一、概述
　 　中國石油大慶石化公司，是中國石油天然氣股份有限公司直屬的地區(qū)分公司，從事煉油、化工、化肥、化纖生產的特大型石油化工聯(lián)合企業(yè)?，F(xiàn)有6個生產廠，2 個輔助生產廠。公司擁有生產裝置131套，年原油加工能力600萬噸，年產乙烯48萬噸，聚乙烯36萬噸，腈綸纖維6萬噸，合成氨33萬噸，尿素56萬 噸，可生產60種151個牌號的石油化工產品。大慶石化公司的前身大慶石油化工總廠，是我國較早的石油化工企業(yè)之一，也是我國重要的石油化工基地。大慶 石化公司在緊抓生產建設的同時，也非常注重信息化建設。
　　 全球信息技術飛速發(fā)展,尤其是因特網的出現(xiàn)和應用的普及,使得信息技術得以迅速滲透到 經濟社會的各個領域,標志著人類進入了信息化時代。信息資源已成為與材料和能源同等重要的戰(zhàn)略資源；信息技術正以其廣泛的滲透性和無與倫比的先進性與傳統(tǒng) 產業(yè)結合；信息產業(yè)已發(fā)展為世界范圍內的朝陽產業(yè)和新的經濟增長點；信息化水平已經成為現(xiàn)代化企業(yè)水平和綜合實力的重要標志。大慶石化公司經過多年的努 力，在信息化建設中已取得了很大進步，如辦公自動化，電子商務。尤其是生產過程自動化，經過多年努力，大慶石化公司全面實現(xiàn)了DCS自動化改造。但是在實 現(xiàn)全廠信息化建設之前，還存在如下問題：
　　 1）生產數(shù)據(jù)沒有有效共享，因而對影響生產過程的主要因素缺乏有效的監(jiān)控手段。雖然公司的主要生產裝 置都安裝了DCS，但絕大部分裝置的數(shù)據(jù)只能顯示在裝置的操作站上，而沒有采集到公司或分廠的辦公系統(tǒng)中。這樣我們只有到各生產裝置的控制室，才能觀察到 生產數(shù)據(jù)，在分廠的調度室，辦公室，或公司領導，都無法直接看到現(xiàn)場的生產數(shù)據(jù)。如果出差在外，想了解一下生產情況就更是無能為力了。在當今互聯(lián)網把大千 世界聯(lián)在一起的今天，不能不說是一種遺憾！
　　 2）分散的“信息孤島”無法進行集中化管理。由于各裝置信息封閉，即使在同一分廠，由于采用的是不 同廠家，或同一廠家不同型號的DCS，彼此間沒有數(shù)據(jù)通訊手段。這致使生產管理的各個環(huán)節(jié)脫節(jié)，生產管理部門不能及時、有效地了解生產狀況，指導組織生 產，造成了一定的浪費。
　　 3）沒有長期的歷史數(shù)據(jù)存儲。隨著存儲介質價格不斷下降，保存海量歷史數(shù)據(jù)不但是必要的，而且是現(xiàn)實的。而DCS本身的歷史數(shù)據(jù)存儲能力一般都比較有限，而長期的歷史數(shù)據(jù)有助于事故診斷。
　 　4）質量信息反饋滯后，導致加工成本增加?；灁?shù)據(jù)直接反映生產的質量情況，對指導生產具有非常重要的意義。先前這些數(shù)據(jù)主要通過手工報表形式報送生產 管理部門，造成信息遲滯，并且不利于對比分析。因此及時準確地將質量數(shù)據(jù)反饋給裝置操作人員和生產調度人員，可以保證有效地控制生產質量、降低生產成本。
　　 5）無法實現(xiàn)全廠信息瀏覽。如何讓公司領導用統(tǒng)一平臺直觀的看到各分廠的生產報表，統(tǒng)計數(shù)據(jù)，對于領導決策非常重要。
　 　通過上面的分析，我們不難看出，如何將分散的“信息孤島”有效地連接起來，實行網絡化、集中化，將生產過程數(shù)據(jù)與生產管理系統(tǒng)有機連接起來；把生產過程 信息、原料消耗、過程產品產量、產品產量、能源消耗、設備狀態(tài)等科學地分類，提供給管理層數(shù)據(jù)庫，從而減少人工操作，提高管理層數(shù)據(jù)庫的準確性，提高公司 的控制力和控制質量。同時也能夠使企業(yè)的先進控制、優(yōu)化計算，流程模擬等更加方便。
　　
　　 二、實施方案
　　 公司信息化內容很多，如裝置達標，LIMS，質量統(tǒng)計，價格管理，成本核算，生產信息化。其中生產信息化是整個系統(tǒng)的基礎，由于篇幅的限制，這里著重對其進行介紹。
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title="實時數(shù)據(jù)庫">實時數(shù)據(jù)庫" title="實時數(shù)據(jù)庫">實時數(shù)據(jù)庫" title="實時數(shù)據(jù)庫">實時數(shù)據(jù)庫" title="實時數(shù)據(jù)庫">實時數(shù)據(jù)庫" title="實時數(shù)據(jù)庫">實時數(shù)據(jù)庫" title="實時數(shù)據(jù)庫">實時數(shù)據(jù)庫是整個信息系統(tǒng)的核心，實時數(shù)據(jù)庫軟件采用大慶紫金橋公司自己開發(fā)的?“紫金橋實時數(shù)據(jù)庫”。該實時數(shù)據(jù)庫在公司多個分廠有過成功應用。關系庫采用的是SQL Server。整體結構如下圖所示：
　　
　　

　　 整體結構圖

　　
　　 由上圖可見，整個結構分為四層，第一層為公司級實時數(shù)據(jù)庫；第二層為分廠級實時數(shù)據(jù)庫，每個分廠一臺；第三層為分廠的前端數(shù)采機；底層為過程控制計算機。下面對各層計算機功能予以說明。
　　
　　 過程控制計算機：完成控制監(jiān)視功能。大慶石化公司控制計算機種類較多，可分為DCS、ESD、PLC、智能表等，但主要是DCS。
　　
　 　前端數(shù)采機：進行數(shù)據(jù)采集，與過程控制計算機通信，將數(shù)據(jù)緩存并傳送給分廠級實時數(shù)據(jù)庫。前端數(shù)采機將各種類型的過程控制計算機的實時數(shù)據(jù)匯總，通過以 太網統(tǒng)一送往分廠級實時數(shù)據(jù)庫，也可以在上游網絡故障時，暫存一段時間的歷史數(shù)據(jù)，當網絡恢復時，將數(shù)據(jù)轉存到分廠級實時數(shù)據(jù)庫。
　　
　　 分廠級實時數(shù)據(jù)庫：用于分廠生產數(shù)據(jù)緩存、歷史存儲、數(shù)據(jù)計算等。具體包括：
　　 1、在這里可以對實時數(shù)據(jù)進行校正、補償、累計、統(tǒng)計等計算。
　　 2、可以對各車間數(shù)據(jù)進行橫向比較分析。
　　 3、也可以在此完成設備運行情況統(tǒng)計，裝置物料平衡計算，生成質量分析報告，或其他統(tǒng)計報表等。
　　 4、分廠內的其他計算機可以通過該服務器對裝置的實時數(shù)據(jù)、歷史數(shù)據(jù)、統(tǒng)計數(shù)據(jù)進行查看。
　　 5、通過該服務器上的Web服務器，可以直接通過IE瀏覽器瀏覽各種生產數(shù)據(jù)。
　　 6、與公司級實時數(shù)據(jù)庫通信。將公司關心的重要生產數(shù)據(jù)上傳到公司級實時數(shù)據(jù)庫中。
　　 7、該服務器還要作為用戶登錄服務器。只有有相關權限的用戶才能訪問該服務器中受保護的數(shù)據(jù)。用戶登錄要在該服務器上驗證。
　　
　　 公司級實時數(shù)據(jù)庫：分廠重要生產參數(shù)緩存、歷史存儲等。另外還包括如下功能：
　　 1）分廠數(shù)據(jù)橫向比較、統(tǒng)計、分析。
　　 2）作為Web服務器，該機器有固定IP，可以在互聯(lián)網上通過IE瀏覽器訪問該服務器的實時數(shù)據(jù)、歷史數(shù)據(jù)等。
　　 3）該服務器可以作為分廠服務器的代理Web服務器，通過該服務器可以在互聯(lián)網上間接訪問分廠數(shù)據(jù)。
　　 作為登錄服務器。訪問該服務器數(shù)據(jù)的用戶要經過該登錄服務器的驗證。訪問分廠數(shù)據(jù)還要經過分廠級數(shù)據(jù)庫用戶驗證。
　　 三、數(shù)采方案
　　 1、概述
　　 數(shù)據(jù)采集是實時數(shù)據(jù)庫的重要組成部分，它負責將現(xiàn)場數(shù)據(jù)實時傳送給數(shù)據(jù)庫，將操作數(shù)據(jù)下送到現(xiàn)場，是數(shù)據(jù)庫服務器與生產控制系統(tǒng)連接的橋梁。如果沒有穩(wěn)定、高效、豐富的數(shù)采接口，實時數(shù)據(jù)庫只能是空中樓閣。
　　 紫金橋軟件具有豐富的I/O接口，能夠與各種DCS，PLC，智能儀表通過多種連接方式，如以太網、串口、撥號等。并支持DDE、OPC、設備專有通信協(xié)議等。同一數(shù)據(jù)庫可以同時與任意多種驅動程序進行通訊。下圖為數(shù)采結構圖。
　　
　　

　　數(shù)采結構圖

　　
　　 圖中的I/O驅動就是各種數(shù)采接口。
　　 本項目的關鍵是實現(xiàn)各分廠生產裝置的數(shù)據(jù)采集。由于大慶石化公司分廠很多，自控裝置種類繁多，有大量的DCS、PLC、智能表等。通信方式多種多樣。如有的通過OPC，有的通過DDE，有的是廠家專有協(xié)議；網絡連接方式也很多，如以太網、串口、現(xiàn)場總線等。
　　 2、關鍵問題
　　 辦公網與控制網隔離
　　 保證自控裝置的安全是致關重要的。為了保證控制網的獨立性，辦公網與控制網間是完全隔離的。實時數(shù)據(jù)庫運行在辦公網一側，為了安全的與控制設備通信，我們采取了多種措施。
　　 1）在控制網與辦公網分別設置數(shù)采機，數(shù)采機間通過串口相連，這樣能夠有效的防止網絡病毒侵入。
　　
　　

　　 串口通訊防病毒
　　
　　 為了提高串口的通信速度可以將兩臺前置數(shù)采機器放的很近，這樣可以將串口通信速度設的很高如112K。對于較遠的可以采用485方式通信。
　　 2）機器配置兩塊網卡，一塊網卡與控制網相連，一塊與辦公網相連，而且兩塊網卡處于不同網段。除了數(shù)據(jù)通信用到的端口號，其余通信端口都禁止掉。并且裝好防火墻，保持防病毒軟件及時自動更新。
　　
　　

　　 雙網卡通訊防病毒

　　
　　 3）數(shù)據(jù)集中到VAX/ALPHA機，以VAX/ALPHA為橋梁實現(xiàn)辦公網與控制網相連。VAX/ALPHA運行的是VMS操作系統(tǒng)，安全性較高。并且很多裝置的上位機是VAX/ALPHA，所以通過VAX/ALPHA為中轉，是比較方便的。
　　 斷線數(shù)據(jù)自動恢復
　 　由于大慶石化公司裝置很多，距離較遠，再加上現(xiàn)場干擾多，所以網絡通信并不是十分可靠，網絡故障時而發(fā)生。紫金橋實時數(shù)據(jù)庫具有斷線后數(shù)據(jù)自動恢復功 能，即當網絡出現(xiàn)故障時，前端數(shù)采機能夠自動將數(shù)據(jù)保存起來，當網絡恢復時將歷史數(shù)據(jù)插入到遠程實時數(shù)據(jù)庫。利用該功能，就不必擔心歷史數(shù)據(jù)缺失了。
　　 手工數(shù)據(jù)錄入
　　 為化驗人員提供化驗數(shù)據(jù)計算處理和錄入界面，以便將生產化驗數(shù)據(jù)收集到實時數(shù)據(jù)庫。紫金橋實時數(shù)據(jù)庫有專門的人工錄入記錄點和操作界面，能夠保證用戶在合理的時間范圍內錄入數(shù)據(jù)，并將數(shù)據(jù)按照填寫的時間插入到歷史數(shù)據(jù)庫中。對于超期沒有錄入的數(shù)據(jù)給出報警。
　　 四、生產管理信息系統(tǒng)帶來的好處
　　 1)及時了解生產動態(tài)。分廠級管理人員隨時了解生產裝置、公用工程運行狀況，包括監(jiān)控點的溫度、壓力、流量等實時數(shù)據(jù)；物料和能源動力消耗數(shù)據(jù)、產品產量和質量數(shù)據(jù)。各級人員及時準確掌握生產動態(tài)，對生產過程中出現(xiàn)的問題及時做出處理，以保證生產安穩(wěn)運行。
　 　2)實時數(shù)據(jù)庫作為控制系統(tǒng)和上層管理系統(tǒng)的中間層，起到承上啟下的作用。其將各控制系統(tǒng)的數(shù)據(jù)集中起來，以統(tǒng)一的形式存放，實現(xiàn)了有效的數(shù)據(jù)共享。由 于實時數(shù)據(jù)庫支持各種開放接口，如OPC、DDE、OLE等，因此保存在實時數(shù)據(jù)庫中的數(shù)據(jù)可直接為先進控制、優(yōu)化控制、流程模擬的數(shù)據(jù)源。另外、也可以 將與上層管理系統(tǒng)相關的數(shù)據(jù)，轉儲到關系數(shù)據(jù)庫中，以實現(xiàn)高層次的生產記錄管理。
　　 3)實現(xiàn)長期歷史存儲。一般DCS中歷史數(shù)據(jù)保存時間較短， 尤其是早期投用的DCS，外存較小，無法長期保存大量的，快速變化的歷史數(shù)據(jù)。而通用的實時數(shù)據(jù)庫具有高效的存儲策略，再加上廉價的大容量的存儲介質，可 以將重要的生產參數(shù)長期保存，現(xiàn)在各裝置歷史數(shù)據(jù)可以保存10年。
　　 4)提供多種數(shù)據(jù)查詢、分析手段。通過查詢工具可以快速查詢生產實時數(shù)據(jù)、歷史數(shù)據(jù)；分析工具可以對產品的生產質量進行評定，給管理者決策提供幫助；統(tǒng)計工具，可以對數(shù)據(jù)進行橫向比較，也可以對數(shù)據(jù)的歷史情況進行分析。
　　 5)與桌面工具集成。可以將生產數(shù)據(jù)引入辦公軟件，如Excel，Word等，可利用辦公軟件的圖表、分析工具對生產數(shù)據(jù)進行統(tǒng)計、分析、報表等。
　　 6)實現(xiàn)了Web瀏覽。無論何時何地，只要有互聯(lián)網，就可以隨時查看各裝置的實時生產數(shù)據(jù)，歷史趨勢，統(tǒng)計報表等。而且在機器中不必預先安裝實時數(shù)據(jù)庫軟件。
　　 7)通過數(shù)據(jù)庫瀏覽器，可以對分廠的數(shù)據(jù)、報表、流程圖、趨勢進行查看。只要分廠的數(shù)據(jù)庫是開放的，有權限的用戶都可以訪問，并且無需將組態(tài)內容復制到本地，紫金橋數(shù)據(jù)庫具有自動搜索功能，能夠自動找到網內的所有實時數(shù)據(jù)庫。
　　 8）只要權限允許，可以在客戶端瀏覽數(shù)據(jù)的同時，在線修改點組態(tài)、畫面、報表、趨勢，并能上傳到實時數(shù)據(jù)庫。
　　 五．結論
　　 通過信息系統(tǒng)的集成，實現(xiàn)整個公司作為一個整體意義上的信息系統(tǒng)，使得各個分公司實現(xiàn)信息共享，減少重復工作，打破信息孤島現(xiàn)象，提高了工作效率。
　　 紫金橋實時數(shù)據(jù)庫自投用以來，運行穩(wěn)定，采集速度快，歷史保存時間長，是信息化建設中的好幫手。