Plant Management System

Abstract

To provide a plant management system capable of improving the efficiency of plant management more than in a conventional manner by associating an operation logbook with history data without complicated work.SOLUTION: A plant management system includes: a logbook device having an operation logbook function for recording a diary sentence including informative matters about plant operation; a process data management device for managing process data acquired through plant operation and performing prescribe first operation associated with the logbook device by transmitting and receiving information to / from the logbook device; and a history data management device for managing alarm history data and operation history data acquired through plant operation and performing prescribed second operation associated with the logbook device by transmitting and receiving information to / from the logbook device.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a plant management system used to manage plant operations. [Background technology]

[0002] Traditionally, in plants that operate 24 hours a day, operation logs have been created for the purpose of taking over work duties during shift work, analyzing problems, and passing on operational know-how. These operation logs (handover books, handover notebooks, etc.) record various communication matters related to plant operation (such as the details of work performed, matters that occurred at the plant, and communication with operators on shift work). Furthermore, operation logs, which were previously created by hand, have recently been digitized, and logbook systems that can create such digitized operation logs are also being introduced.

[0003] Meanwhile, process data management systems have been introduced in plants, which periodically and automatically collect process data (such as data measured by measuring instruments installed in the plant) that represent the behavior of the plant in order to understand the operating status of the plant (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2013-254235 Summary of the Invention [Problem to be solved by the invention]

[0005] The plant also has a history data management system that manages alarm data and operation history. The operator checks the alarm data, performs the operation, and records the operation details in the operation log. When recording, the reason for the operation and the cause of the alarm are recorded along with the alarm and operation details.

[0006] However, when linking a driving logbook with historical data, the contents of the historical data must first be transcribed onto paper or other media before being recorded in the driving logbook. However, this process requires a lot of time and effort, which reduces work efficiency. Furthermore, when transcribing onto paper or other media, omissions, simplifications, and omissions often occur.

[0007] On the other hand, there was a method in which historical data was used as an operation record as is, but this method did not allow for the association of information such as logs entered by operators (information entered manually, such as the reasons for an operation or the cause of an alarm) with the data acquired by the historical data management system.

[0008] Therefore, for example, if manually entered log entries and automatically collected historical data from the plant could be linked without the need for cumbersome work, and if quick recording and viewing were possible, it would be possible to improve work efficiency, respond quickly when problems occur, and efficiently transfer know-how.

[0009] Therefore, the present disclosure aims to provide a plant management system that can improve the efficiency of plant management compared to conventional systems by linking operation logs and historical data without requiring cumbersome work. [Means for solving the problem]

[0010] A plant management system according to one embodiment includes a logbook device having a logbook function for recording logbook text including contact information related to plant operation, a process data management device that manages process data acquired during plant operation and performs a predetermined first operation in cooperation with the logbook device by sending and receiving information to and from the logbook device, and a history data management device that manages alarm history data and operation history data acquired during plant operation and performs a predetermined second operation in cooperation with the logbook device by sending and receiving information to and from the logbook device. The process data management device manages identification information that identifies measuring instruments installed in a plant. As a predetermined first operation, the process data management device performs the following steps: when a journal entry is input in a free format in a journal device, the process data management device performs a first step of searching whether the journal entry contains the identification information managed in the process data management device; and when the identification information is included in the journal entry in the first step, the process data management device performs a second step of setting a predetermined operation function for the identification information in the journal entry. [Effects of the Invention]

[0011] According to the present disclosure, a plant management system can be provided that can improve the efficiency of plant management compared to conventional systems by associating operation logs with historical data without requiring cumbersome work. [Brief explanation of the drawings]

[0012] [Figure 1] FIG. 1 is a diagram illustrating an example of the configuration of a plant management system according to an embodiment. [Figure 2] 1 is a flowchart illustrating an example of an operation of a plant management system according to an embodiment. [Figure 3] 10 is a flowchart illustrating another example of the operation of the plant management system according to an embodiment. [Figure 4] FIG. 10 is a diagram showing a display example of list data (alarm and event list). [Figure 5] FIG. 10 is a diagram showing an example of a display on a display unit of the diary device. [Figure 6] 10 is a flowchart illustrating another example of the operation of the plant management system according to an embodiment. [Figure 7] FIG. 10 is a diagram showing an example of a comment added to a journal text; [Figure 8] 10 is a flowchart illustrating another example of the operation of the plant management system according to an embodiment. [Figure 9] FIG. 9 is a diagram showing an image of utilization of the operation example shown in the flowchart of FIG. 8. [Figure 10] FIG. 10 is a diagram showing an example of a screen on which operation assistance is displayed. [Figure 11] 11 is a conceptual diagram showing an example of the hardware configuration of processing circuits included in the log device, the process data management device, and the history data management device in the embodiment shown in FIGS. 1 to 10. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0013] <Configuration of one embodiment> Hereinafter, an embodiment of a plant management system according to the present disclosure will be described with reference to the drawings.

[0014] 1 is a diagram showing an example of the configuration of a plant management system 1 according to one embodiment. The plant management system 1 is used in plants that operate 24 hours a day, such as chemical plants such as petrochemical plants, and manufacturing plants for iron or paper, etc. These plants are controlled by a DCS (Distributed Control System) (not shown) or the like in a control room or monitoring room (not shown), for example.

[0015] 1, the plant management system 1 includes a logbook device 10, a process data management device 20, and a history data management device 30. The logbook device 10 and the process data management device 20 are connected via a signal line 41, the logbook device 10 and the history data management device 30 are connected via a signal line 42, and the process data management device 20 and the history data management device 30 are connected via a signal line 43.

[0016] The logbook device 10 has a logbook function that can electronically manage and record information about plant operation (operations and work performed, and information that should be communicated, such as the operating status of the plant) as an operation logbook.

[0017] 1, the logbook device 10 has at least a driving log function unit 11, an operation unit 12, a memory unit 13, and a display unit 14. The driving log function unit 11, the operation unit 12, the memory unit 13, and the display unit 14 in the logbook device 10 are connected to each other so as to be able to communicate with each other.

[0018] The driving log function unit 11 is used when creating a driving log entry. The driving log function unit 11 can also create a driving log entry in cooperation with information managed by a process data management device 20 and information managed by a history data management device 30, which will be described later.

[0019] The operation unit 12 is, for example, a mouse, a keyboard, a GUI (Graphical User Interface) type touch panel, or the like, and is used when an operator (worker) operates the logbook device 10. Note that the operation unit 12 can also be used when an operator (worker) operates information managed by a process data management device 20 and information managed by a history data management device 30, which will be described later, in cooperation with these devices.

[0020] The storage unit 13 electronically manages and stores log information (log data), which is information such as log sentences on each log sheet in the driving log. Note that the storage unit 13 can also manage and store information managed by a process data management device 20 and a history data management device 30, which will be described later, in cooperation with these devices, for example, by associating the information with the log information.

[0021] Various information such as log information is displayed on the display unit 14. The display unit 14 can also display information managed by a process data management device 20 (described later) and information managed by a history data management device 30 in cooperation with these devices. The display unit 14 may also serve as the operation unit 12 such as a GUI-type touch panel.

[0022] The details of the operations of the driving log function unit 11, operation unit 12, storage unit 13, and display unit 14 will be described later (see FIGS. 2 to 10, etc.).

[0023] The process data management device 20 manages process data acquired during plant operation. Within a plant, multiple measuring instruments are installed on production lines and the like. Measurement results from these measuring instruments are periodically and automatically collected as process data by the process data management device 20. The process data is data that indicates, for example, the temperature, flow rate, etc. at what time and minute.

[0024] Here, each measuring instrument is assigned with individual identification information (hereinafter also referred to as "tag information") in order to identify each measuring instrument. For example, each piece of process data is associated with the tag information of the measuring instrument that is the source of the measurement, and is managed in chronological order in the process data management device 20.

[0025] 1, the process data management device 20 includes at least a tag information storage unit 21 and a process data storage unit 22. The tag information storage unit 21 and the process data storage unit 22 in the process data management device 20 are connected to each other so as to be able to communicate with each other.

[0026] The tag information storage unit 21 stores tag information managed by the process data management device 20. Generally, tag information of measuring instruments installed in a plant managed by the process data management device 20 is managed by the process data management device 20.

[0027] The process data storage unit 22 stores each automatically collected process data. Furthermore, the process data storage unit 22 stores a plurality of diagram data. Here, the diagram data is data of diagrams configured using process data, such as trend graphs 22a and graphics 22b.

[0028] The trend graph 22a is a graph visually displaying time-series changes in process data. For example, the vertical axis of the trend graph 22a represents the value of a certain process data, and the horizontal axis of the trend graph 22a represents time.

[0029] The graphic 22b is a diagram that schematically displays the configuration of all or part of the manufacturing line installed in the plant, and therefore the configuration of the plant line can be easily understood from the configuration diagram displayed in the graphic 22b.

[0030] Here, each trend graph 22a and each graphic 22b is managed in the process data storage unit 22 in association with at least one piece of tag information.

[0031] For example, in the trend graph 22a associated with tag information A, a graph showing the time-series changes in the measurement results (process data) transmitted from the measuring instrument that is the tag information A is created.

[0032] Furthermore, at least one measuring instrument is installed in the production line of the plant represented by one graphic 22b, and therefore, tag information indicating each measuring instrument installed in the production line represented by that graphic 22b is associated with that graphic 22b.

[0033] For example, suppose that a thermometer and a flow meter are installed at predetermined locations on a production line. In this case, in graphic 22b, which schematically shows the production line, tag information indicating the thermometer is associated with the location where the thermometer is installed, and tag information indicating the flow meter is associated with the location where the flow meter is installed. Then, graphic 22b is created by displaying measurement results (process data) sent from the measuring instruments that represent the tag information at each location in graphic 22b where the tag information is associated.

[0034] The history data management device 30 manages and stores alarm history data and operation history data acquired during plant operation. Note that a plurality of alarm history data and a plurality of operation history data are examples of "history data."

[0035] 1, the history data management device 30 has at least an alarm history storage unit 31, an alarm history display unit 32, an operation history storage unit 33, and an operation history display unit 34. The alarm history storage unit 31 and the alarm history display unit 32 are communicatively connected to each other, and the operation history storage unit 33 and the operation history display unit 34 are communicatively connected to each other. The alarm history storage unit 31, the alarm history display unit 32, the operation history storage unit 33, and the operation history display unit 34 may be communicatively connected to each other. The alarm history storage unit 31 and the operation history storage unit 33 may be common, and the alarm history display unit 32 and the operation history display unit 34 may also be common.

[0036] The alarm history storage unit 31 stores alarm history data. A plurality of alarm history data are managed and stored as list data 31a by the alarm history storage unit 31. Note that a plurality of alarm history data may be managed and stored as list data 31a by the process data management device 20. Note that the alarm history list data 31a may be managed and stored as common list data with the operation history list data 33a described later.

[0037] The alarm history data is data that indicates alarm history, such as information indicating abnormalities in the measurement results of each measuring instrument installed on the production line due to temperature rise, pressure drop, etc., or information indicating a malfunction that has occurred in any unit of each production plant.

[0038] Each alarm included in the alarm history data includes the tag information and process data described above. An alarm may include information such as the date and time when an abnormality or failure occurred, the location where it occurred, the details of the occurrence, and the importance or severity of the abnormality or failure (e.g., minor alarm, medium alarm, major alarm, etc.). An alarm may also include information such as the date and time when the abnormality or failure was resolved, the location where it was resolved, and the details of the resolution. Note that the alarm history data may be automatically collected periodically or each time an alarm occurs, or may be collected by accepting an alarm input by an operator.

[0039] The alarm history display unit 32 displays the alarm history stored in the alarm history storage unit 31. The contents of the alarms displayed on the alarm history display unit 32 are monitored by an operator. The alarm history display unit 32 may display, for example, an abnormality, a malfunction, or the like in a color-coded manner according to the importance or seriousness (e.g., minor alarm, medium alarm, major alarm, etc.), or may display the alarm according to a predetermined operation or keyword, or may notify the alarm by voice, etc. The alarm history display unit 32 may display list data 31a as the alarm history. Note that the list data 31a may be displayed as list data common to list data 33a described below.

[0040] The alarm history display unit 32 may have an operation unit (not shown) that is operated by an operator. Depending on the content of the alarm, the operator may take action on the spot via the operation unit (not shown) to deal with the alarm, or may go to the site to take action. The alarm history display unit 32 may also display various information such as journal information displayed on the display unit 14 of the journal device 10. In this case, for example, the operator may immediately transcribe the content of a desired alarm as a journal entry in the journal device 10 by copying and pasting or with one click, and the journal entry and the alarm content may be associated with each other and managed and saved by the journal device 10.

[0041] The operation history storage unit 33 stores operation history data. A plurality of pieces of operation history data are managed and stored as list data 33a by the operation history storage unit 33. Note that a plurality of pieces of operation history data may be managed and stored as list data 33a by the process data management device 20. Note that the operation history list data 33a may be managed and stored as list data common to the alarm history list data 31a.

[0042] The operation history data is data indicating an operation history, such as information indicating details of operation of the plant, such as how the plant was operated and how the plant was responded to. For example, the operation history data is data indicating, apart from alarms, what date an operation value was changed from what value to what value, or where the location was changed from. Depending on the operation details, an operator may perform operation on-site in a control room or the like via an operation unit (not shown), or may go to the site to perform operation. Note that the operation history data may be automatically collected periodically or each time an operation is performed, or may be collected by accepting input of the operation history by the operator.

[0043] The operation history display unit 34 displays the operation history stored in the operation history storage unit 33. The contents of the operation history displayed on the operation history display unit 34 are monitored by an operator. For example, the operation history may be displayed in different colors according to the operation content, etc., or may be displayed according to the operation content, a predetermined operation, a keyword, etc., or may be notified by voice, etc. The operation history display unit 34 may display list data 33a as the operation history. Note that the list data 33a may be displayed as list data common to the list data 31a.

[0044] The operation history display unit 34 may have an operation unit (not shown) that is operated by an operator. The operator may input the operation history on the spot via the operation unit (not shown) depending on the operation content. The operation history display unit 34 may also display various information such as the journal information displayed on the display unit 14 of the diary device 10. In this case, for example, the operator may immediately transcribe the content of a desired operation history as a journal entry in the diary device 10 by copying and pasting or with one click, and the diary entry and the content of the operation history may be associated with each other and managed and saved by the diary device 10.

[0045] The signal line 41 is capable of transmitting and receiving signals in both directions and connects the diary device 10 and the process data management device 20. The diary device 10 and the process data management device 20 transmit and receive information in both directions by transmitting and receiving signals in both directions via the signal line 41. The diary device 10 and the process data management device 20 perform predetermined operations in cooperation with each other by transmitting and receiving information. The predetermined operation is an example of a "predetermined first operation."

[0046] The signal line 42 is capable of sending and receiving signals in both directions and connects the diary device 10 and the history data management device 30. The diary device 10 and the history data management device 30 send and receive information in both directions by sending and receiving signals in both directions via the signal line 42. The diary device 10 and the history data management device 30 perform predetermined operations in cooperation with each other by sending and receiving information. The predetermined operation is an example of a "predetermined second operation."

[0047] The signal line 43 is capable of transmitting and receiving signals in both directions and connects the process data management device 20 and the history data management device 30. The process data management device 20 and the history data management device 30 transmit and receive information in both directions by transmitting and receiving signals in both directions via the signal line 43. The process data management device 20 and the history data management device 30 transmit and receive information to perform predetermined operations in cooperation with each other by transmitting and receiving information.

[0048] Here, the logbook device 10 is an information system device, and the process data management device 20 and the history data management device 30 are control system devices. For security reasons and the like, information system devices and control system devices have traditionally been separated from each other, and not directly connected to each other via a network (signal lines of a LAN (Local Area Network)). If they are connected, security requirements are strictly restricted. For this reason, the networks between the information system devices and the control system devices have traditionally been separated, and therefore, in principle, the information system devices and the control system devices have not been able to transmit and receive information to and from each other, thereby not operating in cooperation with each other.

[0049] On the other hand, the signal lines 41 and 42 connecting the logbook device 10, which is an information-system device disclosed herein, with the process data management device 20 and the history data management device 30, which are control-system devices, have, for example, gateways 41a and 42a to satisfy security requirements. The gateways 41a and 42a correspond to, for example, a predetermined OPC (OLE (Object Linking and Embedding) for Process Control) server or a predetermined interface that satisfies security requirements. Note that OPC is an interface standard for linking software that controls equipment in, for example, a factory.

[0050] That is, the logbook device 10, which is an information-system device disclosed herein, and the process data management device 20 and history data management device 30, which are control-system devices, are connected via signal lines 41 and 42 having gateways 41a and 42a that satisfy predetermined security requirements. Therefore, the logbook device 10, which is an information-system device disclosed herein, and the process data management device 20 and history data management device 30, which are control-system devices, can operate in cooperation with each other by transmitting and receiving information via the signal lines 41 and 42. Note that although the signal lines 41 and 42 can be wireless, wired lines are preferable due to strict security requirements and the presence of the gateways 41a and 42a.

[0051] Meanwhile, control system devices have traditionally been connected to each other via a network, and have performed mutually coordinated operations by transmitting and receiving information. Therefore, the signal line 43 connecting the process data management device 20 and the history data management device 30, which are control system devices disclosed herein, may or may not include a gateway or the like that satisfies security requirements, and may be wired or wireless. For example, the process data management device 20 and the history data management device 30 mutually transmit and receive tag information and process data managed by the process data management device 20, and alarm history and operation history managed by the history data management device 30, via the signal line 43. The process data management device 20 and the history data management device 30 then transmit and receive information to each other, thereby performing mutually coordinated operations.

[0052] <Operation of one embodiment> Next, an example of the operation of the plant management system 1 according to an embodiment will be described.

[0053] 2 is a flowchart showing an example of the operation of the plant management system 1 according to an embodiment. The flowchart in FIG. 2 starts when an input from an operator (not shown) is received and an operation log is created by the logbook device 10. In this specification, the operation log is also referred to as an "operation logbook" or simply as a "logbook." In the flowchart in FIG. 2, the operation performed in cooperation between the logbook device 10 and the process data management device 20 is an example of a "predetermined first operation."

[0054] In step S1, the logbook device 10 creates a driving logbook using the driving logbook function unit 11. Specifically, the driving logbook function unit 11 displays a logbook sheet on the display unit 14. Then, the driving logbook function unit 11 accepts input of logbook text by an operator using the operation unit 12 into the logbook input unit of the displayed logbook sheet, and creates a driving logbook.

[0055] Here, the diary entries may be entered according to a pre-set format (such as a pre-defined order of entries), but if you want to reduce the amount of work required for workers to create the diary, it is better to enter the diary in a free format that is not bound by any particular format.

[0056] For example, if "PI-100" is managed and stored as tag information A in the tag information storage unit 21, the tag information A may also be input in a free format. In other words, there is no need to provide uniformity in the input of tag information, and for example, distinction between half-width and full-width characters and between uppercase and lowercase letters may not be important, and characters such as "hyphens" and "underscores" may be omitted.

[0057] In step S2, the diary device 10 transmits the diary text input in step S1 to the process data management device 20 via the signal line 41.

[0058] In step S3, the tag information storage unit 21 of the process data management device 20 searches to determine whether or not the journal text acquired in step S2 includes tag information stored and managed in the tag information storage unit 21.

[0059] Here, if the journal text is created in free format, the tag information storage unit 21 uses, for example, a pattern matching method to search whether the journal text contains tag information managed by the tag information storage unit 21.

[0060] In step S4, the process data management device 20 transmits the search results obtained by searching the tag information storage unit 21 in step S3 to the logbook device 10 via the signal line 41. For example, the process data management device 20 transmits to the logbook device 10 a notification that the tag information A (PI-100) included in the logbook text is tag information managed and stored in the tag information storage unit 21.

[0061] In step S5, the driving log function unit 11 of the log device 10 receives the notification in step S4 and sets a predetermined operation function for the typed portion (character input portion) of tag information A (PI-100) in the log text. For example, an underline is added to tag information A (PI-100) included in the log text. This allows the operator to easily visually recognize that a predetermined operation function has been set for tag information A (PI-100) in the log text. Note that the tag information included in the log text may be colored differently from other characters, or may be highlighted.

[0062] Then, for example, when an operator selects the tag information A (PI-100) in the journal text, a predetermined operation function set for the tag information causes the journal device 10 and the process data management device 20 to execute a predetermined operation in cooperation with each other.

[0063] As an example of the predetermined operation, for example, diagram data associated with the selected tag information A (PI-100) or a list summarizing the diagram data is transmitted from the process data management device 20 to the logbook device 10, and the diagram data is displayed on the display unit 14 of the logbook device 10. As another example of the predetermined operation, for example, when the above-mentioned diagram data is displayed on the display unit 14 of the logbook device 10, an operation is performed in which an operator inputs a comment on the diagram data. As another example of the predetermined operation, for example, when the above-mentioned comment is input, an operation is performed in which the input comment and the diagram data are associated with the logbook text and managed and saved in the logbook device 10. As another example of the predetermined operation, for example, an operation is performed in which a predetermined icon is set for the diagram data with the comment, and when the operator selects the icon, the logbook device 10 reads the diagram data from the process data management device 20.

[0064] In step S6, the driving log function unit 11 stores the log sheet including the log text for which the processing of step S5 has been executed in the memory unit 13 as log information (operation information) of the driving log (operation log), and ends the flowchart of Fig. 2. Note that, unlike the above, the log text input to the log sheet may not include tag information managed and stored in the tag information memory unit 21. In this case, the driving log function unit 11 stores the log sheet including the log text in the memory unit 13 as log information of the driving log, without executing the operation of setting the predetermined operation function in step S5.

[0065] Fig. 3 is a flowchart showing another example of the operation of the plant management system 1 according to an embodiment. The flowchart in Fig. 3 starts when an input from an operator (not shown) is received and an operation log is created by the logbook device 10. In the flowchart in Fig. 3, the operation performed in cooperation between the logbook device 10 and the history data management device 30 is an example of a "predetermined second operation."

[0066] In step S11, the driving log function unit 11 of the log device 10 accepts an operation by the operator via the operation unit 12, reads out a log sheet desired by the operator from the storage unit 13, and displays it on the display unit 14.

[0067] In step S12, the driving log function unit 11 of the log device 10 receives the alarm history data managed and stored in the alarm history storage unit 31 of the history data management device 30 via the signal line 42. The alarm history data is managed and stored as list data 31a in the history data management device 30. Therefore, the driving log function unit 11 receives the alarm history data in the format of the list data 31a, for example.

[0068] The list data 31a may be received automatically when the operator reads the diary sheet, or may be received when the operator performs a predetermined operation via the operation unit 12, or may be received periodically.

[0069] In step S13, the driving log function unit 11 of the driving log device 10 displays the alarm history data on the display unit 14. For example, the driving log function unit 11 displays the alarm history data in the form of list data 31a superimposed as a sub-screen on the driving log sheet of the display unit 14. However, the display method is not limited to this, and the driving log function unit 11 may, for example, display the log sheet and the list data 31a separately, or display one of them in the background. Furthermore, the list data 31a may be displayed together with the list data 33a described below, for example, as a separate list, or may be displayed as a list arranged uniformly in chronological order.

[0070] The list data 31a may be displayed automatically when alarm history data is received by the logbook device 10, or may be displayed when a predetermined operation is performed by the operator via the operation unit 12, or may be displayed periodically.

[0071] Hereinafter, in this specification, alarm history or alarm history data will also be referred to as "alarm and event" or "A&E (Alarm and Event)", and list data 31a will also be referred to as "alarm and event list 31a" or "A&E list 31a".

[0072] Fig. 4 is a diagram showing a display example of list data (alarm & event list) 31a. As shown in Fig. 4, alarm & event list 31a includes, for example, the date and time when an abnormality or failure occurred, the location where it occurred, the details of the occurrence, the importance and seriousness of the abnormality or failure (for example, minor alarm, medium alarm, major alarm, etc.), tag information, process data, etc. Alarm & event list 31a also includes, for example, the date and time when the abnormality or failure was recovered from, the location where it was recovered from, the details of the recovery, etc.

[0073] In Figure 4, "HMI" stands for Human Machine Interface, "IC" stands for Interface Card, "CTR" stands for Control, and "SVR" stands for Server. "HI" is not a meaningful abbreviation, but a station name that can be arbitrarily designated by the user.

[0074] Returning to Figure 3, in step S14, the driving log function unit 11 of the log device 10 accepts operation by the operator via the operation unit 12 and accepts the operator's selection of the desired A&E message from the A&E list 31a displayed on the display unit 14.

[0075] Fig. 5 is a diagram showing an example of a display on the display unit 14 of the diary device 10. In Fig. 5, what is shown on the back is a screen for inputting diary text for the diary sheet, and the "Duty Alarm & Event List" shown superimposed (as a pop-up) on the left side is the A&E list 31a. Fig. 5 shows that the fourth A&E from the top has been selected by the operator.

[0076] 3, in step S15, when the driving log function unit 11 of the log device 10 receives the selection of the A&E message in step S14, the driving log function unit 11 transcribes the selected A&E message into a log sentence in the driving log. For example, as shown in Fig. 5, the driving log function unit 11 receives the transcription or recording of the fourth A&E message from the top selected by the operator in the A&E list 31a displayed on the left side of the display unit 14 into a log sentence in the lower right.

[0077] In step S16, when the driving log function unit 11 of the log device 10 accepts transcription of the A&E message selected in step S15 into the log text of the driving log, the driving log function unit 11 accepts operation by the operator via the operation unit 12 and accepts input of a comment. For example, as shown in the lower right of FIG. 5, when the driving log function unit 11 accepts transcription of the fourth A&E message from the top selected by the operator in the A&E list 31a displayed on the left side of the display unit 14 into the log text, the driving log function unit 11 accepts input of a comment. The comment may additionally record, for example, handover matters, transfer matters, details of changes in driving operation, reasons for performing the operation, details of alarm occurrence, cause of occurrence, details of alarm recovery, cause of recovery, etc. It is also possible to additionally record at least one of the cause of alarm occurrence and the reason for operation into the comment.

[0078] In step S17, the driving log function unit 11 stores the log sheet including the log text processed in step S16 in the storage unit 13 as log information (operation information) of the driving log, and ends the flowchart of FIG. 3 . As a result, even if the location of the information-system log device 10 and the location of the control-system history data management device 30 are far apart, the operator can record the operation details and the cause of the A&E occurrence, etc., in association with each other in the driving log with a single click, without having to transcribe the information onto paper. This allows for quick recording and also prevents information from being lost. Furthermore, by storing the operation details and the cause of the A&E occurrence, etc., in association with each other, the operation details and the cause of the A&E occurrence, etc. can be linked at a later stage for search, analysis, big data analysis, etc.

[0079] Unlike the above, the operator may not display, select, or transcribe A&E, or input comments about A&E, etc. In this case, the driving log function unit 11 stores the log sheet including the log text in the memory unit 13 as log information (operation information) of the driving log, without executing the operations shown in steps S13 to S16, for example.

[0080] Fig. 6 is a flowchart showing another example of the operation of the plant management system 1 according to an embodiment. The flowchart in Fig. 6 starts when an input from an operator (not shown) is received and an operation log is created by the logbook device 10. In the flowchart in Fig. 6, the operation performed in cooperation between the logbook device 10 and the history data management device 30 is an example of a "predetermined second operation."

[0081] In step S21, the driving log function unit 11 of the log device 10 accepts an operation by the operator via the operation unit 12, reads out a log sheet desired by the operator from the storage unit 13, and displays it on the display unit 14.

[0082] In step S22, when the operator performs a specified operating operation on the plant, the operation log function unit 11 of the log device 10 receives the operation history data managed and stored in the operation history memory unit 33 of the history data management device 30 via signal line 42.

[0083] For example, at a manufacturing site of a plant, for stable operation, an operator changes the operation based on alarm and event information issued from a DCS (not shown). The change in operation may be made on-site by an operator in a control room or may be made by visiting the manufacturing site of the plant.

[0084] When a driving operation change is made, the operation history of the change is managed and stored as operation history data in the operation history storage unit 33 of the history data management device 30. The operation history data is managed and stored as list data 33a in the history data management device 30. Therefore, the driving log function unit 11 receives the operation history data in the format of the list data 33a, for example.

[0085] The list data 33a may be received automatically when the operator reads the diary sheet, or may be received when the operator performs a predetermined operation via the operation unit 12, or may be received periodically.

[0086] In step S23, the driving log function unit 11 of the driving log device 10 displays the operation history data on the display unit 14. For example, the driving log function unit 11 displays the operation history data in the form of list data 33a superimposed as a sub-screen on the driving log sheet of the display unit 14. However, the display method is not limited to this, and the driving log function unit 11 may, for example, display the log sheet and the list data 33a separately, or display one of them in the background. Furthermore, the list data 33a may be displayed together with the above-mentioned A&E list 31a, for example, as a separate list, or may be displayed as a list arranged uniformly in chronological order.

[0087] The list data 33a may be automatically displayed when an operator changes an operation on-site or when operation history data is received by the logbook device 10. The list data 33a may be displayed when an operator performs a predetermined operation via the operation unit 12, or may be displayed periodically. The list data 33a includes, for example, the date and time when the operation was performed, the location where the operation was performed, the operation content, tag information, process data, etc. Hereinafter, in this specification, the operation history data may also be simply referred to as "operation history," and the list data 33a may also be referred to as "operation history list 33a."

[0088] In step S24, the driving log function unit 11 of the log device 10 accepts an operation by the operator via the operation unit 12, and accepts the selection of a desired operation history message by the operator from the operation history list 33a displayed on the display unit 14. For example, while the above-mentioned FIG. 5 shows an example of the A&E list 31a, the same applies to the operation history list 33a.

[0089] In step S25, when the driving log function unit 11 of the log device 10 receives the selection of the operation history message in step S24, the driving log function unit 11 transcribes the selected operation history message into the log text of the driving log. For example, in the above-mentioned FIG. 5, an example is shown in which the A&E message selected in the A&E list 31a is transcribed into the log text on the screen for inputting the log text, but the same applies to the operation history message.

[0090] In step S26, when the driving log function unit 11 of the log device 10 accepts the transcription of the operation history message selected in step S25 to the log text of the driving log, it accepts an operation by the operator via the operation unit 12 and accepts the input of a comment. For example, FIG. 5 above shows an example in which the input of a comment is accepted when the transcription of an A&E message to the log text is accepted, but the same applies when the transcription of a message from the operation history to the log text is accepted. The comment may additionally record, for example, handover matters, transfer matters, driving operation changes, reasons for performing the operation, alarm occurrence details, cause of occurrence, alarm recovery details, and recovery causes. It is also possible to additionally record at least one of the cause of the alarm and the reason for the operation in the comment.

[0091] Fig. 7 is a diagram showing an example of a comment entered in addition to a journal entry. As shown in Fig. 7, for example, an operation purpose (reason for operation) and operation details such as "to lower the XX tower cooler temperature" or "the cooler fan fin angle was reduced" may be entered. Also, as shown in Fig. 7, for example, an operation purpose (reason for operation) and operation details such as "to reduce the load," "the XX tower reboiler flow rate was increased," or "the air flow rate was increased" may be entered.

[0092] Returning to FIG. 6 , in step S27, the driving log function unit 11 of the driving log device 10 stores the driving log sheet including the driving log text processed in step S26 in the storage unit 13 as driving log information (operation information) of the driving log, and the flowchart of FIG. 6 ends. As a result, even if the location of the information-related driving log device 10 and the location of the control-related history data management device 30 are far apart, the operator can record the operation details and the operation purpose (reason for the operation) in association with each other in the driving log with a single click, without transcribing the details to paper. This enables quick recording and also prevents information from being lost. Furthermore, by storing the operation details and the operation purpose (reason for the operation) in association with each other, the operation details and the operation purpose (reason for the operation) can be linked at a later stage to perform search, analysis, big data analysis, and the like.

[0093] Unlike the above, the operator may not display, select, or transcribe the operation history, or may not input comments about the operation history, etc. In this case, the driving log function unit 11 stores the log sheet including the log text in the memory unit 13 as log information (operation information) of the driving log, without performing the operations shown in steps S23 to S26, for example.

[0094] 7, when an operator inputs a comment or the like, the driving log function unit 11 stores the input operation history of the DCS (not shown) in the storage unit 13 of the log device 10. This allows not only the operation content but also the operation purpose and the operation content to be stored as a set in the log device 10.

[0095] FIG. 8 is a flowchart illustrating another example of the operation of the plant management system 1 according to an embodiment. The flowchart of FIG. 8 is started, for example, when an operator (not shown) finds a highly serious (important) A&E in the A&E list 31a displayed on the display unit 14 of the logbook device 10. Alternatively, the flowchart of FIG. 8 is started, for example, when an operator (not shown) needs to perform a predetermined operation on the plant (or a DCS (not shown)). In this case, "highly serious (important) A&E" includes not only a serious equipment failure but also, for example, an event that may affect the quality of products manufactured in the plant. That is, it also includes, for example, a case where the rate of change of a measurement item related to product quality, such as pressure fluctuation, temperature fluctuation, flow rate, pH (potential of hydrogen), concentration, or the like, exceeds a predetermined value, or a case where the measurement value itself exceeds a predetermined value or falls below a predetermined reference value.

[0096] For example, whether or not an event is an "A&E of high seriousness (importance)" or whether or not an event is a "predetermined driving operation" may be selected and incorporated in advance, or may be selected and incorporated when the operation of the flowchart shown in FIG. 2 or 3 is executed. In this case, the flowchart in FIG. 8 may be automatically started when an event incorporated as an "A&E of high seriousness (importance)" or an event incorporated as a "predetermined driving operation" occurs (is displayed on the display unit 14). Therefore, in the following description, the operation of accepting a selection or operation by the operator also includes a case where an incorporated "A&E of high seriousness (importance)", "predetermined driving operation", etc. is automatically selected or input and accepted.

[0097] Note that the operations shown in steps S11 to S17 in Fig. 2 and the operations shown in steps S21 to S27 in Fig. 3 are performed as a prerequisite for the operations in the flowchart of Fig. 8. That is, the operation logbook stores the operation details and the cause of the A&E occurrence in association with each other, and also stores the operation details and the purpose of the operation (reason for the operation) in association with each other.

[0098] In step S31, the driving log function unit 11 of the log device 10 accepts an operation by the operator via the operation unit 12, and accepts, for example, a selection of an A&E message with a high level of seriousness (importance) from the A&E list 31a displayed on the display unit 14. Note that in step S31, the driving log function unit 11 may accept an operation by the operator via the operation unit 12, and accept an input of an operation purpose when a predetermined operation is performed on the plant (or a DCS, not shown).

[0099] Fig. 9 is a diagram showing an example of utilization of the operation example shown in the flowchart of Fig. 8. In Fig. 9, the same step numbers are assigned to operations corresponding to those shown in the flowchart of Fig. 8. For example, as the operation shown in step S31 of Fig. 8, as shown in step S31 of Fig. 9, the diary device 10 receives an input of an operation purpose of the DCS by the operator, such as "I want to reduce the load."

[0100] 8, in step S32, when the driving log function unit 11 of the log device 10 receives, for example, a selection of a message of A&E with a high degree of seriousness in step S31, the driving log function unit 11 searches for past log sentences related to past A&Es that are the same as or similar to the selected A&E. Also, in step S32, when the driving log function unit 11 of the log device 10 receives, for example, an input of an operation purpose by the operator in step S31, the driving log function unit 11 searches for past log sentences related to past operations that are the same as or similar to the input operation purpose.

[0101] For example, as shown in step S32 of Fig. 9, the diary device 10 searches for past diary entries related to past operations that are the same as or similar to the DCS operation purpose "I want to reduce the load" received from the operator. Note that the diary device 10 may search not only past diary entries but also past process data, alarm history, operation history, etc.

[0102] Returning to FIG. 8 , in step S33, the driving log function unit 11 of the log device 10 extracts log data (e.g., phrases in the log text) that match or are similar to the action taken by A&E, the operation purpose, the operation content, etc. from the searched log text. The extraction is performed, for example, by text analysis. For example, the driving log function unit 11 extracts log data that has a predetermined phrase in the selected A&E message or the input operation purpose. Note that what is extracted may not be the log data, but may be related process data, alarm history, operation history, etc., or may be both the log data and related process data, alarm history, operation history, etc.

[0103] For example, as shown in step S33 of Fig. 9, the diary device 10 performs text analysis to extract diary data having a DCS operation objective of "reducing the load." In the example shown in Fig. 9, two operation details, "XX operation valve pressure increased, air flow rate increased" and "XX tower reboiler flow rate increased, air flow rate increased," are extracted as matching the operation objective of "to reduce the load."

[0104] 8, in step S34, the operation log function unit 11 of the log device 10 detects frequently occurring treatment methods for A&E and frequently occurring operation contents for operation purposes from the extracted log data. The detection is performed, for example, by predetermined frequent pattern mining. Furthermore, the detection may be performed not only from the log data but also by big data analysis including related process data, alarm history, operation history, etc.

[0105] For example, as shown in step S34 of FIG. 9, the operation content "increased the air flow rate" is detected as being included in both of the two operation contents extracted as frequent patterns of operation contents that match the operation purpose of "wanting to reduce the load."

[0106] Returning to Fig. 8, in step S35, the driving log function unit 11 of the log device 10 provides operation support (driving support) to the operator based on the detected treatment method and operation content, and ends the flowchart of Fig. 8. The driving log function unit 11 provides operation support (driving support) to the operator by, for example, displaying an operation support (driving support) screen showing recommended treatment methods, operation content, operation guidance, etc. on the display unit 14 of the log device 10. This provides the operator with guidance such as how the operator's operation purpose has actually been handled (operated) in the past.

[0107] For example, as shown in step S35 of Fig. 9, an operation support (driving support) screen showing the operation content "increased the air flow rate" detected as a frequent operation content pattern is displayed to provide operation support (driving support) to the operator. Note that the operation support (driving support) is not limited to the display of text on the screen, but may also be provided by displaying reference data, links to websites, etc., or by playing still images, videos, audio, etc.

[0108] Fig. 10 is a diagram showing an example of a screen on which operation assistance is displayed. For example, as shown in Fig. 10, a plurality of recommended processing methods for an event that has occurred (A&E) may be displayed on the display unit 14 superimposed (as a pop-up) on the A&E list 31a in descending order of recommendation level or frequency.

[0109] 8, operation content is recommended using text analysis and frequent pattern mining, or based on big data analysis, and operation support (driving support) is provided to the operator. As a result, operation guidance is given to the operator based on the analysis of accumulated data accumulated in the logbook device 10, and it is possible to make efficient operation changes for, for example, A&E, operation purposes, etc.

[0110] 8 illustrates an example of the operation when an operator operates the logbook device 10. However, this is not limiting, and the same applies to, for example, the operation when an operator operates the process data management device 20 or the history data management device 30 in a control room (not shown). In this case, for example, as an example of the cooperative operation between the logbook device 10, the process data management device 20, and the history data management device 30, data managed and stored in each device may be transmitted and received between them and displayed on each device. Furthermore, each device may accept the selection of an A&E message or an operation history message from the A&E list 31a or the operation history list 33a displayed on any of these devices, and any of these devices may accept the input of an operation purpose.

[0111] That is, for example, when an operator operates the process data management device 20 or the history data management device 30 in a control room (not shown) or the like according to the flowchart shown in Fig. 8, an operation support screen may be displayed on the display unit of the operated device. Also, for example, when an operator operates the flowchart shown in Fig. 8 in any of the log book device 10, the process data management device 20, or the history data management device 30, an operation support screen may be displayed on the display units of all the devices, not just the operated device.

[0112] <Effects of one embodiment> As described above, according to the embodiment shown in Figures 1 to 10, it is possible to provide a plant management system that can improve the efficiency of plant management compared to conventional systems by associating the operation log with historical data without requiring cumbersome work.

[0113] 1 to 10, the logbook device 10, which is an information system device, and the process data management device 20, which is a control system device, operate in cooperation with each other (S1 to S6). This allows, for example, an operator to quickly view the operation logbook and process data. This allows manually input logbook text to be associated with process data automatically collected from the plant without requiring any cumbersome work. This enables improved work efficiency, rapid response when a problem occurs, and efficient transfer of know-how.

[0114] Furthermore, for example, in the past, it was difficult to link A&E information with information in the operation log (log), posing a challenge in the transfer of know-how for A&E events that occurred. Furthermore, the volume of A&E records required short periods of time and led to the problem of important A&E events being overlooked. However, according to the embodiment shown in FIGS. 1 to 10, the log device 10, which is an information-based device, and the history data management device 30, which is a control-based device, operate in cooperation with each other (S11 to S17, S21 to S27). This allows for the rapid and efficient association of important A&E and other history information with operational information. Furthermore, when operational procedures are changed, data relating past A&E events to operational information can be saved. This enables improved work efficiency, rapid response when problems occur, and efficient transfer of know-how.

[0115] 1 to 10, the logbook device 10, which is an information system device, and the history data management device 30, which is a control system device, operate in cooperation with each other (S11 to S17, S21 to S27, S31 to S35). That is, the operation logbook (operation logbook) can record not only the operation details but also the reasons leading to the operation, the purpose of the operation, the A&E details, the cause of the A&E, etc., as a set. As a result, according to the embodiment shown in FIGS. 1 to 10, in addition to the data on the operation details in the operation logbook, data on A&E, the purpose of the operation, etc. can be quickly and efficiently recorded, and further, these records can be analyzed to provide guidance to the operator.

[0116] For example, when an operator selects an A&E displayed on the monitoring screen of a plant's DCS, the history of past actions (control parameter adjustments) for that A&E is extracted from the operation log, and recommended actions are presented using techniques such as frequent pattern mining. This provides the operator with operational guidance based on an analysis of accumulated log data, enabling efficient operational changes. Furthermore, multiple recommended actions are presented, including actions that are rare overall but frequently combined with the recommended action. This prevents omissions in the presentation of operational guidance. Furthermore, even operators with limited operational experience can quickly find the recommended action they should take.

[0117] 1 to 10, the logbook device 10, which is an information-system device, and the process data management device 20 and history data management device 30, which are control-system devices, operate in cooperation with each other (S1 to S6, S11 to S17, S21 to S27, S31 to S35). As a result, the process data management device 20 and the history data management device 30, which are control-system devices, can also accept logbook text input by an operator using the logbook function of the logbook device 10, which is an information-system device. As a result, for example, an operator who is referring to process data, A&E, etc. in the process data management device 20 or the history data management device 30 can create an operation logbook on the spot as a matter to be passed on to a shift worker when he or she notices something.

[0118] In the past, for example, 100 to 200 A&E events and operation histories were generated per day. In this regard, the storage capacities of the alarm history storage unit 31 and the operation history storage unit 33 are limited, so that, for example, only about six months' worth of A&E events and operation histories could be stored. For this reason, in the past, A&E events and operation histories with high importance (seriousness) were often buried, or new histories were not saved or old histories were erased due to insufficient storage capacity of the alarm history storage unit 31 and the operation history storage unit 33. On the other hand, according to the embodiment shown in FIGS. 1 to 10 , for example, A&E events and operation histories with high importance (seriousness) are stored in the storage unit 13 of the diary device 10 together with diary entries. This prevents A&E events and operation histories with high importance (seriousness) from being buried, or from being not saved or erased due to insufficient storage capacity of the alarm history storage unit 31 and the operation history storage unit 33.

[0119] <Hardware configuration example> 11 is a conceptual diagram showing an example of the hardware configuration of the processing circuitry 90 included in the logbook device 10, the process data management device 20, and the history data management device 30 in the embodiments shown in FIGS. 1 to 10. The above-described functions are realized by the processing circuitry 90. In one aspect, the processing circuitry 90 includes at least one processor 91 and at least one memory 92. In another aspect, the processing circuitry 90 includes at least one dedicated hardware 93.

[0120] When the processing circuit 90 includes a processor 91 and a memory 92, each function is realized by software, firmware, or a combination of software and firmware. At least one of the software and firmware is written as a program. At least one of the software and firmware is stored in the memory 92. The processor 91 realizes each function by reading and executing the program stored in the memory 92.

[0121] When the processing circuitry 90 comprises dedicated hardware 93, the processing circuitry 90 may be, for example, a single circuit, multiple circuits, a programmed processor, or a combination thereof. Each function is implemented by the processing circuitry 90.

[0122] The functions of the diary device 10, the process data management device 20, and the history data management device 30 may be partially or entirely configured by hardware, or may be configured as a program executed by a processor. That is, the diary device 10, the process data management device 20, and the history data management device 30 can also be realized by a computer and a program, and the program can be stored in a storage medium or provided via a network.

[0123] <Supplementary information on the implementation form> 1 to 11, the operations of steps S1 to S6, steps S11 to S17, steps S21 to S27, and steps S31 to S35 have been described separately as one aspect of the present disclosure. However, this is not limiting, and these operations may be performed in any combination or simultaneously. Note that the operations of steps S1 to S35 are an example of the operations of "first step" to "seventh step."

[0124] 1 to 11, as one aspect of the present disclosure, the process data management device 20 and the history data management device 30, which are control system devices, have been described separately. However, this is not limiting, and a common device that combines these control system devices may also be used.

[0125] 1 to 11, the plant management system 1 is described as an example of one aspect of the present disclosure, in which the logbook device 10, the process data management device 20, and the history data management device 30 are combined. However, the present disclosure is not limited to this. The present disclosure can also be realized as a plant management device or a plant management system that is an independent (single) device.

[0126] The present disclosure can also be realized as a plant management method in which processing steps are performed in each of the log book device 10, the process data management device 20, and the history data management device 30.

[0127] The present disclosure can also be realized as a plant management program that causes a computer to execute processing steps in each of the log book device 10, the process data management device 20, and the history data management device 30.

[0128] The present disclosure can also be realized as a storage medium (non-transitory computer-readable medium) on which a plant management program is stored. The plant management program can be stored and distributed on a removable disk, such as a CD (Compact Disc), a DVD (Digital Versatile Disc), or a USB (Universal Serial Bus) memory. These programs may be uploaded to a network via a network interface (not shown) included in the plant management system 1, or may be downloaded from the network and stored in the memory 92.

[0129] The features and advantages of the embodiments will be apparent from the above detailed description. It is intended that the claims encompass the features and advantages of the above-described embodiments without departing from the spirit and scope of the claims. Furthermore, any improvements and modifications will be readily apparent to those skilled in the art. Therefore, it is not intended that the scope of the inventive embodiments be limited to the above-described embodiments, and appropriate improvements and equivalents within the scope of the disclosed embodiments may be utilized. [Explanation of symbols]

[0130] 1...Plant management system; 10...Logbook device; 11...Operation log function section; 12...Operation section; 13...Memory section; 14...Display section; 20...Process data management device; 21...Tag information memory section; 22...Process data memory section; 22a...Trend graph; 22b...Graphics; 30...History data management device; 31...Alarm history memory section; 31a...List data (alarm & event list, A&E list); 32...Alarm history display section; 33...Operation history memory section; 33a...List data (operation history list); 34...Operation history display section; 41...Signal line; 41a...Gateway; 42...Signal line; 42a...Gateway; 43...Signal line; 90...Processing circuit; 91...Processor; 92...Memory; 93...Hardware; A...Tag information

Claims

1. a logbook device having a logbook function for recording logbook text including contact information related to plant operation; a process data management device that manages process data acquired during plant operation and performs a predetermined first operation in cooperation with the logbook device by transmitting and receiving information to and from the logbook device; a history data management device that manages alarm history data and operation history data acquired during plant operation, and performs a predetermined second operation in cooperation with the log book device by transmitting and receiving information to and from the log book device; Equipped with the process data management device manages identification information for identifying measuring instruments installed in the plant, The process data management device performs the following as the predetermined first operation: a first step of searching whether the identification information managed in the process data management device is included in the journal text when the journal text is input in a free format in the journal device; a second step of setting a predetermined operation function for the identification information in the diary sentence when the identification information is included in the diary sentence in the first step; A plant management system characterized by carrying out the above.

2. In the plant management system according to claim 1, The history data management device managing history data configured using a plurality of alarm history data and a plurality of operation history data, the history data having the identification information and the process data; The historical data includes: The history data is managed as list data in the history data management device, The history data management device performs the following as the predetermined second operation: a third step of displaying the list data managed in the history data management device when the screen for inputting the journal text is displayed; a fourth step of recording the selected history data as the journal entry when the list data is displayed in the third step and any one of the history data is selected from the displayed list data; a fifth step of receiving additional input of at least one of a cause of alarm generation and a reason for operation for the recorded journal text when the history data is recorded as the journal text in the fourth step; A plant management system characterized by carrying out the above.

3. 3. The plant management system according to claim 2, The diary device is a sixth step of searching for past journal sentences related to past history data that is the same as or similar to the selected history data when the list data is displayed in the third step and any one of the history data is selected from the displayed list data; a seventh step of displaying a predetermined operation support screen based on the past journal sentences retrieved in the sixth step; A plant management system characterized by carrying out the above.

4. 4. The plant management system according to claim 3, At least one of the process data management device and the history data management device is The diary function of the diary device can be used to accept input of the diary text and / or display the predetermined operation support screen. A plant management system characterized by:

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