Training simulator, method for constructing training simulator, and training method using training simulator

Abstract

To provide a training simulator capable of easily and inexpensively improving the skill level of an operator who operates large-scale equipment.SOLUTION: The training simulator includes a first controller that executes a process of operating a simulated structure of a large-scale facility, a second controller that executes a process of outputting an operation instruction to the simulated structure and a process of acquiring a state of the simulated structure based on a generated simulated physical quantity, and a storage unit. Each control unit is constituted by at least one PLC. The storage unit stores a program for executing processing in the first control unit. The program is written in the FBD language and the script language. One FB among the plurality of fBS described in the FBD language is configured to be common to the same type of simulated structures among the plurality of simulated structures. The script language is a function that defines a physical model obtained by modeling the operation of the same type of simulated structural object constituting one FB.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present invention relates to a training simulator, a method for constructing a training simulator, and a training method using a training simulator. [Background technology]

[0002] Patent Document 1 discloses a work instruction system that enables even an inexperienced worker to perform multiple elemental tasks appropriately and quickly. The system includes a photographing device, a completion determination unit, a task identification unit, and a display device. The photographing device captures images of a worker performing multiple elemental tasks on an object. The completion determination unit determines the completion of each elemental task based on the captured images. The task identification unit identifies the next elemental task that the worker should perform from among the multiple elemental tasks based on the determination by the completion determination unit. The display device displays the elemental task that the worker should perform next. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent Publication No. 2021-082204 Summary of the Invention [Problem to be solved by the invention]

[0004] The present invention aims to provide a training simulator that can easily and at low cost improve the proficiency of operators who operate large-scale equipment, a method for constructing a training simulator, and a training method using the training simulator. [Means for solving the problem]

[0005] An example of a training simulator is a training simulator for training the operation of large-scale facilities. This example training simulator includes: a first control unit configured to execute a process of operating multiple simulated structures constituting a simulated facility that simulates the large-scale facility; a second control unit configured to execute a process of outputting an operation instruction to at least one of the multiple simulated structures, a process of receiving simulated physical quantities generated as the first control unit simulates the operation of the at least one simulated structure based on the operation instruction, and a process of acquiring the state of the at least one simulated structure based on the received simulated physical quantities; and a storage unit. The first control unit and the second control unit are configured with at least one PLC. The storage unit is configured to store a program for executing the process in the first control unit. The program is written in a function block diagram language and a script language. One of the multiple function blocks written in the function block diagram language is configured to be common to multiple simulated structures of the same type among the multiple simulated structures. The script language is a function that defines a physical model that models the operation of the same type of simulated structure constituting one function block. [Effects of the Invention]

[0006] The training simulator, the method for constructing the training simulator, and the training method using the training simulator according to the present invention make it possible to improve the proficiency of operators who operate large-scale equipment simply and at low cost. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is a schematic diagram showing an example of a large-scale facility. [Figure 2] FIG. 2 is a schematic diagram showing details of the gas supply unit provided in the large-scale facility of FIG. [Figure 3] FIG. 3 is a schematic diagram showing an example of a steam power generation system provided in the processing facility main body. [Figure 4]FIG. 4 is a schematic diagram showing an example of a cooling water supply system provided in the treatment facility main body. [Figure 5] FIG. 5 is a schematic diagram illustrating an example focusing on the hardware configuration of a controller provided in a large-scale facility. [Figure 6] FIG. 6 is a schematic diagram showing an example of a training room in which a training simulator is arranged. [Figure 7] FIG. 7 is a schematic diagram illustrating the hardware configuration of the training simulator. [Figure 8] FIG. 8 is a diagram showing an example of an FB part that describes the water level in a simulated water tank. [Figure 9] FIG. 9 is a schematic diagram showing an example of a configuration in which two simulation tanks (front tank and rear tank) are connected by piping. [Figure 10] FIG. 10 is a diagram showing an example of a script language that describes the arithmetic processing executed in the FB illustrated in FIG. [Figure 11] FIG. 11 is a diagram showing an example of a startup operation scenario (first half) in a simulated reactor. [Figure 12] FIG. 12 is a diagram showing an example of a startup operation scenario (second half) in a simulated reactor. [Figure 13] FIG. 13 is a diagram showing an example of a ladder language for describing a startup operation scenario in a simulated reactor. [Figure 14] FIG. 14 is a diagram showing an example of a power outage scenario (first half). [Figure 15] FIG. 15 is a diagram showing an example of a power outage scenario (second half). DETAILED DESCRIPTION OF THE INVENTION

[0008] In the following description, the same elements or elements having the same functions will be designated by the same reference numerals, and duplicated descriptions will be omitted. Note that in this specification, when referring to the top, bottom, right, and left of a figure, the directions of the reference numerals in the figure will be used as the reference.

[0009] [Overall configuration of large-scale facilities] First, an example of the overall configuration of a large-scale facility 1 will be described with reference to Figures 1 and 2. The large-scale facility 1 may be, for example, a waste treatment facility that treats waste such as garbage. As illustrated in Figure 1, the large-scale facility 1 includes a treatment facility main body 2, a display device 3, and a controller 100 (second control unit). The treatment facility main body 2 includes, for example, a melting furnace 10, a combustion chamber 12, a boiler 13, a coal economizer 14, a cooling tower 15, a dust collector 16, an induced draft fan 17, a chimney 18, and a gas supply unit 20.

[0010] The melting furnace 10 processes waste in a high-temperature reducing atmosphere to produce recyclable molten slag. The melting furnace 10 includes an internal grate 10a, on which waste material fed from the top of the furnace by a crane 19 is dried and pyrolyzed. Combustible gases produced by pyrolysis are discharged downstream toward the combustion chamber 12.

[0011] The melting furnace 10 has a melting section 11 that melts the pyrolysis residue (ash, etc.) of the waste that has been pyrolyzed on the grate 10a together with coke. The molten slag produced by melting the pyrolysis residue is discharged to the outside of the furnace from a tapping port (not shown) provided in the hearth of the melting section 11.

[0012] The combustion chamber 12 has the function of completely combusting the combustible gas discharged from the melting furnace 10. This decomposes dioxins contained in the combustible gas.

[0013] The boiler 13 and the economizer 14 have a function of recovering thermal energy of the post-reaction gas discharged from the combustion chamber 12. The boiler 13 and the economizer 14 are provided with a steam power generation system 30. The boiler 13 is configured to heat boiler feedwater by exchanging heat between the exhaust gas discharged from the combustion chamber 12 and the feedwater flowing through a heat transfer tube. The heat transfer tube may include, for example, pipes D9 and D10 extending from the economizer 14 to a steam tank (described later). The economizer 14 is configured to preheat the feedwater flowing through the heat transfer tube by utilizing the sensible heat of the combustion gas in the boiler 13, and has a function of increasing heat recovery efficiency. The heat transfer tube may include, for example, pipes D6 and D9 extending from a deaerator 35 (described later) to the boiler 13.

[0014] The temperature reducing tower 15 is configured to cool the temperature of the exhaust gas from the economizer 14 to a predetermined temperature. The dust collector 16 has a function of collecting powder and granular matter accompanying the exhaust gas discharged from the temperature reducing tower 15.

[0015] The induced draft fan 17 is configured to send the exhaust gas from which dust has been removed in the dust collector 16 toward a chimney 18 and to release the exhaust gas through the chimney 18 to the outside.

[0016] As shown in FIG. 2, the gas supply unit 20 includes a plurality of gas supply units 21 to 23.

[0017] The gas supply unit 21 includes a gas source 21a, valves 21b to 21d, and a blower 21e. The gas source 21a stores, for example, oxygen gas and is connected to the blower 21e via a pipe 21f. The valve 21b is provided in the pipe 21f and operates based on a control signal from the controller 100 to open and close the pipe 21f before and after the valve 21b.

[0018] Blower 21e is connected to melting portion 11 via pipe 21g and is configured to operate based on a control signal from controller 100. Valve 22c is provided in pipe 21g and is configured to operate based on a control signal from controller 100 to open and close pipe 21g before and after valve 21c. When valves 21b and 21c are open, blower 21e operates, and oxygen gas from gas source 21a is supplied into melting portion 11 through pipe 21g. This allows the oxygen gas to be used for melting in melting furnace 10.

[0019] Valve 21d is provided in pipe 21h and is configured to operate based on a control signal from controller 100 to open and close pipe 21h before and after valve 21d. Pipe 21h branches off from pipe 21g between blower 21e and valve 21c and is open to the atmosphere. Controller 100 may automatically adjust the opening of valve 21d so that the pressure of oxygen gas supplied to melting portion 11 becomes a predetermined set pressure. Note that the set pressure and the rotation speed of blower 21e may be set by an operator OP (e.g., trainee TR), which will be described later.

[0020] Gas supply unit 22 includes air source 22a, blower 22b, and valves 22c to 22f. Air source 22a stores air and is connected to combustion chamber 12 via pipes 22g to 22j, and is also connected to melting furnace 10 via pipe 22k. Gas supply unit 22 may not include air source 22a, and may instead be configured to take in outside air using blower 22b.

[0021] Blower 22b is provided in pipe 22g and operates based on a control signal from controller 100 to send air from air source 22a downstream. Pipes 22h to 22j branch off from pipe 22g and are connected to the upper, middle, and lower portions of combustion chamber 12, respectively. Pipe 22k branches off between blower 22b and pipes 22h to 22j and is connected to the lower portion of melting furnace 10 (below grate 10a).

[0022] Valve 22c is provided in pipe 22h and operates based on a control signal from the controller 100 to open and close pipe 22h on both sides of valve 22c. Valve 22d is provided in pipe 22i and operates based on a control signal from the controller 100 to open and close pipe 22i on both sides of valve 22d. Valve 22e is provided in pipe 22j and operates based on a control signal from the controller 100 to open and close pipe 22j on both sides of valve 22e. Valve 22f is provided in pipe 22k and operates based on a control signal from the controller 100 to open and close pipe 22k on both sides of valve 22f.

[0023] By opening valves 22c to 22e, air from air source 22a is supplied to the upper, middle, and lower portions of combustion chamber 12. The air supplied into combustion chamber 12 by gas supply unit 22 reacts with the flammable gas discharged from melting furnace 10, causing the flammable gas to combust within combustion chamber 12. The openings of valves 22c to 22e are appropriately controlled by controller 100, and the amount of air blown to the upper, middle, and lower portions of combustion chamber 12 is adjusted to provide an amount of air suitable for combustion within combustion chamber 12.

[0024] When the valve 22f is opened, air from the air source 22a is supplied to the bottom of the grate 10a. This air is used as drying air for the grate 10a to dry the waste on the grate 10a. The opening of the valve 22f is appropriately controlled by the controller 100, so that the amount of air blown to the grate 10a is adjusted to an amount suitable for drying the waste on the grate 10a.

[0025] The gas supply unit 23 includes an air compressor 23a, a tank 23b, a nitrogen generator 23c, a tank 23d, and valves 23e and 23f. The air compressor 23a is configured to compress, for example, an air source (not shown) or outside air to a predetermined pressure. The air compressor 23a is connected to a portion of the pipe 22k between the valve 22f and the lower part of the grate 10a via a pipe 23g. The air compressor 23a is connected to a portion of the pipe 21g between the valve 21c and the melting zone 11 via pipes 23g and 23h. The pipe 23h branches off from a portion of the pipe 23g between the tank 23d and the valve 23e.

[0026] Tank 23b is configured to temporarily store the compressed air generated by air compressor 23a. Nitrogen generator 23c is configured to absorb oxygen in the compressed air into an adsorbent (e.g., synthetic zeolite) using, for example, a PSA (Pressure Swing Adsorption) system, and extract nitrogen gas. Tank 23d is configured to temporarily store the nitrogen gas generated by nitrogen generator 23c.

[0027] Valve 23e is provided in pipe 23g downstream of the branch point of pipe 23h, and is configured to operate based on a control signal from controller 100 to open and close pipe 23g before and after valve 23e. Valve 23f is provided in pipe 23h, and is configured to operate based on a control signal from controller 100 to open and close pipe 23h before and after valve 23f.

[0028] When valve 23e is opened, nitrogen gas from tank 23d is supplied to the bottom of grate 10a. When valve 23f is opened, nitrogen gas from tank 23d is supplied to melting section 11. For example, in an emergency (power outage or emergency stop), controller 100 opens valves 23e and 23f to supply nitrogen gas to grate 10a and melting section 11, thereby stopping the melting of waste in melting furnace 10. This controls the emergency stop of melting furnace 10. Also, for example, when igniting the burner of melting furnace 10, controller 100 opens valve 23e to supply nitrogen gas to melting section 11, thereby reducing the oxygen concentration inside. This controls appropriate ignition of the burner.

[0029] Returning to FIG. 1 , a supply device 24 is connected to a flow path 15a connecting the temperature reducing tower 15 and the dust collector 16. The supply device 24 is configured to supply slaked lime and activated carbon to the flow path 15a and includes a blower 24a and supply sources 24b and 24c. The blower 24a is connected to the flow path 15a via a pipe 24d and is configured to operate based on a control signal from the controller 100 to send air downstream. The supply source 24b is configured to store one of the slaked lime and the activated carbon and discharge one of the slaked lime and the activated carbon to the pipe 24d. The supply source 24c is configured to store the other of the slaked lime and the activated carbon and discharge the other of the slaked lime and the activated carbon to the pipe 24d. The slaked lime is used to remove acid gases (e.g., HCl gas and SOx gas) accompanying the exhaust gas discharged from the temperature reducing tower 15. The activated carbon is used to remove harmful substances (for example, mercury) from the exhaust gas discharged from the cooling tower 15.

[0030] [Configuration of steam power generation system] As illustrated in FIG. 3, the steam power generation system 30 includes a steam turbine 31, a generator 32, a condenser 33, a water supply tank 34, a deaerator 35, a coal economizer 14, a boiler 13, a steam drum 36, a high-pressure steam reservoir 37, pumps P11, P12, P21 to P23, valves V1 to V3, a level sensor SE, and pipes D1 to D12.

[0031] The steam turbine 31 is connected to the generator 32 via a shaft 31a. The steam turbine 31 is configured to be rotated by steam generated in the boiler 13, and to rotate the generator 32 via the shaft 31a. This causes the generator 32 to generate electricity. The steam used to rotate the steam turbine 31 is supplied to the condenser 33 via a pipe D1.

[0032] The condenser 33 is configured to cool the steam discharged from the steam turbine 31 and condense it into water. The water condensed in the condenser 33 (condensate) is sent to a water supply tank .

[0033] The feedwater tank 34 is configured to store boiler feedwater to be supplied to the boiler 13. In addition to the condensed water from the condenser 33, the feedwater tank 34 may be configured to store water (make-up water) supplied from a demineralizer 43, which is another water source, via a pipe D3. A valve V1 may be disposed in the pipe D3. The valve V1 operates based on a control signal from the controller 100 and is configured to open and close the pipe D3 before and after the valve V1.

[0034] Water (reserved water) stored in the water supply tank 34 is supplied to the deaerator 35 via pipes D4 and D5. The upstream end of pipe D4 is connected to the water supply tank 34. The downstream end of pipe D4 is connected to the deaerator 35. Pipe D5 branches off from pipe D4 and rejoins pipe D4 on the downstream side.

[0035] A pump P11 is disposed in a portion of the pipe D4 between the branch point of the pipe D5 and the junction point of the pipe D5. A pump P12 is disposed in the pipe D5. The pumps P11 and P12 are each configured to operate based on a control signal from the controller 100 and to send the stored water in the water supply tank 34 to the deaerator 35. A valve V2 is disposed in a portion of the pipe D4 downstream of the junction point with the pipe D5. The valve V2 is configured to operate based on a control signal from the controller 100 and to open and close the pipe D4 before and after the valve V2.

[0036] The deaerator 35 is configured to remove gases (for example, oxygen, carbon dioxide, etc. dissolved in the stored water) contained in the stored water in the water supply tank 34. The deaerator 35 is configured to heat the stored water supplied from the water supply tank 34 with heating steam to turn it into saturated water, and to remove dissolved gases from the stored water.

[0037] The deaerator 35 is provided with a level sensor SE configured to measure the water level in the deaerator 35. Data on the water level measured by the level sensor SE is transmitted to the controller 100.

[0038] The water deaerated in the deaerator 35 (deaerated water) is supplied to the economizer 14 through pipes D6 to D8. The upstream end of pipe D6 is connected to the deaerator 35. The downstream end of pipe D6 is connected to the economizer 14. Pipe D7 branches off from pipe D6 and rejoins pipe D6 on the downstream side. Pipe D8 branches off from pipe D7 and rejoins pipe D7 on the downstream side.

[0039] A pump P21 is disposed in a portion of the pipe D6 between the branch point of the pipe D7 and the junction point of the pipe D7. A pump P22 is disposed in a portion of the pipe D7 between the branch point of the pipe D8 and the junction point of the pipe D8. A pump P23 is disposed in the pipe D8. Each of the pumps P21 to P23 operates based on a control signal from the controller 100, and is configured to send deaerated water in the deaerator 35 to the economizer 14. A valve V3 is disposed in a portion of the pipe D6 downstream of the junction point with the pipe D7. The valve V3 operates based on a control signal from the controller 100, and is configured to open and close the pipe D6 before and after the valve V3.

[0040] The deaerated water preheated in the economizer 14 is supplied to the boiler 13 through a pipe D9. The upstream end of the pipe D9 is connected to the economizer 14. The downstream end of the pipe D9 is connected to the boiler 13. The steam generated in the boiler 13 is supplied to the steam drum 36 through a pipe D10. The upstream end of the pipe D10 is connected to the boiler 13. The downstream end of the pipe D10 is connected to the steam drum 36.

[0041] The steam drum 36 is provided above the boiler 13 and is configured to separate a steam mixture of steam and deaerated water generated in the boiler 13 into steam and deaerated water. The deaerated water separated in the steam drum 36 is returned to the boiler 13 through a water pipe (not shown). The steam separated in the steam drum 36 is supplied to the high-pressure steam reservoir 37 through piping D11. The upstream end of piping D11 is connected to the steam drum 36. The downstream end of piping D11 is connected to the high-pressure steam reservoir 37.

[0042] The high-pressure steam reservoir 37 is configured to temporarily store the high-pressure steam generated in the boiler 13 and separated in the steam drum 36. A part or all of the high-pressure steam temporarily stored in the high-pressure steam reservoir 37 is supplied to the steam turbine 31 through a pipe D12. An upstream end of the pipe D12 is connected to the high-pressure steam reservoir 37. A downstream end of the pipe D12 is connected to the steam turbine 31.

[0043] [Cooling water supply system configuration] The treatment facility main body 2 further includes a cooling water supply system 40 configured to supply cooling water to various equipment included in the treatment facility main body 2. As illustrated in Fig. 4, the cooling water supply system 40 may include a plant water receiving tank 41, an elevated plant water tank 42, a water purifier 43, an equipment cooling water cooling tower 44, valves V4 and V5, and pumps P31, P32, P41 to P43.

[0044] The plant water receiving tank 41 is configured to temporarily store clean water via a pipe D21. A valve V4 is provided in the pipe D21. The valve V4 operates based on a control signal from the controller 100 and is configured to open and close the pipe D21 before and after the valve V4.

[0045] Water (reserved water) stored in the plant water receiving tank 41 is supplied to the elevated plant water tank 42 via pipes D22 and D23. The upstream end of pipe D22 is connected to the plant water receiving tank 41. The downstream end of pipe D22 is connected to the elevated plant water tank 42. Pipe D23 branches off from pipe D22 and rejoins pipe D22 on the downstream side.

[0046] The water stored in the plant water receiving tank 41 is supplied to the deionizer 43 via pipes D22 to D24. The upstream end of pipe D24 branches off from pipe D22 downstream of the junction with pipe D23. The downstream end of pipe D24 is connected to the deionizer 43.

[0047] A pump P31 is disposed in a portion of the pipe D22 between the branch point of the pipe D23 and the confluence point of the pipe D23. A pump P32 is disposed in the pipe D23. The pumps P31 and P32 are each configured to operate based on a control signal from the controller 100 and to send the water stored in the plant water receiving tank 41 to the plant water elevated tank 42 and the pure water system 43.

[0048] The elevated plant water tank 42 is installed at a higher position than the plant water receiving tank 41, and is configured to temporarily store water pumped by pumps P31 and P32 from the plant water receiving tank 41. The elevated plant water tank 42 is configured to supply the stored water downstream by gravity.

[0049] The water purifier 43 is configured to produce pure water from tap water. In the water purifier 43, the pure water may be produced using, for example, an RO membrane (reverse osmosis membrane), an ion exchange resin, or the like.

[0050] The water stored in the elevated plant water tank 42 is supplied to the equipment cooling water cooling tower 44 via a pipe D25. A valve V5 is provided in the pipe D25. The valve V5 operates based on a control signal from the controller 100 and is configured to open and close the pipe D25 before and after the valve V5.

[0051] The equipment cooling water cooling tower 44 is configured to cool the cooling water by, for example, heat exchange between air and the cooling water. The cooling water cooled in the equipment cooling water cooling tower 44 is supplied to the downstream equipment EQ1 to EQ3 via pipes D26 to D30. Note that, although Fig. 4 illustrates an example in which the cooling water supply system 40 supplies cooling water to three equipment EQ1 to EQ3, the cooling water supply system 40 may be configured to supply cooling water to at least one equipment.

[0052] The upstream end of pipe D26 is connected to the equipment cooling water cooling tower 44. The downstream end of pipe D26 is connected to equipment EQ1. Pipe D27 branches off from pipe D26 and merges with pipe D26 again on the downstream side. Pipe D28 branches off from pipe D27 and merges with pipe D27 again on the downstream side.

[0053] The upstream end of pipe D29 branches off from pipe D26 downstream of the junction with pipe D27. The downstream end of pipe D29 is connected to device EQ2. The upstream end of pipe D30 branches off from pipe D29. The downstream end of pipe D30 is connected to device EQ3.

[0054] A pump P41 is disposed in a portion of the pipe D26 between the branch point of the pipe D27 and the junction point of the pipe D27. A pump P42 is disposed in a portion of the pipe D27 between the branch point of the pipe D28 and the junction point of the pipe D28. A pump P43 is disposed in the pipe D28. The pumps P41 to P43 are each configured to operate based on a control signal from the controller 100 and to send cooling water in the equipment cooling water cooling tower 44 to the equipment EQ1 to EQ3.

[0055] The devices EQ1 to EQ3 may be various devices that require cooling with cooling water during operation, such as an air compressor, an oxygen generator, a slag / metal cooler, a kneader, and an emergency generator.

[0056] The cooling water used in equipment EQ1 is returned to the equipment cooling water cooling tower 44 via pipe D31. The upstream end of pipe D31 is connected to equipment EQ1. The downstream end of pipe D31 is connected to the equipment cooling water cooling tower 44. The cooling water used in equipment EQ2 is returned to the equipment cooling water cooling tower 44 via pipes D32 and D31. The upstream end of pipe D32 is connected to equipment EQ2. The downstream end of pipe D32 is connected to pipe D31. The cooling water used in equipment EQ3 is returned to the equipment cooling water cooling tower 44 via pipes D33 and D31. The upstream end of pipe D33 is connected to equipment EQ3. The downstream end of pipe D33 is connected to pipe D31.

[0057] [Display device] The display device 3 is connected to the controller 100 and is arranged, for example, in an operation room (not shown) for operating the processing equipment main body 2. The display device 3 is configured to display, for example, information processed by the controller 100 and information input from an input device 4 (for example, an operation switch, an operation lever, a mouse, a keyboard, etc.) connected to the controller 100.

[0058] [Controller Configuration] As illustrated in FIG. 5, the controller 100 is configured to process data received from the processing equipment main body 2 and control the operation of each part of the processing equipment main body 2.

[0059] The hardware of the controller 100 may be configured, for example, by at least one control computer. More specifically, the controller 100 may be configured, for example, by at least one programmable logic controller (PLC).

[0060] 5, the controller 100 includes, as a hardware configuration, a processor 101, a memory 102, an input port 103, and an output port 104. The controller 100 may be configured with at least one electric circuit element.

[0061] The processor 101 executes programs in cooperation with the memory 102 and inputs and outputs signals via the input port 103 and the output port 104, thereby constituting various functional modules. The functional modules are merely a division of the functions of the controller 100 into multiple modules for convenience's sake, and do not mean that the hardware constituting the controller 100 is divided into such modules. Each functional module is not limited to being realized by executing a program, but may also be realized by a dedicated electrical circuit (e.g., a logic circuit) or an integrated circuit (ASIC: Application Specific Integrated Circuit) that integrates such circuits. The processor 101 is configured to receive various measurement data measured by sensors or the like in the processing equipment main body 2, generate control signals for operating each part of the processing equipment main body 2 based on the measurement data, and output the control signals to each part of the processing equipment main body 2.

[0062] The memory 102 is configured to store programs, measurement data, control signals, etc. The input port 103 is configured to transmit measurement data from the processing equipment main body 2 to the processor 101. The output port 104 is configured to transmit control signals generated by the processor 101 to the processing equipment main body 2.

[0063] [Training simulator] Next, a training simulator 5 for training the operation of the processing facility main body 2 will be described with reference to Fig. 6 and Fig. 7. The training simulator 5 includes a controller 200 (first control unit), a controller 100A, a display device 3A, and an input device 4A. As illustrated in Fig. 6, the controllers 100A and 200 and the display device 3A are arranged in a training room R for carrying out training using the training simulator 5. An operator OP who operates the training simulator 5 can operate the controllers 100A and 200 in the training room R while visually checking the display device 3A.

[0064] The controller 200 is a device that reproduces, by software, a simulated facility that simulates the processing facility main body 2. The simulated facility is composed of various simulated elements that simulate the processing facility main body 2. In other words, the controller 200 is configured to execute a process that causes multiple simulated elements to operate on the software. In this document, the term "simulated element" is a concept that includes simulated structures and simulated physical quantities. The term "simulated structure" refers to a software simulation of various structures that physically constitute the processing facility main body 2. The simulated structure, in the form illustrated in Figures 1 to 3, includes, for example, a melting furnace 10 (grate 10a), a combustion chamber 12, a boiler 13, a coal economizer 14, a cooling tower 15, a dust collector 16, an induced draft fan 17, a gas supply unit 21 (gas source 21a, valves 21b to 21d), a gas supply unit 22 (air source 22a, blower 22b, valves 22c to 22e), a gas supply unit 23 (air compressor 23a, nitrogen generator 23c, valves 23e, 23f), a supply unit 24 (blower 24a, supply sources 24b, 24c), a steam power generation system 30 (condenser 33, feedwater tank 34, deaerator 35, steam drum 36, pumps P11, P12, P21 to P23, valves V1 to V3), and the like. The simulated physical quantities are the states of the simulated structure and the simulated fluid that change as a result of the simulated operation of the simulated structure, i.e., the physical quantities of the simulated structure and the simulated fluid. The simulated fluid is a gas, liquid, or solid (including powder) that flows through the simulated facility, such as air, oxygen, steam, water, or chemicals. In the configurations exemplified in Figures 1 to 3, the simulated physical quantities are, for example, pressure, temperature, valve opening, water level, gas concentration, air flow rate, steam flow rate, and inverter device rotation speed.

[0065] In the actual treatment facility main body 2, when one structure that physically constitutes the treatment facility main body 2 operates and a physical quantity of the structure fluctuates, another physical quantity of the structure or a physical quantity of another structure related to the structure may fluctuate. Similarly, in the simulated facility simulated by the controller 200, the simulated physical quantity that fluctuates in accordance with the simulated operation of the simulated structure is output to itself or another simulated structure. The controller 200 simulates the operation of the simulated structure based on the received simulated physical quantity, and further outputs the simulated physical quantity that fluctuates in accordance with the operation to itself or another simulated structure. The controller 200 simulates the operation of the treatment facility main body 2 in the simulated facility by repeatedly calculating the simulated operation of various simulated structures that constitute the simulated facility and the output of the simulated physical quantity.

[0066] The hardware of the controller 200 may be configured, for example, by at least one control computer. More specifically, the controller 200 may be configured, for example, by at least one programmable logic controller (PLC) (first PLC). The controllers 100A and 200 may be configured by different PLCs, or may be configured by the same physical PLC. In other words, the controllers 100A and 200 may be configured by at least one PLC.

[0067] 7, the controller 200 includes, as a hardware configuration, a processor 201, a memory 202 (storage unit), an input port 203, and an output port 204. The controller 200 may be configured with at least one electric circuit element.

[0068] The processor 201 executes programs in cooperation with the memory 202 and inputs and outputs signals via the input port 203 and the output port 204, thereby constituting various functional modules. The functional modules are merely a division of the functions of the controller 200 into multiple modules for convenience, and do not mean that the hardware constituting the controller 200 is divided into such modules. Each functional module is not limited to being realized by the execution of a program, but may also be realized by a dedicated electric circuit (e.g., a logic circuit) or an integrated circuit (ASIC: Application Specific Integrated Circuit) integrating such dedicated electric circuits. The processor 201 is configured to operate multiple simulated structures based on control signals (operation instructions) output from the controller 100A, generate simulated physical quantities indicating the states of the multiple simulated structures by simulating the operations of the multiple simulated structures, and output the simulated physical quantities to the controller 100A.

[0069] 7, the memory 202 is configured to store programs 210 and 220 and a processing procedure 230. These will be described in detail later.

[0070] The input port 203 is configured to transmit measurement data from the processing equipment main body 2 to the processor 201. The output port 204 is configured to transmit a control signal generated by the processor 201 to the processing equipment main body 2.

[0071] The controller 100A is a device equivalent to that included in the large-scale facility 1. The controller 100A for the training simulator 5 may be a separate controller having a configuration similar to that of the controller 100 included in the large-scale facility 1, or may be the same device as the controller 100 used in the existing large-scale facility 1. The controller 100A is configured to output a control signal (operation instruction) to at least one simulated structure among multiple simulated structures simulated in the controller 200. The controller 100A is configured to receive, from the controller 200, simulated physical quantities that are generated in the controller 200 as the controller 200 simulates the operation of the at least one simulated structure based on the control signal. The controller 100A is configured to acquire a state of the at least one simulated structure based on the received simulated physical quantities.

[0072] The display device 3A is connected to the controllers 100A and 200. As illustrated in FIG. 6, the display device 3A is disposed in a training room R in which training is carried out using the training simulator 5 by operating the controllers 100A and 200. The display device 3A is configured to display, for example, information processed by the controllers 100A and 200, information input from an input device 4A (e.g., an operation switch, an operation lever, a mouse, a keyboard, etc.) connected to the controller 100A, etc. The display device 3A is configured to display information regarding each simulated structure and its status. The display device 3A is configured to display the contents of the programs 210 and 220 and the processing procedure 230 for creating, editing, and executing these programs.

[0073] [Details of the program and processing procedures] The programs 210 and 220 are software for reproducing the controller 200 as a simulated facility and simulating the operation of the simulated facility. That is, the programs 210 and 220 are software for executing various processes in the controller 200.

[0074] The program 210 is written in a function block diagram (FBD) language 211 and a script language 212 .

[0075] The FBD language 211 is defined as one of the programming languages ​​for PLCs in the standard IEC61131-3 issued by the International Electrotechnical Commission (IEC). The FBD may include, for example, function blocks (FBs), connection lines, and variables as its main components.

[0076] Using a programming tool that uses the FBD language 211, a builder of the training simulator 5 (sometimes simply referred to as the "builder" in this document) can graphically describe a series of processes by placing FBs corresponding to predetermined processes on a computer and connecting the FBs to each other and connecting the FBs to variables along the flow of data and signals. That is, by modularizing the FBs and their inputs and outputs as a single FB component, the series of processes is simplified to resemble a single command. That is, by connecting FBs or variables to the input and output sides, respectively, the FB is configured to perform a predetermined calculation based on one or more input simulated physical quantities and output one or more simulated physical quantities, thereby functioning as a function. Note that multiple FBs may be configured as a single FB component.

[0077] The program 210 includes multiple FB components for operating multiple simulated structures on the software. That is, the program 210 includes multiple FBs written in the FBD language 211. One of the multiple FBs may be configured as a common FB for multiple simulated structures of the same type among multiple simulated structures. In other words, one FB may be created for each simulated structure of the same type that performs equivalent functions. For example, a certain FB may be written as a common FB for multiple simulated tanks that respectively simulate the multiple water tanks in the treatment facility main body 2. In this case, each simulated tank performs the equivalent function of receiving water from the upstream side and discharging water to the downstream side. Therefore, for example, by constructing an FB with simulated physical quantities such as water intake and discharge as input and with simulated physical quantities such as the water level in the simulated tank as output, it is possible to realize calculation processing of fluctuations in the water level in each simulated tank with a single FB.

[0078] The script language 212 is a function that defines a physical model that models the behavior of the above-mentioned similar simulated structure. The script language 212 may be, for example, a description of arithmetic processing to be executed in the FB. In the above-mentioned example of the simulated water tank, the script language 212 may be a function for executing arithmetic processing of fluctuations in the water level in the simulated water tank. The script language 212 may be, for example, an ST language. The ST language is a text-based programming language that can describe control such as conditional judgment and repetition using syntax. In addition, the ST language can describe calculation formulas and the like in a format similar to general mathematical formulas, allowing mathematical formulas and arithmetic formulas to be described concisely.

[0079] The program 220 (another program) may be written in a ladder language 221. The ladder language 221 is a language that uses symbols representing circuits such as contacts and coils to diagram a sequence circuit diagram. The ladder language 221 is defined as one of the programming languages ​​for PLCs in the standard IEC61131-3 issued by the International Electrotechnical Commission (IEC). With a programming tool that uses the ladder language 221, a developer can graphically describe a series of processes by placing symbols corresponding to predetermined processes on a computer and connecting the symbols according to the process flow.

[0080] The processing procedure 230 is a preset operation scenario (operation rule) for operating the simulated facility in accordance with certain conditions. The processing procedure 230 may include a plurality of operation scenarios that simulate various operations, such as start-up operations, normal operations, and unsteady operations (e.g., emergency stop operations, abnormal operations, etc.) in the processing facility main body 2. The processing procedure 230 may be described in the ladder language 221 of the program 220. When the processing procedure 230 described in the ladder language 221 is executed by the processor 201, at least one of the plurality of simulated structures operates based on the processing procedure 230. In other words, the simulated structure that operates based on the processing procedure 230 is not subject to operation based on the FBD language 211 and the script language 212. On the other hand, the simulated structure that does not operate based on the processing procedure 230 is subject to operation based on the FBD language 211 and the script language 212. The simulated physical quantities generated as the simulated structure operates based on the processing procedure 230 and the simulated physical quantities generated as the simulated structure operates based on the FBD language 211 and the script language 212 are used to calculate the operation of the simulated structure in the program 220, or are transmitted to the controller 100A via the output port 204 and the input port 103. For example, when the processing procedure 230 is a start-up operation scenario in which a start-up operation for starting up the simulated equipment is set in advance, the controller 200 can operate at least one simulated structure based on the start-up operation scenario, and can execute a process in the controller 200 to calculate the operation of the simulated structure based on the simulated physical quantities that change according to the start-up operation scenario, or a process to transmit the simulated physical quantities to the controller 100A.

[0081] The programs 210, 220 and the processing procedure 230 may be rewritably stored in the memory 202. That is, a description in at least one of the FBD language 211 and the script language 212 that construct the program 210 may be rewritably stored in the memory 202. A description in the ladder language 221 that constructs the program 220 may be rewritably stored in the memory 202. The processing procedure 230 may be rewritably stored in the memory 202.

[0082] [How to build a training simulator] Next, a method for constructing a training simulator 5 for training the operation of large-scale equipment 1 will be described.

[0083] First, the controllers 100A and 200 are constructed. The controller 100A has the same configuration as the above-described controller 100, and therefore a description thereof will be omitted. Note that the controller 100A may be newly constructed for the training simulator 5, or may be a controller 100 used in an existing large-scale facility 1 that is reused.

[0084] Meanwhile, the controller 200 is constructed as follows. First, the builder investigates the multiple structures that physically constitute the large-scale facility 1 and the interactions between the multiple structures when the large-scale facility 1 is in operation. Next, the builder collects structures of the same type that perform equivalent functions from the multiple structures. Next, the builder constructs a single shared FB component corresponding to the collected structures of the same type using the FBD language 211 and the script language 212. As a result, simulated structures are constructed on the controller 200 for each type of the collected structures of the same type. Meanwhile, the builder individually constructs FB components corresponding to other structures using the FBD language 211 and the script language 212. As a result, simulated structures are constructed on the controller 200 for each of the other structures. The builder combines these multiple simulated structures on the controller 200 to reproduce a simulated facility corresponding to the processing facility main body 2 on the controller 200. Thus, the memory 202 of the controller 200 stores a program 210 for executing a process for operating a plurality of simulated structures that constitute the simulated facility.

[0085] Furthermore, the builder builds a processing procedure 230 for training in the training simulator 5 using the ladder language 221, and stores it in the memory 202. The processing procedure 230 stored in the memory 202 is not particularly limited, but may be, for example, an operation scenario that occurs infrequently in the processing equipment main body 2, or an operation scenario that particularly requires training.

[0086] This completes the construction of the training simulator 5.

[0087] [Training method using a training simulator] Next, a training method for trainees TR (see FIG. 6; sometimes simply referred to as "trainees TR" in this document) of the large-scale facility 1 using the training simulator 5 will be described.

[0088] At the start of training, the training simulator 5 first displays a predetermined steady-state screen on the display device 3A. This steady-state screen displays simulated physical quantities along with simulated structures of a simulated facility such as the large-scale facility 1 illustrated in FIG. 1. Then, the program 210 is executed, causing the values ​​and states of the simulated physical quantities to change. The steady-state screen is similar to the screen monitored by an operator who operates and maintains an actual large-scale facility.

[0089] The trainee TR operates the training simulator 5 to select a predetermined operation scenario from the processing procedure 230. As a result, the simulated equipment starts operating in accordance with the selected operation scenario. That is, the program 220 is executed so that the simulated equipment operates in accordance with the conditions of the selected operation scenario.

[0090] As each simulated structure operates in accordance with the execution of the processing procedure 230 by the program 220, simulated physical quantities indicating the state of each simulated structure and the simulated fluid are generated. The program 210 displays each simulated structure and the generated simulated physical quantities on the display device 3A. For example, when water is received and discharged from a simulated water tank simulating the water tank of the large-scale facility 1 in accordance with a selected operation scenario, the resulting change in the water level in the simulated water tank is displayed on the display device 3A. For example, the trainee TR, while checking the display of the display device 3A together with the instructor CO (see FIG. 6) in the training room R, performs input operations on the simulated facility in the controller 200 via the controller 100A so that the simulated facility operates correctly. For this input operation, the input device 4A connected to the controller 100A is used. In this way, the trainee TR is trained using the training simulator 5 under the guidance of the instructor CO. Note that both the trainee TR and the instructor CO are also operators OP who operate the training simulator 5.

[0091] Furthermore, even on a steady screen where the processing procedure 230 (operation scenario) is not being executed, the trainee TR can operate an appropriate simulated structure (for example, by opening or closing a valve) via the input device 4A while viewing the steady screen, and can perform training by checking the state of a series of changes in simulated physical quantities corresponding to the operation (for example, in response to the valve opening or closing operation). Also, when a series of operational procedures is defined, such as "close a specific valve before operating a specific pump," the trainee TR can operate the input device 4A while viewing the steady screen to perform training for this series of operational procedures. The changes in the simulated physical quantities at this time are realized by the program 210.

[0092] [Example of FB parts] Next, specific examples of the FB components described below will be explained. An FB part 310 that describes the water level in a simulated water tank that simulates a water tank (e.g., a water supply tank 34, a deaerator 35, a coal economizer 14, a boiler 13, a steam drum 36, etc.) provided in the treatment facility main body 2.

[0093] FIG. 8 shows an example of an FB component 310 that describes the water level in a simulated water tank. The FB component 310 may include two FBs 311 and 312. The FB component 310 shown in FIG. 8 is an example of a configuration in which two simulated water tanks (a front tank and a rear tank) are connected by piping, as shown in FIG. 9, configured as a function block. A valve is disposed in the piping connected upstream of the front tank. In the configuration shown in FIG. 9, a plurality of pumps 1 to 3 and a plurality of valves 1 and 2 are disposed in the piping connecting the front tank and the rear tank. The plurality of pumps 1 to 3 are connected in parallel to the piping connecting the front tank and the rear tank, and the plurality of valves 1 and 2 are connected in series to the piping connecting the front tank and the rear tank.

[0094] Returning to FIG. 8 , FB 311 includes a plurality of input terminals to which simulated physical quantities are respectively input. The simulated physical quantities EN, before Vmax, after Vmax, before Lmax, after Lmax, before offset, after offset, previous post-tank level, previous post-tank level, pump operation_1, pump operation_2, pump operation_3, valve opening_1, valve opening_2, and reset are input to the respective input terminals. FB 311 also includes a plurality of output terminals to which the simulated physical quantities are respectively output. The simulated physical quantities EN0, post-tank level, and previous-tank level are output from the respective output terminals. Note that, in FIG. 8 , M999 and the like connected to the respective input terminals are examples of variable names that store the variable values ​​provided to the respective input terminals. These variable names are names of variables used in program 210 and can be determined arbitrarily by the program builder.

[0095] A bit signal is input to EN, and when ON, FB311 operates, and when OFF, FB311 does not operate. Note that an ON signal is constantly input to EN by program 220 while program 220 is running. Before Vmax, data on the volume of the front tank is provided as an initial value by the builder. After Vmax, data on the volume of the rear tank is provided as an initial value by the builder. Before Lmax, data on the height of the front tank is provided as an initial value by the builder. After Lmax, data on the height of the rear tank is provided as an initial value by the builder. Before offset, the unmeasurable height of the front tank is provided as an input. After offset, the unmeasurable height of the rear tank is provided as an input. Note that the "unmeasurable height" of the tank refers to the height that indicates the lower limit of the tank's water level that can be measured by a level gauge. The previous rear tank level is provided as an input with the previous rear tank water level calculated by FB part 310. The previous water level of the front tank calculated by the FB part 310 is given as input to the previous front tank level. The pump operation_1 is given as input regarding the operating status of pump 1 between the front tank and the rear tank. The pump operation_2 is given as input regarding the operating status of pump 2 between the front tank and the rear tank. The pump operation_3 is given as input regarding the operating status of pump 3 between the front tank and the rear tank. The valve opening_1 is given as input the opening of valve 1 between the front tank and the rear tank. The valve opening_2 is given as input the opening of valve 2 between the front tank and the rear tank. Note that pump operation_1, pump operation_2, pump operation_3, valve opening_1, and valve opening_2 are each given as initial values ​​by the builder based on the number of pumps and valves in the actual structure that the two simulated water tanks are to simulate, or are determined based on the operation of the operator OP.

[0096] EN0 outputs ON when FB311 is operating, and outputs OFF when FB311 is not operating. Rear tank level outputs the result of calculation of the water level of the rear tank using a script language (see FIG. 10) described later. Front tank level outputs the result of calculation of the water level of the front tank using a script language (see FIG. 10) described later. D100, which is connected to the output terminal that outputs the front tank level as a simulated physical quantity, is an example of a variable name that stores the variable value output from the output terminal. This variable name is the name of a variable used in program 210, and can be determined arbitrarily by the programmer.

[0097] FB312 includes an input terminal to which a simulated physical quantity is input. IN is input as the simulated physical quantity to the input terminal. The input terminal is connected to the output terminal of FB311, which outputs the rear tank level as the simulated physical quantity. Therefore, the calculation result of the rear tank level output from FB311 is provided as input to IN. FB312 processes the input rear tank level using the REAL_TO_INT function. The REAL_TO_INT function is a function that converts the input value (here, the rear tank level) from a real number to an integer. FB312 includes an output terminal to which a simulated physical quantity is output. The output terminal outputs the rear tank level converted to an integer as a simulated physical quantity. Note that D170 connected to the output terminal is an example of a variable name that stores the variable value output from the output terminal. This variable name is the name of a variable used in program 210 and can be determined arbitrarily by the implementer.

[0098] In FB311, the rear tank level and the front tank level are calculated according to the script language shown in Fig. 10. Here, each symbol used in the script language shown in Fig. 10 is defined as follows (see also Fig. 9): u_0: Amount of water supplied to the rear tank BOOL_TO_INT(argument): A function that returns 1 if the pump specified in the argument is ON, and 0 if it is OFF. INT_TO_REAL(argument): A function that converts the integer specified in the argument to a real number.

[0099] Here, with respect to the two simulated water tanks illustrated in FIG. 9, the front tank may correspond to the water supply tank 34 in FIG. 3, and the rear tank may correspond to the deaerator 35 in FIG. 3. In this case, two pumps P11 and P12 and one valve V2 are present between the water supply tank 34 and the deaerator 35, and therefore, of the pumps 1 to 3 and valves 1 and 2 between the two simulated water tanks in FIG. 9, two pumps 1 and 2 and one valve 1 are used. That is, in FB311 in FIG. 8 and the script language in FIG. 10, pump operation_3 is set to 0, and valve opening_2 is set to 1. Also, with respect to the two simulated water tanks illustrated in FIG. 9, the front tank may correspond to the deaerator 35 in FIG. 3, and the rear tank may correspond to the economizer 14 in FIG. 3. In this case, three pumps P21 to P23 and one valve V3 are present between the deaerator 35 and the economizer 14, and therefore, of the pumps 1 to 3 and valves 1 and 2 between the two simulated water tanks in FIG. 9, three pumps 1 to 3 and one valve 1 are used. That is, in the FB 311 in FIG. 8 and the script language in FIG. 10, valve opening_2 is set to 1. Similarly, with respect to the two simulated water tanks illustrated in FIG. 9, the front tank may correspond to the economizer 14 and the rear tank may correspond to the boiler 13, or the front tank may correspond to the boiler 13 and the rear tank may correspond to the steam tank 36. In this way, the FB component 310, in which the form of the two simulated water tanks illustrated in FIG. 9 is configured by function blocks, can generally simulate two structures that can store water and are located on the upstream and downstream sides.

[0100] [Example of processing procedure] Next, the following operational scenarios will be described as examples of the processing procedure 230. Start-up operation scenario for a simulated facility that simulates large-scale facility 1 - Power outage scenario in which a simulated facility simulating large-scale facility 1 experiences a power outage

[0101] (1) Figures 11 and 12 show an example of a startup operation scenario in a simulated facility. In Figures 11 and 12, the horizontal axis represents time, and the vertical axis represents the value of each element. Note that Figure 11 shows the first half of the startup operation scenario, and Figure 12 shows the second half of the startup operation scenario. In this startup scenario, simulated physical quantities, including the generated gas concentration, the carbonization grate gas temperature (corresponding to the ambient temperature near the grate 10a in Figures 1 and 2), the combustion chamber temperature (corresponding to the temperature of the combustion chamber 12 in Figures 1 and 2), the steam drum pressure (corresponding to the steam pressure in the steam drum 36 in Figure 3), the steam drum level (corresponding to the water level in the steam drum 36 in Figure 3), the oxygen concentration at the outlet of the boiler (corresponding to the boiler 13 in Figures 1 and 2), the inlet temperature of the bag filter (corresponding to the dust collector 16 in Figure 1), and the terminal monoxide concentration, NOx concentration, and HCl concentration in the exhaust gas discharged from the chimney (corresponding to the chimney 18 in Figure 1), are varied according to certain conditions illustrated in Figures 11 and 12. Note that in Figures 11 and 12, BF, CC, PB, FDF, C, and A mean the following, respectively. BF: Bag filter (device for removing soot from exhaust gas) CC: Combustion chamber PB: Button operated by the operator OP (for example, PB for ignition means that the operator OP pressed the ignition button) FDF: blower operation signal (for example, an operation signal for blower 21e that blows air into melting portion 11) C: Cascade control A: Auto (automatic control)

[0102] When the startup operation scenario begins, first, as illustrated in FIG. 11, the steam tank level changes from -400 mm to -200 mm. Next, from the point of "CC temperature increase start [PB]" shown in the upper part of FIG. 11, the combustion chamber temperature and BF inlet temperature each gradually increase from 25°C. After that, as the lower N2 valve opens (corresponding to the opening of valve 20b in FIG. 2), the O2 concentration in the generated gas decreases to 0% at a rate of -0.5% / sec. After that, the main steam temperature in the steam tank gradually increases from 0°C, and the steam tank pressure increases from 0 kPa. Furthermore, the main steam flow rate in the steam tank changes from 0 tons / hour to 1.5 tons / hour.

[0103] When the combustion chamber temperature reaches 500°C and the BF inlet temperature reaches 120°C, the trainee TR presses the ignition button, executing "Ignition [PB added]" shown in the upper part of Figure 11, and in response to the ignition of a burner in the simulated furnace (for example, a furnace bottom ignition burner installed below the melting part 11), the CO concentration rises to 17%, and with a delay after the start of the CO concentration rise, the CO2 concentration rises to 18%. During this time, the main steam temperature and pressure in the steam drum continue to rise.

[0104] As shown in Figure 12, the carbonization grate gas temperature then rises to 270°C, the combustion chamber temperature rises to 850°C, the main steam flow rate in the steam drum rises to 5.0 tons / hour, and the BF inlet temperature rises to 165°C. Meanwhile, the O2 concentration at the boiler outlet temporarily drops before rising slightly. Furthermore, the O2 concentration in the generated gas and the CO concentration in the exhaust gas temporarily rise before falling back to 0%. The NOx and HCl concentrations in the exhaust gas then rise to their respective predetermined values. During this time, the main steam temperature and steam drum pressure in the steam drum continue to rise.

[0105] After that, in response to the start of airflow to the grate in the simulated furnace, the temperature of the carbonization grate gas rises to 320°C, and the combustion chamber temperature and the main steam flow rate in the steam drum increase. 3 N / hour, the carbonization grate gas temperature rises to 850°C, the combustion chamber temperature rises to 1000°C, the main steam temperature in the steam drum rises to 400°C, the steam drum pressure rises to 4000kPa, and the main steam flow rate in the steam drum rises to 10 to 12 ton / hour. In addition, the O2 concentration in the generated gas temporarily rises before dropping back to 0%.

[0106] In the start-up operation scenario described above, the above-mentioned simulated physical quantities fluctuated according to certain conditions, but the operations of simulated physical quantities other than those mentioned above may be simulated by calculations in accordance with the FBD language 211 and the script language 212. For example, in the start-up operation scenario, the steam tank level fluctuated according to certain conditions shown in Figures 11 and 12, but the water levels of other simulated water tanks included in the simulated equipment (e.g., the feedwater tank 34, the deaerator 35, the economizer 14, the boiler 13, etc.) may also be fluctuated by calculations in accordance with the FBD language 211 and the script language 212.

[0107] The startup operation scenario described above may be written in ladder language 221 in program 220. FIG. 13 shows an example of the ladder language for writing the startup operation scenario. The ladder language shown in FIG. 13 is a so-called step ladder method, which realizes the operation of each process in a sequential manner. The time point indicated by "S1" in FIG. 13 corresponds to "CC temperature rise start [PB]" in FIG. 11. The time point indicated by "S2" in FIG. 13 corresponds to "ignition [PB added]" in FIG. 11. The time point indicated by "S3" in FIG. 13 corresponds to "FDF" in FIGS. 11 and 12. The time point indicated by "S4" in FIG. 13 corresponds to "secondary combustion air flow rate [C]" in FIG. 12.

[0108] The startup operation scenario described above may be written in a combination of the ladder language 221 and the script language 212. The script language 212 used here may be, for example, the ST language.

[0109] (2) Figures 14 and 15 show an example of a power outage scenario in which the simulated equipment experiences a power outage. In Figures 14 and 15, the horizontal axis represents time, and the vertical axis represents the value of each element. Note that Figure 14 shows the first half of the power outage scenario, and Figure 15 shows the second half of the power outage scenario. In the power outage scenario, simulated physical quantities, such as the equipment cooling water cooling tower level, the steam tank level (corresponding to the water level of the steam tank 36 in Figure 3), the operating state (operating or stopped) of the air compressor (corresponding to air compressor 23a in Figure 2), the pressure of the air compressor receiver tank (corresponding to tank 23b in Figure 2), the operating state (operating or stopped) of the N2PSA (corresponding to nitrogen generator 23c in Figure 2), and the open / closed state (open or closed) of the emergency N2 supply valve (corresponding to valves 23e and 23f in Figure 2), fluctuate according to certain conditions exemplified in Figures 14 and 15. In Figures 14 and 15, L1, SA, N2PSA, equipment cooling water supply P, boiler feedwater P, C, shutoff valve 1.2, A, steam tank level LLSA, air receiver tank LL, pressure LL, plant water supply P, and 52F1 respectively mean the following. L1: Contact signal when the tank level is low SA: An abbreviation for Safety Assessment, a signal to safely shut down the furnace when the furnace is in a dangerous state. N2PSA: Nitrogen generator Equipment cooling water supply P: Equipment cooling water supply pump (a pump for supplying cooling water, corresponding to P41 to P43 illustrated in FIG. 4) Boiler feedwater P: Boiler feedwater pump (a pump for supplying water to the boiler, corresponding to P21 to P23 shown in Figure 3) C: Cascade control A: Auto (automatic control) · LLSA: Emergency stop due to low steam level (Safety Assessment) Air receiver tank LL: The pressure in the air receiver tank is low. Pressure LL: Low pressure ·Plant water supply P: Plant water supply pump 52F1: A type of circuit breaker (when 52F1 is turned on, it means that the power company has automatically detected the restoration of power and turned on 52F1)

[0110] When the power outage scenario begins, as illustrated in Figure 14, the air compressor and N2PSA related to N2 are shut down, while the emergency N2 supply valve related to N2 is opened. The equipment cooling water cooling tower level decreases at a rate of -1.0 mm / sec, and the steam tank level and the pressure in the air compressor receiver tank decrease. After that, the equipment cooling water cooling tower level stops decreasing and remains at a constant level in response to the restart of the equipment cooling water cooling tower due to the operation of the emergency generator. During this time, the steam tank level continues to decrease. Note that the equipment cooling water cooling tower level in Figure 14 is bifurcated to indicate the continuous decrease in the water level of the equipment cooling water cooling tower if the trainee TR fails to operate the pump (plant water supply pump) that supplies water to the equipment cooling water cooling tower via the input device 4A while viewing the display device 3A after the emergency generator starts.

[0111] Thereafter, the steam tank level rises in response to the restart of the boiler feed pump, as exemplified in Figure 15. Note that the reason the steam tank level branches into two in Figure 15 is that the water level in the steam tank continues to fall when the trainee TR does not operate the pump that supplies water to the steam tank after the emergency generator starts operating, although he or she should have done so via the input device 4A while looking at the display device 3A.

[0112] After that, in response to the restoration of power (resumption of power supply after a power outage), the air compressor and N2-related N2PSA operations resume, and the emergency N2 supply valve for N2-related equipment is closed. This causes the pressure in the air compressor receiver tank to increase. During this time, the steam tank level continues to rise.

[0113] When the steam tank level returns to the original water level before the power outage, the makeup water valve is set to automatic, and the equipment cooling water cooling tower level rises. After that, the equipment cooling water cooling tower level stops rising and a constant water level is maintained, corresponding to the resumption of plant water supply operation.

[0114] In the power outage scenario described above, the above-mentioned simulated physical quantities fluctuated according to certain conditions. However, the behavior of simulated physical quantities other than those described above may be simulated by calculations in accordance with the FBD language 211 and the script language 212. For example, in the power outage scenario, the equipment cooling water cooling tower level and the steam tank level fluctuated according to certain conditions shown in FIGS. 14 and 15. However, the water levels of other simulated water tanks included in the simulated facility may fluctuate by calculations in accordance with the FBD language 211 and the script language 212. The trainee TR can visually recognize the fluctuations of each simulated physical quantity according to such a scenario on the display device 3A, and can also operate the input device 4A (e.g., press an operation button) at an appropriate timing while visually recognizing the fluctuations. During scenario execution, the display device 3A displays each simulated structure as exemplified in FIGS. 1 and 2, and simultaneously displays the constantly changing simulated physical quantities on the screen (on the same screen or on a different screen).

[0115] Although not shown in the figures, the power outage scenario described above may be written in ladder language 221 in program 220. The ladder language may be a so-called step ladder system. Although not shown in the figures, the power outage scenario described above may be written in combination with ladder language 221 and script language 212. The script language 212 used here may be, for example, ST language.

[0116] [Effect] Incidentally, in order to operate large-scale facilities such as plants safely and smoothly, operators (OPs) are required to correctly control the large-scale facilities for startup operations and non-steady operations (e.g., emergency stop operations, abnormal operations, etc.). However, there are usually few opportunities to start up large-scale facilities, and non-steady operations rarely occur. For this reason, there is a concern that it is difficult for operators (OPs) to gain experience in appropriately controlling large-scale facilities for such low-frequency operations, and that it is difficult for operators (OPs) to improve their proficiency in low-frequency operations.

[0117] In this case, it is possible to build a system that simulates low-frequency operations using computer equipment such as a personal computer. However, it is extremely difficult to reproduce the behavior of large-scale equipment one by one on a computer. Even if it were possible to reproduce it, the development of the computer system and software required would be extremely costly, making it unrealistic.

[0118] However, in the above example, the controllers 100A and 200 are configured using a PLC, and the controller 200 is capable of using both the FBD language 211 and the script language 212. Therefore, the training simulator 5 can be constructed without using a large-scale, expensive, advanced system such as a process control computer. Furthermore, in the above example, the FB can be configured as a common function block for multiple simulated structures of the same type. Therefore, the FB has a certain degree of versatility. Therefore, by preparing an FB for each simulated structure of the same type, a huge number of responses (e.g., temperature, pressure, flow rate, gas concentration, water level) in the treatment facility main body 2 can be simulated with a smaller number of FBs than when a program is created for each response. As a result, it is possible to easily and inexpensively improve the operator OP's proficiency with the treatment facility main body 2.

[0119] According to the above example, the memory 202 stores a program 220 for executing processing in the controller 200 in accordance with a preset processing procedure 230, and the program 220 can be written in a ladder logic language 221. In this case, by setting processing procedures in advance according to various operations such as start-up operations, normal operations, and non-steady operations (e.g., emergency stop operations, abnormal operations, etc.) of the large-scale equipment 1, training can be performed in accordance with the processing procedures. Therefore, training simulating a specific situation can be efficiently performed in the training simulator 5 by a simple operation such as selecting from a menu displayed on the display device 3A.

[0120] According to the above example, the processing procedure is a startup operation scenario in which startup operations for starting up the simulated equipment are set in advance, and the controller 200 can execute processing to operate at least one simulated structure based on the startup operation scenario and transmit simulated physical quantities that change according to the startup operation scenario to the controller 100A. In this case, training for the startup operation scenario that simulates the startup procedure of the processing equipment main body 2 can be efficiently executed in the training simulator 5.

[0121] According to the above example, the multiple simulated structures include multiple simulated water tanks (first simulated water tank, second simulated water tank), and the controller 200 can be configured to execute a process of changing the water level of the first simulated water tank in accordance with a processing procedure, and a process of changing the water level of the second simulated water tank through calculations in accordance with the FBD language 211 and the script language 212. In this case, the water level of the first simulated water tank changes based on preset content through execution of the processing procedure. On the other hand, the water level of the second simulated water tank, for which no water level change is preset, changes through calculations in accordance with the FBD language 211 and the script language 212. Therefore, it is not necessary to set processing procedures for all simulated structures. This makes it possible to simplify and simplify the setting of processing procedures.

[0122] According to the above example, the controllers 100A and 200 can be configured using separate PLCs. For example, if the PLC configuring the controller 100A performs various processes with the existing large-scale facility 1, the training simulator 5 can be constructed simply by adding a PLC configuring the controller 200 that operates a simulated facility that simulates the large-scale facility 1. That is, when constructing the training simulator 5, the PLC used in the existing large-scale facility 1 can be reused. Therefore, there is no need to significantly modify the program executed in the PLC of the existing large-scale facility 1, making it possible to construct the training simulator 5 more easily. Furthermore, according to the above example, since the PLC used in the existing large-scale facility 1 can be reused, a training simulator 5 that has an operational feel equivalent to that of the large-scale facility 1 can be constructed. Therefore, the operator OP can efficiently utilize the experience gained through training using the training simulator 5 in actual operations of the large-scale facility 1.

[0123] According to the above example, the memory 202 can be configured to store a program such that the descriptions in the FBD language 211 and the script language 212 can be rewritten. In this case, for example, even if an existing simulated structure in the simulated facility is changed or a new simulated structure is added, the operation of the added or changed simulated structure can be simulated in the controller 200 by rewriting the descriptions in the FBD language 211 and the script language 212. Therefore, even if an addition or change is made to the processing facility main body 2 that is the training target for the training simulator 5, it is possible to easily respond to the addition or change.

[0124] [Variations] The disclosure of this specification should be considered in all respects as illustrative and not restrictive. Various omissions, substitutions, modifications, etc. may be made to the above examples without departing from the scope and gist of the claims. For example, the large-scale facility 1 may be a waste treatment facility that incinerates waste or a nuclear power plant.

[0125] [Other examples]Example 1. An example of a training simulator is a training simulator for training the operation of large-scale facilities. This example of the training simulator includes: a first control unit configured to execute a process of operating multiple simulated structures constituting a simulated facility that simulates the large-scale facility; a second control unit configured to execute a process of outputting operation instructions to at least one of the multiple simulated structures, a process of receiving simulated physical quantities generated as the first control unit simulates the operation of the at least one simulated structure based on the operation instructions, and a process of acquiring the state of the at least one simulated structure based on the received simulated physical quantities; and a storage unit. The first control unit and the second control unit are configured with at least one PLC. The storage unit is configured to store a program for executing the process in the first control unit. The program is written in a function block diagram language and a script language. One of the multiple function blocks written in the function block diagram language is configured to be common to multiple simulated structures of the same type among the multiple simulated structures. The script language is a function that defines a physical model that models the operation of the same type of simulated structure constituting one function block. In this case, the first and second control units are configured using PLCs, and the first control unit is capable of using both function block diagram and scripting languages. This allows for the construction of a training simulator without using large-scale, expensive, advanced systems such as process control computers. Furthermore, in Example 1, a single function block is configured as a common component for multiple simulated structures of the same type. Therefore, the single function block has a certain degree of versatility. Therefore, by providing a function block for each simulated structure of the same type, it is possible to simulate a vast number of responses (e.g., temperature, pressure, flow rate, gas concentration, water level) in large-scale equipment using a smaller number of function blocks than would be possible if each response were individually programmed. This makes it possible to easily and inexpensively improve the operator's (OP) proficiency with large-scale equipment.

[0126] Example 2: In the training simulator of Example 1, the storage unit stores another program for executing processing in the first control unit according to a preset processing procedure, and the other program may be written in ladder programming language. In this case, by setting processing procedures in advance according to various operations such as startup operations, normal operations, and non-steady operations (e.g., emergency stop operations, abnormal operations, etc.) of large-scale equipment, training can be conducted according to the processing procedures. Therefore, training simulating a specific situation can be efficiently conducted in the training simulator by a simple operation such as selecting from a menu.

[0127] Example 3. In the training simulator of Example 2, the processing procedure may be a startup operation scenario in which startup operations for starting up the simulated facility are preset, and the first control unit may be configured to operate at least one simulated structure based on the startup operation scenario and to execute processing to transmit simulated physical quantities that change according to the startup operation scenario to the second control unit. In this case, training based on the startup operation scenario that simulates the startup procedures of large-scale facility can be efficiently executed in the training simulator.

[0128] Example 4: In the training simulator of Example 2 or Example 3, the multiple simulated structures may include a first simulated water tank and a second simulated water tank, and the first control unit may be configured to execute a process of changing the water level of the first simulated water tank in accordance with a processing procedure and a process of changing the water level of the second simulated water tank through calculations in accordance with a function block diagram language and a script language. In this case, the water level of the first simulated water tank changes based on preset content through execution of the processing procedure. On the other hand, the water level of the second simulated water tank, for which no water level change is preset, changes through calculations in accordance with the function block diagram language and the script language. Therefore, it is not necessary to set processing procedures for all simulated structures. This makes it possible to simplify and simplify the setting of processing procedures.

[0129] Example 5. In the training simulator of any of Examples 1 to 4, the first control unit may be configured with a first PLC among at least one PLC, and the second control unit may be configured with a second PLC among at least one PLC. For example, if the second PLC constituting the second control unit performs various processes with an existing large-scale facility, the training simulator can be constructed simply by adding a first PLC constituting the first control unit that operates a simulated facility that simulates the large-scale facility. That is, when constructing the training simulator, the second PLC used in the existing large-scale facility can be reused. Therefore, there is no need to significantly modify the program executed by the second PLC, making it possible to more easily construct the training simulator. Furthermore, according to Example 5, since the second PLC used in the existing large-scale facility can be reused, a training simulator with an operational feel equivalent to that of the large-scale facility can be constructed. Therefore, the operator OP can efficiently utilize the experience gained through training using the training simulator in actual operation of the large-scale facility.

[0130] Example 6: In the training simulator of any of Examples 1 to 5, the storage unit may be configured to store a program such that descriptions in the function block diagram language and the script language are rewritable. In this case, for example, even if an existing simulated structure in the simulated facility is changed or a new simulated structure is added, the operation of the added or changed simulated structure can be simulated in the first control unit by rewriting the descriptions in the function block diagram language and the script language. Therefore, even if an addition or change is made to a large-scale facility that is the subject of training using the training simulator, the addition or change can be easily accommodated.

[0131] Example 7. One example of a method for constructing a training simulator is a method for training the operation of a large-scale facility. This example of the construction method includes constructing a first control unit in at least one PLC included in the training simulator, the first control unit executing a process for operating multiple simulated structures that constitute a simulated facility that simulates the large-scale facility; constructing a second control unit in the at least one PLC, the second control unit executing a process for outputting an operation instruction to at least one of the multiple simulated structures, a process for receiving simulated physical quantities generated as the first control unit simulates the operation of the at least one simulated structure based on the operation instruction, and a process for acquiring the state of the at least one simulated structure based on the received simulated physical quantities; and storing a program for executing the process in the first control unit in a memory unit included in the training simulator. The program is written in a function block diagram language and a script language. One of the multiple function blocks written in the function block diagram language is configured to be common to multiple simulated structures of the same type among the multiple simulated structures. The script language is a function that defines a physical model that models the behavior of the same type of simulated structure that constitutes one function block. In this case, the same effects as those of the training simulator in Example 1 can be obtained.

[0132] Example 8 In the method of Example 7, the storage unit may be configured to store the program in a rewritable manner, in the function block diagram language and the script language. In this case, the same effects as those of the training simulator of Example 6 can be obtained.

[0133] Example 9. An example of a training method using a training simulator is a training method using any of the training simulators of Examples 1 to 6. This example of the training method includes: executing, via an input device, another program for executing processing in the first control unit according to a preset processing procedure; and displaying, on a display device, a state of at least one simulated structure based on simulated physical quantities generated by the at least one simulated structure operating according to the processing procedure through the execution of the other program in the first control unit. In this case, the same effects as those of the training simulator of Example 1 can be obtained. [Explanation of symbols]

[0134] 1...large-scale equipment, 3A...display device, 4A...input device, 5...training simulator, 100A...controller (second control unit, second PLC), 200...controller (first control unit, first PLC), 202...memory (storage unit), 210...program, 211...function block diagram (FBD) language, 212...script language, 220...program (another program), 221...ladder language, 230...processing procedure, CO...instructor, OP...operator, TR...trainee.

Claims

1. A training simulator for training the operation of large-scale equipment, a first control unit configured to execute a process for operating a plurality of simulated structures that constitute a simulated facility that simulates the large-scale facility; a second control unit configured to execute a process of outputting an operation instruction to at least one simulated structure among the plurality of simulated structures, a process of receiving a simulated physical quantity generated when the first control unit simulates the operation of the at least one simulated structure based on the operation instruction, and a process of acquiring a state of the at least one simulated structure based on the received simulated physical quantity; a storage unit, the first control unit and the second control unit are configured by at least one PLC, the storage unit is configured to store a program for executing processing in the first control unit, the program is written in a function block diagram language and a script language; One of the plurality of function blocks described in the function block diagram language is configured to be common to the same type of simulated structures among the plurality of simulated structures, A training simulator, wherein the script language is a function that defines a physical model that models the behavior of the same type of simulated structure that constitutes the one function block.

2. the storage unit stores another program for executing processing in the first control unit according to a preset processing procedure; 2. The training simulator of claim 1, wherein the separate program is written in ladder programming language.

3. the processing procedure is a startup operation scenario in which a startup operation for starting up the simulated equipment is set in advance, 3. The training simulator according to claim 2, wherein the first control unit is configured to execute a process of operating the at least one simulated structure based on the start-up operation scenario and transmitting simulated physical quantities that change according to the start-up operation scenario to the second control unit.

4. the plurality of simulated structures include a first simulated water tank and a second simulated water tank; The first control unit a process of changing the water level of the first simulation tank in accordance with the process procedure; 3. The training simulator according to claim 2, further comprising: a function block diagram language for executing a process for changing the water level of the second simulated water tank by calculation according to the function block diagram language and the script language;

5. the first control unit is configured by a first PLC of the at least one PLC, 2. The training simulator of claim 1, wherein the second control unit is configured by a second PLC of the at least one PLC.

6. The training simulator according to claim 1 , wherein the storage unit is configured to store the program in such a manner that descriptions in the function block diagram language and the script language are rewritable.

7. A method for constructing a training simulator for training the operation of large-scale equipment, comprising: constructing a first control unit in at least one PLC included in the training simulator for executing a process of operating a plurality of simulated structures that constitute a simulated facility that simulates the large-scale facility; constructing a second control unit for executing a process of outputting an operation instruction to at least one simulated structure among the plurality of simulated structures in the at least one PLC, a process of receiving a simulated physical quantity generated when the first control unit simulates the operation of the at least one simulated structure based on the operation instruction, and a process of acquiring a state of the at least one simulated structure based on the received simulated physical quantity; storing a program for executing processing in the first control unit in a storage unit included in the training simulator; the program is written in a function block diagram language and a script language; One of the plurality of function blocks described in the function block diagram language is configured to be common to the same type of simulated structures among the plurality of simulated structures, A construction method, wherein the script language is a function that defines a physical model that models the behavior of the simulated structure of the same type that constitutes the one function block.

8. The method according to claim 7 , wherein the storage unit is configured to store the program in such a manner that descriptions in the function block diagram language and the script language are rewritable.

9. A training method using the training simulator according to any one of claims 1 to 6, Executing, via an input device, another program for executing processing in the first control unit according to a preset processing procedure; and displaying on a display device a state of the at least one simulated structure based on the simulated physical quantity generated by the operation of the at least one simulated structure in accordance with the processing procedure by executing the other program in the first control unit.

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