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(chǎn)的特大型石油化工聯(lián)合企業(yè)?，F(xiàn)有6個生產(chǎn)廠，2 個輔助生產(chǎn)廠。公司擁有生產(chǎn)裝置131套，年原油加工能力600萬噸，年產(chǎn)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(chǎn)60種151個牌號的石油化工產(chǎn)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(chǎn)建設(shè)的同時，也非常注重信息化建設(shè)。
　　 全球信息技術(shù)飛速發(fā)展,尤其是因特網(wǎng)的出現(xiàn)和應(yīng)用的普及,使得信息技術(shù)得以迅速滲透到 經(jīng)濟社會的各個領(lǐng)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(shù)正以其廣泛的滲透性和無與倫比的先進性與傳統(tǒng) 產(chǎn)業(yè)結(jié)合；信息產(chǎn)業(yè)已發(fā)展為世界范圍內(nèi)的朝陽產(chǎn)業(yè)和新的經(jīng)濟增長點；信息化水平已經(jīng)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(jīng)過多年的努 力，在信息化建設(shè)中已取得了很大進步，如辦公自動化，電子商務(wù)。尤其是生產(chǎn)過程自動化，經(jīng)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(shè)之前，還存在如下問題：
　　 1）生產(chǎn)數(shù)據(jù)沒有有效共享，因而對影響生產(chǎn)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(chǎn)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(chǎn)裝置的控制室，才能觀察到 生產(chǎn)數(shù)據(jù)，在分廠的調(diào)度室，辦公室，或公司領(lǐng)導(dǎo)，都無法直接看到現(xiàn)場的生產(chǎn)數(shù)據(jù)。如果出差在外，想了解一下生產(chǎn)情況就更是無能為力了。在當(dāng)今互聯(lián)網(wǎng)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(chǎn)管理的各個環(huán)節(jié)脫節(jié)，生產(chǎn)管理部門不能及時、有效地了解生產(chǎn)狀況，指導(dǎo)組織生 產(chǎn)，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(zhì)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(zhì)量信息反饋滯后，導(dǎo)致加工成本增加?；灁?shù)據(jù)直接反映生產(chǎn)的質(zhì)量情況，對指導(dǎo)生產(chǎn)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(chǎn) 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(zhì)量數(shù)據(jù)反饋給裝置操作人員和生產(chǎn)調(diào)度人員，可以保證有效地控制生產(chǎn)質(zhì)量、降低生產(chǎn)成本。
　　 5）無法實現(xiàn)全廠信息瀏覽。如何讓公司領(lǐng)導(dǎo)用統(tǒng)一平臺直觀的看到各分廠的生產(chǎn)報表，統(tǒng)計數(shù)據(jù)，對于領(lǐng)導(dǎo)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(wǎng)絡(luò)化、集中化，將生產(chǎn)過程數(shù)據(jù)與生產(chǎn)管理系統(tǒng)有機連接起來；把生產(chǎn)過程 信息、原料消耗、過程產(chǎn)品產(chǎn)量、產(chǎn)品產(chǎn)量、能源消耗、設(shè)備狀態(tài)等科學(xué)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(zhì)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(nèi)容很多，如裝置達標，LIMS，質(zhì)量統(tǒng)計，價格管理，成本核算，生產(chǎn)信息化。其中生產(chǎn)信息化是整個系統(tǒng)的基礎(chǔ)，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?qū)崟r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(yīng)用。關(guān)系庫采用的是SQL Server。整體結(jié)構(gòu)如下圖所示：
　　
　　

　　 整體結(jié)構(gòu)圖

　　
　　 由上圖可見，整個結(jié)構(gòu)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(wǎng)統(tǒng)一送往分廠級實時數(shù)據(jù)庫，也可以在上游網(wǎng)絡(luò)故障時，暫存一段時間的歷史數(shù)據(jù)，當(dāng)網(wǎng)絡(luò)恢復(fù)時，將數(shù)據(jù)轉(zhuǎn)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(chǎn)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(shè)備運行情況統(tǒng)計，裝置物料平衡計算，生成質(zhì)量分析報告，或其他統(tǒng)計報表等。
　　 4、分廠內(nèi)的其他計算機可以通過該服務(wù)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(wù)器上的Web服務(wù)器，可以直接通過IE瀏覽器瀏覽各種生產(chǎn)數(shù)據(jù)。
　　 6、與公司級實時數(shù)據(jù)庫通信。將公司關(guān)心的重要生產(chǎn)數(shù)據(jù)上傳到公司級實時數(shù)據(jù)庫中。
　　 7、該服務(wù)器還要作為用戶登錄服務(wù)器。只有有相關(guān)權(quán)限的用戶才能訪問該服務(wù)器中受保護的數(shù)據(jù)。用戶登錄要在該服務(wù)器上驗證。
　　
　　 公司級實時數(shù)據(jù)庫：分廠重要生產(chǎn)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(wù)器，該機器有固定IP，可以在互聯(lián)網(wǎng)上通過IE瀏覽器訪問該服務(wù)器的實時數(shù)據(jù)、歷史數(shù)據(jù)等。
　　 3）該服務(wù)器可以作為分廠服務(wù)器的代理Web服務(wù)器，通過該服務(wù)器可以在互聯(lián)網(wǎng)上間接訪問分廠數(shù)據(jù)。
　　 作為登錄服務(wù)器。訪問該服務(wù)器數(shù)據(jù)的用戶要經(jīng)過該登錄服務(wù)器的驗證。訪問分廠數(shù)據(jù)還要經(jīng)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(zé)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(wù)器與生產(chǎn)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(wǎng)、串口、撥號等。并支持DDE、OPC、設(shè)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(qū)動程序進行通訊。下圖為數(shù)采結(jié)構(gòu)圖。
　　
　　

　　數(shù)采結(jié)構(gòu)圖

　　
　　 圖中的I/O驅(qū)動就是各種數(shù)采接口。
　　 本項目的關(guān)鍵是實現(xiàn)各分廠生產(chǎn)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(wǎng)絡(luò)連接方式也很多，如以太網(wǎng)、串口、現(xiàn)場總線等。
　　 2、關(guān)鍵問題
　　 辦公網(wǎng)與控制網(wǎng)隔離
　　 保證自控裝置的安全是致關(guān)重要的。為了保證控制網(wǎng)的獨立性，辦公網(wǎng)與控制網(wǎng)間是完全隔離的。實時數(shù)據(jù)庫運行在辦公網(wǎng)一側(cè)，為了安全的與控制設(shè)備通信，我們采取了多種措施。
　　 1）在控制網(wǎng)與辦公網(wǎng)分別設(shè)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(wǎng)絡(luò)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(shè)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(wǎng)卡，一塊網(wǎng)卡與控制網(wǎng)相連，一塊與辦公網(wǎng)相連，而且兩塊網(wǎng)卡處于不同網(wǎng)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(wǎng)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(wǎng)與控制網(wǎng)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(zhuǎn)，是比較方便的。
　　 斷線數(shù)據(jù)自動恢復(fù)
　 　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(wǎng)絡(luò)通信并不是十分可靠，網(wǎng)絡(luò)故障時而發(fā)生。紫金橋?qū)崟r數(shù)據(jù)庫具有斷線后數(shù)據(jù)自動恢復(fù)功 能，即當(dāng)網(wǎng)絡(luò)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(dāng)網(wǎng)絡(luò)恢復(fù)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(dān)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(chǎn)化驗數(shù)據(jù)收集到實時數(shù)據(jù)庫。紫金橋?qū)崟r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(nèi)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(chǎn)管理信息系統(tǒng)帶來的好處
　　 1)及時了解生產(chǎn)動態(tài)。分廠級管理人員隨時了解生產(chǎn)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(chǎn)品產(chǎn)量和質(zhì)量數(shù)據(jù)。各級人員及時準確掌握生產(chǎn)動態(tài)，對生產(chǎn)過程中出現(xiàn)的問題及時做出處理，以保證生產(chǎn)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(guān)的數(shù)據(jù)，轉(zhuǎn)儲到關(guān)系數(shù)據(jù)庫中，以實現(xiàn)高層次的生產(chǎn)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(zhì)，可 以將重要的生產(chǎn)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(chǎn)實時數(shù)據(jù)、歷史數(shù)據(jù)；分析工具可以對產(chǎn)品的生產(chǎn)質(zhì)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(chǎn)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(chǎn)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(wǎng)，就可以隨時查看各裝置的實時生產(chǎn)數(shù)據(jù)，歷史趨勢，統(tǒng)計報表等。而且在機器中不必預(yù)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(quán)限的用戶都可以訪問，并且無需將組態(tài)內(nèi)容復(fù)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(wǎng)內(nèi)的所有實時數(shù)據(jù)庫。
　　 8）只要權(quán)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(jié)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(fù)工作，打破信息孤島現(xiàn)象，提高了工作效率。
　　 紫金橋?qū)崟r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(shè)中的好幫手。