flowchart showing the processing of the plant control and monitoring system (see also FIG. 2 as appropriate). It is assumed that each device in the plant P1 (see FIG. 1) is operating normally at the time of "START" in Fig. 7. It is also assumed that the value of each input signal is stored in the input value storage unit 21c at predetermined time intervals (for example, 0.01 seconds, 0.1 seconds, or several seconds).

[0051] In step S101, the plant control and monitoring system 100 records input values ​​that exceed a predetermined threshold value using the maintenance system 2. That is, the plant control and monitoring system 100 stores, in the input value storage unit 21c, those of the multiple input signals that are input from time to time whose values ​​exceed a predetermined threshold value. As described above, this threshold value is the value of the input signal that indicates the condition when an alarm signal is output, and is set in advance in association with the alarm signal (see FIG. 5).

[0052] In the input value storage unit 21c, once recorded data is automatically deleted after a predetermined time has elapsed, based on the upper limit of its storage capacity. This is intended to reduce the memory capacity of the input value storage unit 21c. However, when a predetermined alarm signal is output, the input signal associated with that alarm signal is moved from the input value storage unit 21c to the analysis data storage unit 21d. Since the data stored in the analysis data storage unit 21d may include the input signal that caused the alarm signal to be output, it is not automatically deleted but remains stored.

[0053] In step S102, the plant control and monitoring system 100 determines whether or not an abnormality has occurred in the equipment of the plant P1 (see FIG. 1) using the controller 11. That is, the controller 11 performs a predetermined calculation in accordance with the controller object 11a based on input signals acquired from the plant P1 or other control devices (not shown) via the PI / O device 12 (see FIG. 1). Then, the controller 11 determines whether or not an abnormality has occurred in the plant P1.

[0054] If there is no abnormality in the equipment of the plant P1 in step S102 (S102: No), the processing of the plant control and monitoring system 100 returns to step S101. On the other hand, if there is an abnormality in the equipment of the plant P1 in step S102 (S102: Yes), the processing of the plant control and monitoring system 100 proceeds to step S103.

[0055] In step S103, the plant control and monitoring system 100 outputs a predetermined alarm signal based on the processing result of the controller 11 through the maintenance system 2 (alarm signal output processing). Specifically, the plant control and monitoring system 100 displays the alarm signal on the control logic diagram of the monitor 22 (see FIG. 1) of the maintenance system 2, and also displays a list of alarms on the monitor 32 (see FIG. 1) of the operation monitoring system 3. Note that an alarm indicating an abnormality in the plant P1 may be output not only to the maintenance system 2 and the operation monitoring system 3, but also to other monitoring devices.

[0056] In step S104, the plant control and monitoring system 100 extracts input signals associated with the alarm signal using the maintenance system 2. For example, when the alarm signal α in Fig. 3 is output, the maintenance system 2 extracts input signals A to D associated with this alarm signal α (see Fig. 5). As described above, the input signals corresponding to a predetermined alarm signal are identified in the process of compiling the data of the control logic diagram D1a (see Fig. 3).

[0057] In step S105, the plant control and monitoring system 100 records necessary data using the maintenance system 2. That is, the maintenance system 2 reads out the input signal data extracted in step S104 from the input value storage unit 21c, and stores this data in the analysis data storage unit 21d.

[0058] For example, when the alarm signal α of Fig. 3 is output, the maintenance system 2 stores the data of the input signals A to D (see Fig. 5) corresponding to the alarm signal α in the analysis data storage unit 21d. As described above, the data stored in the analysis data storage unit 21d is not automatically deleted even after a certain period of time has passed. The data stored in the analysis data storage unit 21d may be displayed in a predetermined format of a table or graph (see Fig. 6) on the monitor 22 (see Fig. 1) of the maintenance system 2.

[0059] Next, in step S106, the plant control and monitoring system 100 extracts the circuit in which the bit has changed using the maintenance system 2. That is, the maintenance system 2 extracts, from among the plurality of bit memories 51 to 55 (see FIG. 3), a circuit including a bit memory whose value changed from 0 to 1 immediately before the alarm signal is output. Here, "immediately before" the alarm signal is output means the period from a point in time a predetermined time before the alarm signal is output until the alarm signal is output.

[0060] Furthermore, a "circuit including a bit memory" refers to a circuit that can be traced back (traced) from its memory bit to a predetermined input signal. For example, assume that the value of bit memory 53 changed from 0 to 1 immediately before alarm signal β shown in FIG. 3 was output. Tracing the circuit back from bit memory 53 toward the input side, the input terminals are input signals D and E. In such a case, the maintenance system 2 extracts the circuit from input signals D and E to alarm signal β as a simplified control logic diagram D1c (see FIG. 8). It is assumed that there is no particular branch in the direction from the input signal to the bit memory in the circuit extracted in the processing of step S106.

[0061] In this way, when a predetermined alarm signal is output (S103), the maintenance system 2 identifies an input signal identified by tracing back from the bit memory whose value has changed to the input side as an input signal that may have contributed to the output of this alarm signal (S106). Here, "may have contributed to the output of the alarm signal" means that there is a possibility that a change in the value of the input signal was the trigger for the output of the alarm signal (i.e., the cause of the output).

[0062] The "input signal identification process" in which the maintenance system 2 identifies input signals that may contribute to the output of an alarm signal from among the input signals associated with the alarm signal includes the process of step S106.

[0063] 7, the plant control and monitoring system 100 causes the monitor 22 (display device) to display (display process) a simplified control logic diagram from the input signal (i.e., the input signal that can contribute to the output of the alarm signal) to the alarm signal using the monitor program 21b of the maintenance system 2. Specifically, the maintenance system 2 reflects the data in the analysis data storage unit 21d in the circuit including the bit memory extracted in step S106, and then generates the simplified control logic diagram.

[0064] FIG. 8 is an example of a screen display of the simplified control logic diagram D1c. The simplified control logic diagram D1c shown in Fig. 8 is a simplification of the control logic diagram D1a in Fig. 3. Also, assume that the value of the bit memory 53 changes from 0 to 1 immediately before the alarm signal β is output. In such a case, the maintenance system 2 (see Fig. 1) traces back from the bit memory 53 to the input side to identify input signals D and E that may have contributed to the output of the alarm signal β. Then, a simplified control logic diagram D1c from the input signals D and E to the alarm signal β is generated.

[0065] In the example of FIG. 8, the value of input signal D is 35 and the value of input signal E is 1 immediately before the alarm signal is output. The values ​​of these input signals D and E are read from the analysis data storage unit 21d (see FIG. 2) when the alarm signal is output, and are displayed in the simplified control logic diagram D1c in association with the input signals D and E. For example, even if the input signal D is an analog signal whose value continuously changes over time, the input value at the moment the alarm signal β is output is displayed in association with the input signal D. This allows the operator to easily grasp, for example, the value of input signal D at the moment the alarm signal β is output. Because the values ​​of input signals D and E shown in FIG. 8 exceed predetermined thresholds (see also FIG. 6), the values ​​of the logic macro 43a and AND gate 43b included in the arithmetic circuit 43 are 1, and the value of the OR gate 47 is also 1.

[0066] It is also possible to provide multiple sheets that partially display the original control logic diagram D1a (see FIG. 3) before simplification. The maintenance system 2 (see FIG. 1) displays the sheet number of a specific sheet ("Sheet No." in FIG. 8) in the simplified control logic diagram D1c in a portion corresponding to that sheet. This allows the operator to understand at a glance which range of circuits belongs to which sheet. When a specific sheet number is selected via an input device (not shown), the maintenance system 2 displays the screen of the sheet corresponding to that sheet number on the monitor 22 (see FIG. 1). This improves convenience for the operator.

[0067] Furthermore, when the simplified control logic diagram D1c spans multiple sheets, terminals (not shown) indicating the correspondence between adjacent sheets may be omitted from the simplified control logic diagram D1c, thereby further simplifying the simplified control logic diagram D1c.

[0068] Furthermore, when the maintenance system 2 displays the simplified control logic diagram D1c, if the input value of an operator and the output value of this operator are the same, the illustration of this operator is omitted. For example, since the OR gate 47 shown in FIG. 8 has both input and output values ​​of 1, this OR gate 47 may be omitted from the simplified control logic diagram D1c. This reduces the number of operators included in the simplified control logic diagram D1c, thereby reducing the burden on the operator when tracing the circuit. Note that when the operator performs a predetermined input operation, the aforementioned operator (the OR gate 47 in the example of FIG. 8) may be displayed again in the simplified control logic diagram D1c.

[0069] <Effects> According to this embodiment, input signals that may contribute to the output of an alarm signal are extracted based on changes in the bit memories 51 to 55 (see FIG. 3), and a simplified control logic diagram from the input signals to the alarm signal (i.e., a simplified control logic diagram) is displayed. By displaying the simplified control logic diagram in this way, the operator can easily and quickly identify the situation that led to the output of the alarm signal. Furthermore, because the simplified control logic diagram is displayed, even if the operator does not have particularly high level judgment or many years of experience, the situation of the plant P1 and the cause of the alarm signal can be quickly identified.

[0070] Furthermore, when an alarm signal is output, input signals associated with the alarm signal whose values ​​are recorded in the input value storage unit 21c (i.e., whose input values ​​are on the abnormal side of the predetermined threshold) are stored in the analysis data storage unit 21d. The values ​​of the input signals stored in the analysis data storage unit 21d are displayed in association with the input signals in the simplified control logic diagram, and are also displayed in chronological order as tables and graphs. This allows the operator to quickly understand how the input signals behave when an alarm signal is output.

[0071] <<Variations>> The plant control and monitoring system 100 and the plant control and monitoring method according to the present disclosure have been described above in the embodiments, but the present disclosure is not limited to these descriptions and various modifications can be made. For example, in the embodiments, a case has been described in which a predetermined control logic diagram is displayed on the monitor 22 (see FIG. 1) of the maintenance system 2, but this is not limiting. That is, a predetermined control logic diagram may be displayed on the monitor 32 (see FIG. 1) of the operation monitoring system 3.

[0072] In the embodiment, when a predetermined alarm signal is output, a portion including a bit memory whose value changes from 0 to 1 is extracted and displayed as a simplified control logic diagram. However, this is not limited to this. For example, a portion including all of the input signals corresponding to the alarm signal may be displayed as a simplified control logic diagram. Specifically, in the original control logic diagram before simplification, input signals identified by tracing back from the predetermined alarm signal to the input side are associated with the alarm signal. Then, when a predetermined alarm signal is output, the maintenance system 2 identifies the input signals associated with the alarm signal as input signals that may contribute to the output of the alarm signal. This processing is also included in the phrase "when a predetermined alarm signal is output, identifying input signals that may contribute to the output of the alarm signal from among the input signals associated with the alarm signal." For example, when the alarm signal α in FIG. 3 is output, a portion including input signals A to D associated with the alarm signal α may be displayed as a simplified control logic diagram. This processing also allows the operator to easily identify input signals that may contribute to the alarm signal, thereby improving convenience.

[0073] Of the input signals included in the circuit extracted in step S106, those whose values ​​are not stored in the analysis data storage unit 21d (those whose input values ​​do not exceed the threshold) may be omitted from the simplified control logic diagram. For example, when a predetermined alarm signal α (see FIG. 3) is output, the maintenance system 2 identifies, among the input signals A to D associated with this alarm signal α, those whose input values ​​were within a range on the abnormal side of the predetermined threshold when this alarm signal α was output, as input signals that may have contributed to the output of this alarm signal α. In this case, the maintenance system 2 displays the circuit from the extracted input signals to the alarm signal α as a simplified control logic diagram. Even with this processing, the operator can easily identify the input signals that may have contributed to the alarm signal α.

[0074] Furthermore, for example, when a predetermined alarm signal α (see FIG. 3) is output, the maintenance system 2 may identify, as input signals that may contribute to the output of the alarm signal α, input signals that are identified by tracing back from the bit memory where the value has changed to the input side and whose input value was within a range on the abnormal side of the predetermined threshold when the alarm signal α was output. This can further simplify the control logic diagram, thereby reducing the burden on the operator when identifying the input signal that is the cause of the alarm signal being output.

[0075] Furthermore, when multiple alarm signals are output sequentially, the maintenance system 2 may extract a predetermined number of alarm signals in order of earliest output timing. The maintenance system 2 generates a simplified control logic diagram for each of these alarm signals and displays a predetermined number of simplified control logic diagrams in association with the output sequence of the alarm signals. For example, if an abnormality occurs in the plant P1 and a predetermined input signal exhibits an abnormal value, other input signals may also exhibit abnormal values ​​as a secondary consequence. Even in such a case, the maintenance system 2 generates a simplified control logic diagram in association with the output sequence of the alarm signals, allowing the operator to easily identify which input signal caused the alarm signal to occur. Note that the input signal corresponding to the alarm signal with the earliest output timing is likely to be the cause of the output of the alarm signal (multiple alarm signals including the earliest output timing).

[0076] Furthermore, in the embodiment, the case where the cause of outputting the alarm signal is identified by the operator has been described, but the processing results of AI (Artificial Intelligence) may also be used in combination. In addition, in the embodiment, a case where an abnormality in a device of the plant P1 is detected has been described, but the present invention is not limited to this. For example, when a ladder circuit based on sequence control is used, the embodiment can also be applied to the control of devices other than plants.

[0077] Furthermore, the processing performed by the plant control and monitoring system (the plant control and monitoring method) may be executed as a predetermined program on a computer. The program may be provided via a communication line, or may be written to a recording medium such as a CD-ROM and distributed.

[0078] Furthermore, the present disclosure is not limited to the embodiments and includes various modifications. For example, the embodiments have been described in detail to clearly explain the present disclosure, and the present disclosure is not necessarily limited to those including all of the described configurations. Furthermore, it is possible to add, delete, or replace part of the configuration of the embodiments with other configurations.

[0079] Furthermore, the above-mentioned configurations, functions, processing units, processing means, etc. may be partly or entirely implemented in hardware, for example, by designing them as integrated circuits. Furthermore, the above-mentioned configurations, functions, etc. may be implemented in software, with a processor interpreting and executing a program that implements each function. Information such as the programs, tables, and files that implement each function can be stored in a memory, a recording device such as a hard disk or SSD (Solid State Drive), or a recording medium such as an IC card, SD card, or DVD.

[0080] In addition, the control lines and information lines shown are those that are considered necessary for the explanation, and do not necessarily show all the control lines and information lines in the product. In reality, it can be assumed that almost all components are interconnected. [Explanation of symbols]

[0081] 1. Control device 2 Maintenance System 3 Operation monitoring system 4 Control Network 11 Controller 12 PI / O device 21 System Device 21a Backup Objects 21b Monitor program 21c Input value storage section 21d Analysis data storage section 22 Monitor (display device) 22a Monitor screen 41, 42, 43 Arithmetic circuit (operator) 44 AND gate (operator) 45, 46, 47 OR gate (operator) 51, 52, 53, 54, 55 bit memory 100 Plant Control and Monitoring System D1, D1a, D1b control logic diagram D1c Simplified control logic diagram P1 Plant S103 Step (Warning signal output processing) Step S106 (input signal identification processing) S107 Step (display processing)

Claims

1. a control device having a controller for controlling equipment of the plant; a maintenance system connected to the control device via a control network, When the maintenance system outputs a predetermined alarm signal based on the processing result of the controller, it identifies input signals that may contribute to the output of the alarm signal from among the input signals associated with the alarm signal, and displays a simplified control logic diagram, which is a simplified control logic diagram from the input signals to the alarm signal, on a display device.

2. In the original control logic diagram before simplification, bit memory is provided on the predetermined wiring through which digital signals are transmitted, the bit memory is provided at a location where a predetermined alarm signal is output when the value of the digital signal changes; When a predetermined alarm signal is output, the maintenance system identifies an input signal that can contribute to the output of the alarm signal by tracing back from the bit memory whose value has changed to the input side.

2. The plant control and monitoring system according to claim 1, wherein:

3. When a predetermined alarm signal is output, the maintenance system identifies, among the input signals associated with the alarm signal, those whose input values ​​were within a range on the abnormal side of a predetermined threshold when the alarm signal was output, as input signals that may contribute to the output of the alarm signal.

2. The plant control and monitoring system according to claim 1, wherein:

4. In the original control logic diagram before simplification, bit memory is provided on the predetermined wiring through which digital signals are transmitted, the bit memory is provided at a location where a predetermined alarm signal is output when the value of the digital signal changes; When a predetermined alarm signal is output, the maintenance system identifies an input signal that can contribute to the output of the alarm signal, the input signal being identified by tracing back from the bit memory whose value has changed to the input side, and whose input value was within a range on the abnormal side of a predetermined threshold when the alarm signal was output.

2. The plant control and monitoring system according to claim 1, wherein:

5. In the original control logic diagram before simplification, an input signal identified by tracing back from a predetermined alarm signal to the input side is associated with the alarm signal, When a predetermined alarm signal is output, the maintenance system identifies an input signal associated with the alarm signal as an input signal that may contribute to the output of the alarm signal.

2. The plant control and monitoring system according to claim 1, wherein:

6. There are multiple sheets that partially display the original control logic diagram before it is simplified. The maintenance system displays the sheet number of a predetermined sheet in a portion of the simplified control logic diagram corresponding to the sheet, and when the predetermined sheet number is selected by an operation via an input device, displays a screen of the sheet corresponding to the sheet number.

2. The plant control and monitoring system according to claim 1, wherein:

7. The original control logic diagram before simplification contains the given operators: When the maintenance system displays the simplified control logic diagram, if the input value of the operator and the output value of the operator are the same, the maintenance system omits the illustration of the operator.

2. The plant control and monitoring system according to claim 1, wherein:

8. When a plurality of alarm signals are output in sequence, the maintenance system extracts a predetermined number of alarm signals in order from the earliest output timing, generates the simplified control logic diagram for each of the alarm signals, and displays the predetermined number of simplified control logic diagrams in association with the output sequence of the alarm signals.

2. The plant control and monitoring system according to claim 1, wherein:

9. an alarm signal output process in which a maintenance system connected via a control network to a control device having a controller that controls equipment in a plant outputs a predetermined alarm signal based on a processing result of the controller; an input signal identification process in which the maintenance system identifies input signals that may contribute to output of the alarm signal from among the input signals associated with the alarm signal; a display process in which the maintenance system displays on a display device a simplified control logic diagram that is a simplified control logic diagram from the input signal to the alarm signal.

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