Verification method and connection tool for replacing old sequencer with new sequencer

Abstract

To provide a verification method for replacing an old sequencer with a new sequencer, whereby stable, continuous operation of a plant and reliable verification of the new sequencer can be made compatible, and to provide a connection tool.SOLUTION: A verification method for replacing an old sequencer 21 with a new sequencer 31, according to the present disclosure, includes: a post-transfer operation confirmation step of connecting an apparatus terminal block 43 and a temporary adapter 55 and connecting a temporary terminal block 53 and an old sequencer input / output module 22 to control a plant by means of the old sequencer 21; an installation step of installing the new sequencer 31 on a sequencer board 30; a verification step of connecting the apparatus terminal block 43 and a new sequencer input / output module 32 to verify the new sequencer 31; and a stable control step of removing the apparatus terminal block 43 from the new sequencer input / output module 32 and connecting it with the temporary adapter 55 to control the plant by means of the old sequencer 21.SELECTED DRAWING: Figure 10

Description

[Technical field]

[0001] The present disclosure relates to a verification method and connection tool for replacing an old programmable controller that controls the operation of a plant with a new programmable controller. [Background technology]

[0002] In plants such as water purification plants, sewage treatment plants, and waste disposal equipment, a controller called a sequencer is used to control sequences (orders) in order to smoothly manage the operation of the entire plant.By using a sequencer, it is possible to control the plant according to predefined conditions based on the state of input devices such as switches, sensors, timers, and counters.

[0003] For example, Patent Document 1 discloses an operation authentication system for plant equipment, in which, when an operator approaches within a certain range of an operation panel C that operates the plant equipment, optical and radio wave transmission is performed between an authentication controller 1 arranged on the side of the operation panel and a tag T, the unique ID of the tag T is determined from an authentication database pre-entered on the controller 1 side to identify the location ID and tag ID, the operation authority of the operator is identified, etc., and based on this authentication result, a control sequencer 2 determines the operable range of the operation panel C and selects whether or not to grant the specific operator authority to operate the operation panel C. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2006-119860 A Summary of the Invention [Problem to be solved by the invention]

[0005] However, with the recent improvement of the programmable controller's functions and the increasing complexity of plants, the verification work of newly introduced programmable controllers has become more complicated and the verification time tends to increase. On the other hand, it is often not easy to increase the number of workers who can perform the verification work. Therefore, it is possible to perform the verification work in bulk during the daytime when workers can perform the verification work, but in order to complete the verification work during the daytime hours, there are cases where only important verification items have to be verified. Therefore, it is difficult to reliably verify whether the plant is operating stably with the new programmable controller, and there is room for improvement in this regard.

[0006] The present disclosure aims to solve these problems, and its purpose is to propose a verification method and connection tool for replacing an old sequence controller with a new sequence controller, which enables both stable and continuous operation of the plant and reliable verification of the new sequence controller. [Means for solving the problem]

[0007] The verification method of the present disclosure includes: A verification method for replacing an old sequence controller with a new sequence controller in a plant control system that operates a plant using a sequence controller, comprising: The plant control system includes: An old sequence controller that connects to the controlled device via the old sequence controller I / O module, A new PLC that connects to the controlled equipment via a new PLC I / O module, A temporary rack for accommodating the old sequencer; a sequencer board housing either the old sequencer or the new sequencer; A connection tool that connects the old PLC to the controlled device. Equipped with the connection tool includes a temporary terminal block that is detachably connected to the old sequence controller input / output module, a temporary adapter that detachably connects an equipment terminal block that is connected to a controlled equipment, and a connection cable that electrically connects the temporary terminal block and the temporary adapter to each other; the device terminal block is detachably connectable to any one of the old sequence controller input / output module, the temporary adapter, or the new sequence controller input / output module; The verification method includes: an initial operation confirmation step of connecting the device terminal block to the old sequencer input / output module and controlling the plant by the old sequencer in the sequencer board; a relocation step of moving and installing the old sequence controller installed on the sequence controller board on the temporary rack; a post-relocation operation confirmation step of connecting the device terminal block and the temporary adapter, and also connecting the temporary terminal block and the old sequence controller input / output module, and controlling the plant by the old sequence controller; a verification step of connecting the device terminal block and the new sequence controller input / output module to verify the new sequence controller; a stable control step of removing the device terminal block from the new PLC input / output module and connecting it to the temporary adapter to control the plant using the old PLC; The present invention is characterized by comprising: By adopting such a configuration, it is possible to provide a verification step for the new sequence controller described above and a stable control step using the old sequence controller, and by performing the relatively simple switching operation of replacing the equipment terminal block, it is possible to achieve both stable and continuous operation of the plant and reliable verification of the new sequence controller.

[0008] In the connection tool of the present disclosure having the above-mentioned configuration, it is preferable that the verification step and the stability control step are executed alternately for each of predefined time periods. By adopting such a configuration, the verification steps of the new sequence controller can be performed during times when workers are able to perform verification work on the new sequence controller, and the stable control steps using the old sequence controller can be performed during times when workers are unable to perform verification work on the new sequence controller, thereby enabling reliable verification work on the new sequence controller and stable, continuous operation of the plant to be performed with a limited number of workers.

[0009] The connection tool of the present disclosure is characterized in that it is a connection tool used in any one of the above-mentioned verification methods. By adopting such a configuration, the stable control step can be executed using the old sequence controller by connecting the old sequence controller to the equipment terminal block using a connection tool, so that it is possible to easily switch between the above-mentioned verification step of the new sequence controller and the stable control step using the old sequence controller, thereby achieving both stable and continuous operation of the plant and reliable verification of the new sequence controller.

[0010] In addition, the connection tool of the present disclosure includes: In a plant operated by an old or new PLC, a connection tool is provided for connecting an old PLC to a device terminal block connected to a controlled device, a temporary terminal block for connecting to an old sequence controller input / output module capable of inputting and outputting signals to and from the old sequence controller, a temporary adapter for detachably connecting an equipment terminal block, and a connection cable for electrically connecting the temporary terminal block and the temporary adapter to each other; The temporary adapter is characterized in having a connection interface that is the same as a connection interface that can connect to the device terminal block in a new sequencer input / output module that can input and output signals to and from the new sequencer. By adopting such a configuration, it is possible to provide a verification step for the new sequence controller described above and a stable control step using the old sequence controller, and by performing the relatively simple switching operation of replacing the equipment terminal block, it is possible to achieve both stable and continuous operation of the plant and reliable verification of the new sequence controller. Effect of the Invention

[0011] According to the present disclosure, it is possible to propose a verification method and connection tool for replacing an old sequence controller with a new sequence controller, which enables both stable and continuous operation of the plant and reliable verification of the new sequence controller. [Brief description of the drawings]

[0012] [Figure 1] 1 is a diagram showing the configuration of a plant control system used in a verification method for replacing an old programmable controller with a new programmable controller according to an embodiment of the present disclosure. [Figure 2A] FIG. 1 is a block diagram showing the configuration of a new sequencer used in a plant control system. [Figure 2B] FIG. 2 is a block diagram showing a configuration of a relay controlled by the plant control system. [Diagram 3] 1 is a flowchart illustrating a procedure for implementing a verification method for replacing an old sequencer with a new sequencer according to an embodiment of the present disclosure. [Figure 4] FIG. 1 is a diagram showing a state in which a plant is controlled by an old sequence controller in a sequence controller panel. [Diagram 5] This figure shows the state in which the old sequence controller in the sequence controller panel has been moved to a temporary rack and the plant is being controlled by the old sequence controller using a connection tool. [Figure 6] FIG. 2 is a diagram illustrating a configuration of a connection tool according to an embodiment of the present disclosure. [Figure 7] A diagram showing the new sequencer installed on the sequencer board. [Figure 8] This figure shows the state in which the equipment terminal block and the new sequencer input module are connected and the new sequencer is being verified. [Figure 9] This figure shows the state in which the equipment terminal block is connected to a temporary adapter and the plant is controlled by the old sequencer. [Figure 10] 11 is a flowchart showing a flow for switching between verification of a new sequence controller and control of a plant by an old sequence controller depending on a time period. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] The present disclosure will now be described more specifically with reference to the drawings.

[0014] 1 shows the configuration of a plant control system 100 used in a verification method for replacing an old programmable controller 21 with a new programmable controller 31 according to an embodiment of the present disclosure. The plant control system 100 includes a control computer 10 that controls at least one of the old programmable controller 21 and the new programmable controller 31, a temporary rack 20 in which the old programmable controller 21 that can be operated stably is installed, a programmable controller panel 30 in which the new programmable controller 31 that needs to be verified before being introduced is installed, and a relay panel 40 in which a relay 45 that receives a signal from the old programmable controller 21 or the new programmable controller 31 and controls the plant is installed.

[0015] In the verification method for replacing the old sequencer 21 with the new sequencer 31 according to this embodiment, as shown in Figures 4 to 9, the installation positions of the old sequencer 21 and the new sequencer 31 are changed or newly installed during the implementation process, but the configuration shown in Figure 1 shows the state when step S105 shown in Figure 3 (connecting the device terminal block 43 and the new sequencer I / O module 32 and verifying the new sequencer 31) is being executed.

[0016] The control computer 10 communicates with the old sequencer 21 and the new sequencer 31, transmits programs and commands to the old sequencer 21 and the new sequencer 31, and transmits and receives data between the old sequencer 21 and the new sequencer 31. The control computer 10 is connected to the old sequencer 21 and the new sequencer 31 by communication means 15, 17 including wired communication such as USB (Universal Serious Bus) or Ethernet (registered trademark) or wireless communication such as Bluetooth (registered trademark) or WiFi (registered trademark), but is not limited to the communication means exemplified above and various communication means can be used.

[0017] The temporary rack 20 has a housing capable of housing the old sequence controller 21, etc. The temporary rack 20 is used when verifying the new sequence controller 31, and is provided for installing and operating the old sequence controller 21 when the new sequence controller 31 and the old sequence controller 21 are switched and connected to the relay panel 40 depending on the time of day.

[0018] The sequence controller board 30 has a housing capable of housing either the new sequence controller 31 or the old sequence controller 21. In this embodiment, the sequence controller board 30 has a housing that has a track record of housing the old sequence controller 21 and operating it stably, and can also house the new sequence controller 31 that is the subject of verification. In addition to the new sequence controller 31 and the old sequence controller 21, the sequence controller board 30 can be provided with various sensors, timers, counters, meters, switches, touch panels, etc. on the front. It may also be configured to house other devices such as servo devices and inverters.

[0019] Here, we will explain the configuration of the new sequencer 31. As shown in Fig. 2A, the new sequencer 31 includes a control unit 31a that executes programs stored in a storage unit 31b and performs various controls of the new sequencer 31, a storage unit 31b that stores control programs, received data, and calculation results in the control unit 31a, an input unit 31c that inputs signals from the new sequencer input / output module 32, an output unit 31d that outputs signals to the new sequencer input / output module 32, and a communication unit 31e that communicates with the control computer 10, etc.

[0020] Each process in the control unit 31a can be realized as software processing by, for example, executing a predetermined program stored in the storage unit 31b or the like with a CPU (Central Processing Unit) or DSP (Digital Signal Processor) included in the control unit 31a. However, this is not limited to the above, and each process may be configured to be realized as hardware processing by, for example, an ASIC (Application Specific Integrated Circuit), a PLD (Programmable Logic Device), an FPGA (Field Programmable Gate Array), or the like.

[0021] The storage unit 31b includes a readable storage medium, and the storage medium includes a rewritable and programmable ROM such as an EPROM, an EEPROM, or a flash memory, or other tangible storage medium such as a magnetic disk storage medium capable of storing information, or any combination thereof. The storage unit 31b may be provided in the control unit 31a, or may be a storage medium in an external storage device connectable to the new sequencer 31, such as a magnetic cassette, a magnetic tape, or other magnetic and optical storage device (e.g., a CD (Compact Disk), a Laser Disk (registered trademark), a DVD (Digital Versatile Disc), a floppy disk (registered trademark), and a Blu-ray Disk (registered trademark)).

[0022] The control unit 31a executes a program stored in the storage unit 31b or received from the control computer 10, based on various control parameters and the like received from the control computer 10 via the communication unit 31e. By executing the program, the control unit 31a generates an output signal based on the state of an input signal of a sensor, a switch, etc. from the new sequencer input / output module 32 received via the input unit 31c.

[0023] In this embodiment, the output signal output by the control unit 31a is output from the new sequence controller I / O module 32 via the output unit 31d, or via the output unit 31d and a drive circuit (not shown). The output signal output from the new sequence controller I / O module 32 is input to at least one relay 45 provided in the relay board 40 via the device terminal block 43 and the relay connection wiring 46 in FIG.

[0024] FIG. 2B shows an example of a block diagram showing the internal configuration of the relay 45. The relay 45 includes an electromagnet and a contact mechanism (not shown), and opens and closes the contacts by using the electromagnetic attraction force generated when a current of a certain value or more flows through the electromagnet. In the figure, the numbers surrounded by circles indicate terminal numbers. In FIG. 2B, when a voltage is applied between terminals 1 and 11, the current is converted by resistor 45b and flows through the coil, and neon lamp 45a indicating operation is turned on, and the contacts between terminals 3 and 5, between terminals 2 and 6, and between terminals 7 and 10 are closed. The operation of this relay 45 controls the corresponding controlled device.

[0025] In this embodiment, the control unit 31a in the new sequencer 31 executes a program to generate an output signal based on an input signal from the input unit 31c, but the present invention is not limited to this embodiment. For example, the new sequencer 31 may transmit an input signal to an externally disposed control unit, receive the generated output signal, and output it to a controlled device.

[0026] In this embodiment, the new sequencer 31 is configured to receive programs, various commands, and parameters from the control computer 10 via the communication unit 31e, but is not limited to this. The new sequencer 31 may receive this information via the input unit 31c.

[0027] Incidentally, the basic configuration of the old sequencer 21 is similar to that shown in FIG. 2A, so further description thereof will be omitted here.

[0028] 1 includes a housing capable of housing the relay 45 and the like. As described above, the output signal output from the new PLC 31 via the new PLC input / output module 32 is input to the relay 45 provided in the relay board 40 via the device terminal block 43 and the relay connection wiring 46. In this manner, by controlling the relay 45 using the new PLC 31 or the old PLC 21, it is possible to open and close the contacts connected to other devices to be controlled that are connected to the relay 45. That is, in this embodiment, the relay 45 and other devices connected to the relay 45 are the devices to be controlled.

[0029] The connection tool 50 in FIG. 1 includes a temporary terminal block 53 that is electrically and mechanically detachably connected to the connection interface 22a of the old sequencer input / output module 22, a temporary adapter 55 that detachably connects the device terminal block 43 that is connected to the relay 45 that is the device to be controlled, and a connection cable 51 that electrically connects the temporary terminal block 53 and the temporary adapter 55 to each other (see FIG. 6 for details).

[0030] As shown in FIG. 1, the connection tool 50 has a temporary terminal block 53 connected to the old sequencer input / output module 22 of the old sequencer 21 arranged in the temporary rack 20, while the temporary adapter 55 is arranged in the sequencer board 30.

[0031] Next, a verification method for replacing the old PLC 21 with the new PLC 31 according to this embodiment will be described with reference to the flow diagram of Fig. 3 and Figs. 4 to 9. This verification method is a technique for reliably verifying the new PLC 31 by a limited number of workers when it is desired to introduce a new PLC 31 in place of the old PLC 21 for the purpose of adding new functions or dealing with aging equipment, in a state in which the old PLC 21 is being used to stably and continuously control the controlled equipment.

[0032] In the verification method for replacing the old programmable controller 21 with the new programmable controller 31 according to the present embodiment, first, as shown in FIG. 4, the old programmable controller 21 controls a plant through control of control target devices such as a relay 45 by the old programmable controller 21 in a state in which the old programmable controller 21 is arranged in the programmable controller board 30 (step S101 in FIG. 3). In this step S101, as shown in FIG. 4, the device terminal block 43 is directly and detachably connected to the old programmable controller input / output module 22 of the old programmable controller 21, and the connection tool 50 is not used. That is, the connection state shown in FIG. 4 is a state in which the old programmable controller 21 and the relay 45 (see FIG. 1), which is a control target of the old programmable controller 21, are electrically connected via the device terminal block 43 and the old programmable controller input / output module 22. Step S101 (corresponding to FIG. 4) is a state in which the old programmable controller 21 stably and continuously controls the plant before the new programmable controller 31 is introduced.

[0033] Next, as shown in Fig. 5, the old PLC 21 installed on the PLC board 30 is moved and installed on the temporary rack 20 (step S102 in Fig. 3). Also, as shown in Fig. 5, the device terminal block 43 connected to the relay 45 is connected to the temporary adapter 55 of the connection tool 50, and the temporary terminal block 53 is connected to the old PLC input / output module 22 of the old PLC 21, and the plant is controlled by the old PLC 21 (step S103 in Fig. 3). The device terminal block 43 and the temporary adapter 55 are connected mechanically and electrically in a detachable manner via a connection interface 55a provided in the temporary adapter 55. The temporary terminal block 53 and the old PLC input / output module 22 are connected mechanically and electrically in a detachable manner via a connection interface 22a provided in the old PLC input / output module 22. 5 is a state in which the old sequence controller 21 and the relay 45 (see FIG. 1) that is the control target of the old sequence controller 21 are electrically connected via the temporary terminal block 53, the connection cable 51, the temporary adapter 55, and the equipment terminal block 43. This step S103 makes it possible to confirm that even in a state in which the temporary rack 20 and the connection tool 50 are used, the plant can be controlled by the old sequence controller 21 in the same manner as before (similar to step S101 and FIG. 4).

[0034] In FIG. 5, the connection tool 50 includes a temporary terminal block 53 that is detachably connected to the connection interface 22a of the old sequencer input / output module 22, a temporary adapter 55 that detachably connects the device terminal block 43 that is connected to the relay 45 that is the device to be controlled, and a connection cable 51 that connects the temporary terminal block 53 and the temporary adapter 55 to each other (see FIG. 6).

[0035] 6, the temporary terminal block 53 has a plurality of terminals exposed on its upper surface (the surface vertical to the paper surface of FIG. 6), and one end of each of the plurality of cables of the connection cable 51 is electrically connected to each of the plurality of terminals in a one-to-one relationship. The temporary terminal block 53 is electrically and mechanically detachably connected to the connection interface 22a of the old sequencer input / output module 22 at its lower portion (the portion vertical to the paper surface of FIG. 6). In this embodiment, the device terminal block 43 connected to the relay 45, which is the device to be controlled, also has a configuration similar to that of the temporary terminal block 53.

[0036] 6, the temporary adapter 55 is connected to the end of the connection cable 51 of the connection tool 50 on the opposite side to the temporary terminal block 53, and in this embodiment, is electrically connected to the connection cable 51 via a plurality of connectors 56. As shown in FIG. 5, the temporary terminal block 53 of the connection tool 50 is connected to the old sequence controller input / output module 22 of the old sequence controller 21 arranged in the temporary rack 20, while the temporary adapter 55 is arranged in the sequence controller board 30. Then, as shown in FIG. 5, by connecting the device terminal block 43 to the connection interface 55a of the temporary adapter 55, the old sequence controller 21 can control the relay 45, which is a controlled device.

[0037] Next, as shown in Fig. 7, the new sequencer 31 is installed in the storage section 30s (see Fig. 5) in which the old sequencer 21 was installed in step S101 in the sequencer board 30 (step S104 in Fig. 3). In this embodiment, the new sequencer 31 is housed in a housing that is large enough to fit in the storage section 30s, just like the old sequencer 21, so it can be fixed in the storage section 30s via a mounting member dedicated to the new sequencer 31. The housing of the new sequencer 31 may be made common to the housing of the old sequencer 21 to further facilitate installation of the new sequencer 31.

[0038] Next, as shown in Fig. 8, the device terminal block 43 connected to the relay 45, which is the device to be controlled, is removed from the connection interface 55a of the temporary adapter 55 and connected to the new sequencer input / output module 32 of the new sequencer 31, and the new sequencer 31 is verified (step S105 in Fig. 3). By connecting the device terminal block 43 to the new sequencer input / output module 32 via the connection interface 32a, the relay 45, which is the device to be controlled, can be controlled by the new sequencer 31 without going through the connection tool 50. That is, the connection state in Fig. 8 is a state in which the new sequencer 31 and the relay 45, which is the control target of the new sequencer 31 (the same relay 45 as the control target of the old sequencer 21), are electrically connected via the device terminal block 43 and the new sequencer input / output module 32.

[0039] In this embodiment, the temporary adapter 55 is configured to have a connection interface 55a that is the same as the connection interface 32a that can connect the device terminal block 43 in the new sequence controller input / output module 32 that can input and output signals to and from the new sequence controller 31. Therefore, as shown in Fig. 8, the device terminal block 43 can be easily replaced from the connection interface 55a of the temporary adapter 55 to the connection interface 32a of the new sequence controller input / output module 32 to start verification of the new sequence controller 31.

[0040] When the verification of the new PLC 31 is to be interrupted, as shown in Fig. 9, the device terminal block 43 is removed from the new PLC input / output module 32 and connected to the connection interface 55a of the temporary adapter 55, and the plant is controlled by the old PLC 21 (step S106 in Fig. 3). By reattaching the device terminal block 43 to the temporary adapter 55 as described above, the device terminal block 43 and the old PLC 21 can be connected via the connection tool 50 as in Fig. 5, so that the verification of the new PLC 31 can be interrupted midway and the plant can be quickly switched to control by the old PLC 21.

[0041] It is desirable to finish the verification of the new PLC 31 without interruption, but as the PLC functions improve and plants become more complicated, the verification work of the newly introduced new PLC 31 becomes more complicated and the verification time tends to increase. Therefore, for example, as shown in Figure 10, a method can be considered in which the verification of the new PLC 31 is performed during the daytime when workers are available to work, and the verification of the new PLC 31 is interrupted during the nighttime when workers are unable to work, and the control of the plant continues with the old PLC 21.

[0042] 10, after starting the verification of the new PLC 31, during the daytime hours when the worker can perform the verification work (YES in step S201 in FIG. 10), as shown in FIG. 8, the device terminal block 43 is connected to the new PLC I / O module 32 of the new PLC 31, and the new PLC 31 is verified (step S205 in FIG. 10). This step S205 corresponds to step S105 in FIG. 3.

[0043] Thus, during the daytime, step S201 is YES, and verification of the new PLC 31 continues. Then, when verification of the new PLC 31 is completed (step S207 in FIG. 10 is YES), the connection state of FIG. 8 is maintained, and the operation of controlling the plant by the new PLC 31 continues. In this case, the temporary rack 20, old PLC 21, and connection tool 50 in FIG. 8 may be removed.

[0044] On the other hand, if verification of the new PLC 31 has not been completed in step S207 of Fig. 10 (NO in step S207 of Fig. 10) and it is not the verification time period in step S201, that is, it is the night time period (NO in step S201 of Fig. 10), the connection state is switched to that of Fig. 9, and the plant is controlled by the old PLC 21 (step S206 of Fig. 10). This step S206 corresponds to step S106 in Fig. 3.

[0045] When the midnight period that is not a verification period ends (YES in step S201 in FIG. 10), the connection state is switched back to that in FIG. 8, and verification of the new sequencer 31 is resumed (step S205 in FIG. 10). Steps S205 and S206 are repeated until verification of the new sequencer 31 is completed (until YES is determined in step S207 in FIG. 10).

[0046] As described above, the present embodiment is a verification method for replacing the old sequence controller 21 with the new sequence controller 31 in the plant control system 100 that operates a plant using a sequence controller. The plant control system 100 includes the old sequence controller 21 that is connected to the controlled device (relay 45) via the old sequence controller input / output module 22, the new sequence controller 31 that is connected to the controlled device via the new sequence controller input / output module 32, the temporary rack 20 that houses the old sequence controller 21, and the new sequence controller 31 that is connected to the controlled device via the new sequence controller input / output module 32. The connection tool 50 has a temporary terminal block 53 that is detachably connected to the old sequencer input / output module 22, a temporary adapter 55 that is detachably connected to the device terminal block 43 that is connected to the device to be controlled, and a connection cable 51 that electrically connects the temporary terminal block 53 and the temporary adapter 55 to each other, and the device terminal block 43 is connected to the old sequencer input / output module 22, the temporary The new PLC can be detachably connected to either the adapter 55 or the new PLC input / output module 32, and the verification method is configured to include an initial operation confirmation step of connecting the equipment terminal block 43 to the old PLC input / output module 22 and controlling the plant using the old PLC 21 in the PLC board 30, a relocation step of moving and installing the old PLC 21 installed on the PLC board 30 to the temporary rack 20, a post-relocation operation confirmation step of connecting the equipment terminal block 43 to the temporary adapter 55 and connecting the temporary terminal block 53 to the old PLC input / output module 22 and controlling the plant using the old PLC 21, an installation step of installing the new PLC 31 on the PLC board 30, a verification step of connecting the equipment terminal block 43 to the new PLC input / output module 32 and verifying the new PLC 31, and a stable control step of removing the equipment terminal block 43 from the new PLC input / output module 32 and connecting it to the temporary adapter 55, and controlling the plant using the old PLC 21.By adopting such a configuration, a verification step of the above-mentioned new sequence controller 31 and a stable control step using the old sequence controller 21 are provided, and by performing a relatively simple switching operation of replacing the equipment terminal block 43, it is possible to achieve both stable and continuous operation of the plant and reliable verification of the new sequence controller.

[0047] In this embodiment, the verification step and the stable control step are alternately executed in predetermined time periods. By adopting such a configuration, the verification step of the new PLC 31 can be executed during the time period when the worker can verify the new PLC 31, and the stable control step by the old PLC 21 can be executed during the time period when the worker cannot verify the new PLC 31. This allows a limited number of workers to perform reliable verification of the new PLC 31 and stable and continuous operation of the plant.

[0048] In this embodiment, a connection tool 50 is configured to be used in any of the above-mentioned verification methods. By adopting such a configuration, the connection tool 50 can connect the old PLC 21 to the device terminal block 43, thereby executing the stable control step by the old PLC 21. Therefore, it is possible to easily switch between the verification step of the new PLC 31 and the stable control step by the old PLC 21, thereby achieving both stable and continuous operation of the plant and reliable verification of the new PLC.

[0049] In addition, in this embodiment, in a plant operated by the old PLC 21 or the new PLC 31, the connection tool 50 connects the old PLC 21 to the device terminal block 43 connected to the controlled device, and includes a temporary terminal block 53 connected to the old PLC input / output module 22 capable of inputting and outputting signals to the old PLC 21, a temporary adapter 55 for detachably connecting the device terminal block 43, and a connection cable 51 for electrically connecting the temporary terminal block 53 and the temporary adapter 55 to each other, and the temporary adapter 55 is configured to have the same connection interface 55a as the connection interface 32a that can connect the device terminal block 43 in the new PLC input / output module 32 capable of inputting and outputting signals to the new PLC 31. By adopting such a configuration, the above-mentioned verification step of the new PLC 31 and the stable control step by the old PLC 21 are provided, and by a relatively easy switching operation of replacing the device terminal block 43, it is possible to achieve both stable and continuous operation of the plant and reliable verification of the new PLC.

[0050] Although the present disclosure has been described based on the drawings and embodiments, it should be noted that those skilled in the art can easily make various modifications and corrections based on the present disclosure. Therefore, it should be noted that these modifications and corrections are included in the scope of the present invention. For example, the functions included in each component can be rearranged so as not to cause logical inconsistency, and multiple components can be combined into one or divided. It should be understood that these are also included in the scope of the present invention.

[0051] For example, in the present embodiment, the new sequencer 31 or the old sequencer 21 is configured to control other control target devices via the relay 45, which is a control target device, but is not limited to this aspect. The new sequencer 31 or the old sequencer 21 may be configured to directly control control target devices other than the relay 45 without going through the relay 45.

[0052] In addition, in this embodiment, the new PLC 31 is verified during the daytime hours when workers can work, and the old PLC 21 controls the plant during the nighttime hours, but this is not limited to the above. It is possible to switch between verifying the new PLC 31 and controlling the plant with the old PLC 21 at any time. For example, the new PLC 31 can be verified during a first time period during the day, and the old PLC 21 controls the plant during a second time period during the day, allowing flexible switching to be performed according to the working hours of workers, etc. [Industrial Applicability]

[0053] According to the present disclosure, it is possible to propose a verification method for replacing the old sequence controller 21 with a new sequence controller 31, which enables both stable and continuous operation of the plant and reliable verification of the new sequence controller. [Explanation of symbols]

[0054] 10 Control computer 15,17 Means of communication 20 Temporary Rack 21 Old sequencer 22 Old sequencer input / output module 22a Connection Interface 30 Sequencer Board 30s storage section 31 New sequencer 31a Control section 31b Storage section 31c Input section 31d Output section 31e Communication Department 32 New sequencer input / output module 32a Connection Interface 40 Relay Board 43 Equipment terminal block 45 Relay 45a Neon lamp 45b resistance 46 Relay connection wiring 50 Connection Tools 51 Connection cable 53 Temporary terminal block 55 Temporary Adapter 55a Connection Interface 56 Connector 100 Plant Control System

Claims

1. A verification method for replacing an old sequence controller with a new sequence controller in a plant control system that operates a plant using a sequence controller, comprising: The plant control system includes: An old sequence controller that connects to the controlled device via the old sequence controller I / O module, A new PLC that connects to the controlled equipment via a new PLC I / O module, A temporary rack for accommodating the old sequencer; a sequencer board housing either the old sequencer or the new sequencer; A connection tool that connects the old PLC to the controlled device. Equipped with the connection tool includes a temporary terminal block that is detachably connected to the old sequence controller input / output module, a temporary adapter that detachably connects an equipment terminal block that is connected to a controlled equipment, and a connection cable that electrically connects the temporary terminal block and the temporary adapter to each other; the device terminal block is detachably connectable to any one of the old sequence controller input / output module, the temporary adapter, or the new sequence controller input / output module; The verification method includes: an initial operation confirmation step of connecting the device terminal block to the old sequencer input / output module and controlling the plant by the old sequencer in the sequencer board; a relocation step of moving and installing the old sequence controller installed on the sequence controller board on the temporary rack; a post-relocation operation confirmation step of connecting the device terminal block and the temporary adapter, and also connecting the temporary terminal block and the old sequence controller input / output module, and controlling the plant by the old sequence controller; a verification step of connecting the device terminal block and the new sequence controller input / output module to verify the new sequence controller; a stable control step of removing the device terminal block from the new PLC input / output module and connecting it to the temporary adapter to control the plant using the old PLC; A verification method comprising:

2. 2. The method according to claim 1, wherein the verification step and the stability control step are alternately performed for each predefined time period.

3. A connection tool for use in the verification method according to claim 1 or 2.

4. In a plant operated by an old or new PLC, a connection tool is provided for connecting an old PLC to a device terminal block connected to a controlled device, a temporary terminal block for connecting to an old sequence controller input / output module capable of inputting and outputting signals to and from the old sequence controller, a temporary adapter for detachably connecting an equipment terminal block, and a connection cable for electrically connecting the temporary terminal block and the temporary adapter to each other; A connection tool characterized in that the temporary adapter has a connection interface that is the same as a connection interface that can connect to the device terminal block in a new sequencer input / output module that can input and output signals to and from the new sequencer.

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