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INSTITUTE FOR ADVANCED ENGINEERING

그린시스템/인텔리전스센터 Object Detection for P&ID Images

· 저자

차재민,이태경,Shelly Salim, 류보현

Piping and instrumentation diagram(P&ID) is an essential design document which is continuously modified and managed from design phase to O&M phase. For the ease of data transfer, P&IDs are generally converted into PDF which is hard to be modified. Therefore, engineering companies who need to manage P&IDs should manually re-convert their P&ID images into the P&IDs in CAD formats. To reduce the inefficiency of the P&ID re-conversion, various symbols and texts in P&ID images should be automatically detected before the re-conversion. As the first step to the auto P&ID conversion, in this study, we propose methods detecting symbols and texts in P&ID image using geometrical and deep learning-based approaches.

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그린시스템/인텔리전스센터 Features Recognition from Piping and Instrumentation Diagrams in Image Format Using a Deep Learning Network

· 저자

유은섭,차재민,이태경,김진일,문두환

A piping and instrumentation diagram (P&ID) is a key drawing widely used in the energy industry. In a digital P&ID, all included objects are classified and made amenable to computerized data management. However, despite being widespread, a large number of P&IDs in the image format still in use throughout the process (plant design, procurement, construction, and commissioning) are hampered by difficulties associated with contractual relationships and software systems. In this study, we propose a method that uses deep learning techniques to recognize and extract important information from the objects in the image-format P&IDs. We define the training data structure required for developing a deep learning model for the P&ID recognition. The proposed method consists of preprocessing and recognition stages. In the preprocessing stage, diagram alignment, outer border removal, and title box removal are performed. In the recognition stage, symbols, characters, lines, and tables are detected. The objects for recognition are symbols, characters, lines, and tables in P&ID drawings. A new deep learning model for symbol detection is defined using AlexNet. We also employ the connectionist text proposal network (CTPN) for character detection, and traditional image processing techniques for P&ID line and table detection. In the experiments where two test P&IDs were recognized according to the proposed method, recognition accuracies for symbol, characters, and lines were found to be 91.6%, 83.1%, and 90.6% on average, respectively.

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그린시스템/인텔리전스센터 Sensor Drift Detection in SNG Plant using Auto-Associative Kernel Regression

· 저자

차재민,이태경,김준영,신중욱,김진일,염충섭

With the rapid development of ICTs, condition monitoring has been used as a key technology in the plant industries. For reliable condition monitoring, sensors should output same values under same conditions regardless of time, but the sensitivity of sensors is gradually changed due to several factors such as temperature, humidity, contamination, aging, and etc. This type of situation is called as sensor drift problem. To solve this, several methods such as auto-associative neural network, auto-associative support vector regression, and etc. have been developed to detect sensor drifts earlier by estimating new input based on historical data. This study applied the auto-associative kernel regression model into a synthetic natural gas plant which produces synthetic natural gas from coals to detect sensor drifts during operation phase. To validate the auto-associative kernel regression model in the synthetic natural gas plant, a real data collected from an experimental operation are used. Based on the experimental results, the auto-associative kernel regression model can rapidly detect the sensor drift in the synthetic natural gas plant.

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그린시스템/인텔리전스센터 Steel Plate Faults Diagnosis with S-MTS

· 저자

김준영,차재민,신중욱,염충섭,

Steel plate faults is one of important factors to affect the quality and price of the steel plates. So far many steelmakers generally have used visual inspection method that could be based on an inspector's intuition or experience. Specifically, the inspector checks the steel plate faults by looking the surface of the steel plates. However, the accuracy of this method is critically low that it can cause errors above 30% in judgment. Therefore, accurate steel plate faults diagnosis system has been continuously required in the industry. In order to meet the needs, this study proposed a new steel plate faults diagnosis system using Simultaneous MTS (S-MTS), which is an advanced Mahalanobis Taguchi System (MTS) algorithm, to classify various surface defects of the steel plates. MTS has generally been used to solve binary classification problems in various fields, but MTS was not used for multiclass classification due to its low accuracy. The reason is that only one mahalanobis space is established in the MTS. In contrast, S-MTS is suitable for multi-class classification. That is, S-MTS establishes individual mahalanobis space for each class. 'Simultaneous' implies comparing mahalanobis distances at the same time. The proposed steel plate faults diagnosis system was developed in four main stages. In the first stage, after various reference groups and related variables are defined, data of the steel plate faults is collected and used to establish the individual mahalanobis space per the reference groups and construct the full measurement scale. In the second stage, the mahalanobis distances of test groups is calculated based on the established mahalanobis spaces of the reference groups. Then, appropriateness of the spaces is verified by examining the separability of the mahalanobis diatances. In the third stage, orthogonal arrays and Signal-to-Noise (SN) ratio of dynamic type are applied for variable optimization. Also, Overall SN ratio gain is derived from…

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그린시스템/인텔리전스센터 Plant Modeling Based on SysML Domain Specific Language

· 저자

이태경,차재민,김준영,신정욱,김진일, 염충섭

Successful implementation of Model-based Systems Engineering(MBSE) obviously needs a model supporting efficient communication among engineers of various domains. The system modeling language standard, SysML is designed to create MBSE supporting models. However, SysML itself is not practical enough to be used for real-world engineering projects. As SysML is designed for generic systems and requires specialized knowledge, a model written in SysML has a limited capability to support communication between a systems engineer and a subsystem engineer. Our research's main goal is to develop a SysML based plant model integrating most outputs from plant design phases. As mentioned, a standard SysML based plant model is not specific enough to be understood by plant engineers. To make the SysML model more practical, a customized SysML for the plant engineering domain is required. Unfortunately, current researches on SysML Domain Specific Language(DSL) for the plant engineering industry are still on the early stage. So, as a pilot, we have developed our own SysML-based Piping &Instrumentation Diagram (P&ID) creation environment and P&ID itself for a specific plant system, via widely known SysML modeling tool called MagicDraw. P&ID is one of the most important output during the plant design phase, which contains all information for the plant construction phase. So a SysML based P&ID has a great potential to bridge gaps between plant engineers.

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그린시스템/인텔리전스센터 Smart Chemical Plant Architecture Development Based on a Systems Engineering

· 저자

김준영

Chemical plant is a factory producing chemical goods through a continuous chemical reactions flow process in a set of equipment and apparatus. In this factory, equipment is the most crucial components in the whole life cycle of the plant encompassing planning, design, engineering, construction, commissioning, operation &maintenance (O&M) and disposal. According to the industrial statistics, cost of equipment takes over 52% of the total construction cost, and maintenance fee due to equipment failure during operation is reported over 10M,andaveragedailylossof150K in some plants. The main reason for this is due to lack of data and information flow during the planning and operation stage. In other words, transparent and live information for the whole stakeholders of the chemical plant is utmost important for the chemical plant industry. In this thesis, a way of achieving such a purpose is investigated based on the technology called IoT (Internet of Things) and Smart Factory. Specifically, architecture of smart plant for chemical plant was developed based on the Systems Engineering (SE), a powerful methodology for successfully developing the complex system, involving multi-disciplinary domain and a variety of stakeholders. The developed architecture was illustrated and verified by developing a prototype for a natural gas based hydrogen generation plant. Through the prototype, the impact of the cost saving as well as information infrastructure of the developed architecture is significant. Even so, it should be verified through more industrial cases; i.e., tailoring process in the future. Considering that there is almost no work in the open literature dealing with the smart factory for continuous process plant, such as the chemical plant dealt with in the thesis, the research results will contribute in this area.

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그린시스템/인텔리전스센터 정상 운전조건 중 반잠수식 플랫폼의 평형 자세에 따른 부유식 해상풍력 시스템의 하중 완화 연구

· 저자

김정태, 김관수, 고혁준, 김현종, 박종포

Rotor thrust causes the tilt of floating offshore wind systems. Due to wind-induced inclination, not only does the power performance of the wind turbine decrease, but also the load of the floating offshore wind system increases. In this study, to investigate the effects of load mitigation on a floating offshore wind system, the inclination of the floating offshore wind system is straightened by adjusting the amount of ballast water in the floater. The coupled aero-hydro-servo-elastic simulation code FAST is used to perform the load analysis. Then the short-term fatigue damage is calculated using MCrunch based on rainflow counting and Miner’s rule. As a result of dynamic analysis, it was found that the power performance is improved and the bending moment of the tower base is mitigated by ballasting. However, in the case of fatigue load, it was shown that load mitigation is insignificant from the results of DEL.

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그린시스템/인텔리전스센터 Resonance Avoidance Control Algorithm for Semi-submersible Floating Offshore Wind Turbine

· 저자

김관수 김현종 김현규 손재훈 김정태 박종포

In this study, a resonance avoidance control algorithm was designed to address the tower resonance problem of a semi-submersible floating offshore wind turbine (FOWT) and the dynamic performance of the wind turbine, floater platform, and mooring line at various exclusion zone ranges were evaluated. Simulations were performed using Bladed, a commercial software for wind turbine analysis. The length of simulation for the analysis of the dynamic response of the six degrees of freedom (DoF) motion of the floater platform under a specific load case was 3600 s. The simulation results are presented in terms of the time domain, frequency domain, and using statistical analysis. As a result of applying the resonance avoidance control algorithm, when the exclusion zone range was ± 0.5 rpm from the resonance rpm, the overall performance of wind turbine was negatively affected and when the range was sufficiently wide at ± 1 rpm, the mean power was reduced by 0.05%, and the damage equivalent load of the tower base side-side bending moment was reduced by approximately 14%. The tower resonance problem of the FOWT caused by practical limitations in design and cost issues can be resolved by changing the torque control algorithm.

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그린시스템/인텔리전스센터 반잠수식 풍력터빈 공진 회피 제어 알고리즘 설계

· 저자

김관수, 김정태, 김현종, 박종포

In this paper, a resonance avoidance control algorithm was designed to suppress the resonance phenomenon acting on the tower of a semi-submersible wind power system. Floating wind systems have some parts that need to be redesigned due to interface problems between the floater and turbine. In particular, the resonance of the tower is a serious issue, and a tower redesign process is generally conducted. Since the target wind power system has operating point in which resonance easily occurs due to the frequency of wind, it is difficult to satisfy design life requirements. Therefore, in this study, DNV GL Bladed wind turbine design software was used to analyze the performance of the control algorithm in wind conditions that frequently produce resonance. The results showed that the maximum load and fatigue load of the bending moment in the side-side direction of the tower base were reduced by 21.84 % and 48.05 %, respectively.

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플랜트공정개발센터 Computational fluid dynamics analysis of ventilation characteristics with various design parameters in single-span greenhouses

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윤종혁, 송형운, 장은석

With the advent of the fourth industrial revolution, smart farming technology is being introduced that can properly maintain the growing environment of crops remotely and automatically by grafting information and communication technology (ICT) to greenhouses. To maintain an appropriate growth environment for these crops, the effects of the greenhouse design parameters on these environments need to be evaluated. In this study, the thermal and flow characteristics in the single-span greenhouse were examined with commercial computational fluid dynamics (CFD) code. To validate the numerical method applied herein, the numerical results of the temperature distribution at several monitoring points were compared with the experimental results. The low-average error rate (0.87–1.90%) between them was measured and the numerical results of the temperature distribution exhibited good agreement with the experimental data. In addition, a parametric study was conducted to determine the effects of the various design parameters on the ventilation performance. These study findings will offer appropriate data for design guidelines for greenhouses.

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플랜트공정개발센터 Thermal Flow and Particle Behavior Characteristics in Ejector Applied Thermal Decomposition Reactor

· 저자

송형운, 윤종혁, 정희숙

In this study, a numerical study is performed on the thermal flow characteristics of a pyrolysis reactor to which an ejector was applied that enables heat recovery through internal gas recirculation. Depending on the ejector figure, the recirculation rate of the high temperature internal gas in the reactor is increased upto a maximum of 6.49 %, and the heat recovery rate is improved upto 14.7 %. In addition, a high-temperature internal gas circulation rate of 3.39 % is observed in a small-scale model based on the similitude theory. Among the silicon dioxide particles introduced into the small-scale reactor, the maximum particle diameter released through the outlet was numerically measured to be 78 ㎛, and about 40 % of the silicon dioxide particles were collected from the internal recirculation path at the bottom of reactor.

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플랜트공정개발센터 바이오가스 유래 수소제조기술 동향 및 효과적인 적용

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송형운,정희숙,엄성현

바이오가스를 이용한 수소 제조는 주요한 에너지 및 환경 관련 이슈들을 동시에 해결할 수 있다는 장점으로 꾸준히 주목받아 왔다. 바이오가스 정제를 통해 얻은 바이오메탄 수증기 개질은 천연가스 개질을 대체할 수 있는 좋은 현실적인 대안이다. 하지만 경제성과 환경 유해성을 모두 고려한다면 바이오가스를 직접 개질반응에 활용하는 바이오가스 수증기 개질 및 건식 개질을 활용한 수소 제조가 보다 효과적이라 평가된다. 본 논문에서는 바이오가스 기반 추출수소 제조관련 최근의 기술 이슈 및 개발 동향을 소개하며 향후 상업화를 위한 효과적인 적용 방향에 대해서 고찰하고자 한다.

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플랜트공정개발센터 상사이론 기반 설계된 가스 스크러버 반응챔버 내 열유동특성에 관한 연구

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윤종혁,김동수,김현경,송형운

반응챔버와 세정부로 구성되는 가스 스크러버는 반도체 제조공정으로부터 배출되는 폐가스를 정제하기 위해 사용되고 있다. 이때, 전반적인 운전안정성 및 높은 제거효율을 얻기 위해 스크러버에에서 반응챔버의 효율적인 설계가 필수적이다. 본 연구에서는 상용 반응챔버에 대한 기하학적 상사 및 운동학적 상사를 만족하는 반응챔버 축소모델을 설계·제작하고 상용 CFD 코드를 이용한 수치해석 연구를 수행하여 반응챔버 내부 열유동 특성을 분석하였다. 이를 통해 개선설계안 도출을 위한 설계기초자료를 확보하여 다양한 종류의 스크러버를 설계하기 위한 자료로 활용 될 것으로 기대한다.

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플랜트공정개발센터 반도체 폐가스처리용 가스 스크러버의 전열반응기내 열유동 특성에 관한 수치해석 연구

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윤종혁,김영배,송형운

최근에 반도체 산업의 지속적인 발전에 따라 반도체 생산공정에서 발생하는 다양한 오염가스를 처리하는 기술에 대한 관심도 늘어나고 있다. 이처럼 반도체 공정후 배출되는 폐가스를 제거하는 장치 중의 하나로서 다양한 종류의 스크러버 시스템이 사용되고 있다. 이러한 스크러버 시스템 내 열분해반응기 성능은 폐가스 내 오염원 제거효율와 전반적인 운전안정성에 영향을 미치기 때문에 열분해반응기의 효율적인 설계가 매우 중요하다. 본 연구에서는 수치해석 방법을 기반으로 반응기 내 폐가스의 열유동특성을 파악하고자 하였다. 해석기법을 검증하기 위해 온도분포에 대한 해석결과를 실험결과와 비교하였다. 온도결과에 대한 해석과 실험간의 약 1.27~2.25% 수준의 낮은 오차를 보였으며 이를 통해 해석결과의 타당성을 확보하였다. 검증된 해석기법을 이용하여, 기존 반응기의 성능개선을 위한 설계가이드라인을 제시하기 위해 폐가스 형상 변화에 따른 해석을 수행하여 기존모델 및 수정모델에서 폐가스의 거동특성을 비교분석하였다. 본 연구에서 수행한 결과는 다양한 스크러버 시스템 내 열유동특성을 분석하는데 기초자료로 활용할 것으로 기대한다.

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플랜트공정개발센터 2 kW급 고체산화물연료전지의 고온배기가스 폐열회수를 위한 일체형 Hot BoP의 설계 및 성능 평가

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김영배,김은주,윤종혁,송형운

본 연구에서는 2 kW급 SOFC에서 배출되는 고온 배기가스의 폐열회수를 위한 일체형 Hot BoP의 설계와 성능 분석에 대한 연구를 수행하였다. Hot BoP 시스템은 스택 배기가스의 연소를 위한 촉매 연소기와 연소 후 배기가스의 폐열회수를 위한 원통다관형 공기예열기 및 스팀발생기로 구성되었다. 시스템 설계에서 폐열회수 시스템의 배치에 따른 최대허용열용량을 산출하여 열분배 공정을 분석하였으며, 열전달 방정식을 통하여 공기예열기 및 스팀 발생기의 상세설계를 수행하였다. Hot BoP는 방열손실의 저감을 위해 일체형으로 제작되었으며, SOFC와 연계운전을 가정한 스택배기가스를 모사하여 성능실험에 사용하였다. Hot BoP 성능실험에서 부하별 열전달량 및 시스템 효율이 측정 및 분석되었으며, 당량비에 따른 배기가스의 CO 발생량을 측정하여 연소성을 분석하였다. 실험결과로써, 2 kW급 SOFC 정격운전시 배기가스 연소열부하 기준으로 hot BoP의 열적 효율은 약 60%이며, 연소 후 배기가스의 CO 발생량은 당량비 0.25 이상에서 급격히 감소되는 것으로 나타났다.

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플랜트공정개발센터 단동온실의 태양복사에 의한 열유동 특성 해석

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윤종혁,김영배,유인호,이종원,송형운

본 연구에서는 대류 및 복사열전달에 따른 단동온실 내 열유동 특성을 예측하기 위해 3차원 정상상태 열유동해석을 수행하였다. 넓은 파장대역폭에서 연속적으로 방사되는 태양복사에너지를 수치해석적으로 모사하기 위해 특정 파장영역대를 기준으로 복사에너지를 유한한 영역으로 구분하는 다중대역모델 적용하였다. 또한 비회체 특성을 갖는 비닐의 물성을 해석상에 적용하기 위해 파장영역대별 투과율(또는 흡수율)을 변화하여 적용하였고 유속, 온도, 복사에너지의 경계조건을 변화시켜 추가적인 해석을 수행하였다. 이러한 수치해석기법을 검증하기 위해 수치해석 결과를 실제 온실에서 측정된 온도 값과 비교분석한 결과 평균오차가 12.2~14.2 % 정도에 차이를 보이지만 유사한 경향성을 나타내고 있어 해석기법의 타당성을 확인하였다. 또한 복사에너지는 파장영역대별 비닐 투과율에 따라 온실 내에서 복사강도가 현저히 감소하고, 온실 내 열유동은 환기팬에 의한 강제 대류에 의해 크게 영향을 받고 있음을 확인하였다.

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플랜트공정개발센터 음식물류 폐기물 분해산물 활용 고형연료 생산에서 고품위화 특성

· 저자

송형운,정철진,박세용

본 연구에서는 높은 함수율을 가진 음식물류 폐기물을 Bio-dying 공법을 이용하여 처리 후 발생되는 분해산물을 활용하여 고형연료의 가치를 확인하고 고품위화를 위한 고형연료 제조의 조건 도출 및 분석을 통해 특성 확인을 하였다. 왕겨 혼합비율 10%와 볏짚 혼합비율이 5%에서 외형유지와 강도에서 좋은 품질을 나타내었고 혼합 펠렛의 겉보기 밀도는 평균 605 kg/m3의 값을 나타내었다. 이때, 압출 성형기에 부하를 주지 않는 혼합 펠렛 제조 함수율 조건은 25%가 최적인 것으로 판단되었다. 열중량 분석을 통한 중량 감소 곡선을 보면 볏짚, 왕겨 및 분해산물 원료의 순서로 가장 먼저 열분해 되었으며 혼합비율 왕겨 5%, 볏짚 10%, 볏짚 5%, 왕겨 10%의 순서대로 천천히 진행되었다. 볏짚 혼합비율 10% 보다 5%가 천천히 열분해가 진행되고 이는 밀도 값과 관련하여 5%의 펠렛 압축력이 높음을 간접적으로 확인되었고 볏짚은 혼합비율 5%가 최적 조건인 것으로 판단되었다. 왕겨와 볏짚의 혼합비율을 비교하면 왕겨의 혼합비율이 10%일 때 펠렛 밀도가 가장 높은 것으로 확인되어 본 실험결과에서는 혼합 효율면에서 왕겨의 혼합비율 10%가 최적의 혼합 연료 조건일 것으로 판단된다. 혼합 펠렛의 고위발열량은 평균 3,870 kcal/kg으로 분해산물 원료보다 5% 증가하였고 3,500 kcal/kg 이상의 값을 나타내었다.

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플랜트공정개발센터 2 kW급 SOFC 시스템에서 Hot BoP의 열분배시스템과 열적 성능에 대한 실험적 연구

· 저자

김영배,김은주,윤종혁,송형운

본 연구에서는 SOFC 시스템에서 배출되는 폐열원을 효과적으로 활용하기 위하여 수치적인 계산과 실험적 검증을 수행하였다. Hot BoP 내 열분배 시스템은 열원의 효율적인 공급을 위한 연소기 및 공기예열과 폐열회수를 위한 열교환기들로 구성되었다. 실험에 사용된 연료는 메탄가스이며 일정한 과잉공기와 합께 예혼합되어 안정적인 희박연소가 가능하게 하였다. 결과로써, SOFC 시스템의 열 부하에 따른 열교환기의 전열면적과 열교환율이 반복적 수치 계산을 통하여 분석되었다. 또한 연료의 저위발열량을 기준으로 시스템의 열부하, 열교환기의 효율, 열 손실, 열 회수 성능을 실험적으로 비교분석하였다. 최종적으로 열분배 시스템은 2 kW급 SOFC 시스템에 상응하는 열 부하에서 약 40 %의 열효율 성능을 나타내었다.

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플랜트공정개발센터 Pd-Pt계 촉매를 이용한 Anode Off Gas (AOG) 산화특성 및 활성평가

· 저자

김은주,김영배,윤종혁,송형운

SOFC 스택에서 배출되는 가스는 미반응 연료를 포함하고 있으며, 연료전지 시스템 열관리에 활용할 수 있다. 본 연구에서는 2 kW급 SOFC 양극오프가스(AOG)의 촉매 산화실험을 통해 산화반응 특성 및 촉매활성을 평가하였다. AOG 산화촉매로써 2 wt% Pd-Pt 허니컴과 볼 형상의 상용 촉매를 사용하였으며, 스택 모사장치 및 촉매 산화기를 포함하는 촉매 산화시스템을 구축하였다. 산화실험에서 촉매의 유무 및 조성에 따른 반응온도 분석을 통해 촉매산화 성능을 평가하였으며, 배기가스 내 일산화탄소 농도 분석으로부터 촉매의 AOG 산화활성을 확인하였다. 이때, 허니컴 형태의 촉매가 가장 낮은 일산화탄소 및 질소산화물의 배출 농도를 나타내어 산화성능이 가장 우수한 촉매로 평가되었다. 그리고 산화염 발달특성을 비교하기 위해 허니컴 촉매를 적용하여 당량비에 따른 산화염 가시화 분석을 진행하였고, 환형의 산화염이 발달되는 현상을 확인하였다. 또한, 당량비별 AOG 산화실험을 통해 시스템의 열부하에 대한 대응성을 평가하였다. 최종적으로 설계된 촉매산화시스템은 2 kW급 SOFC 시스템의 정격출력 조건하에서 미반응가스의 산화특성이 우수한 것으로 평가된다.

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플랜트공정개발센터 Numerical and experimental analysis of thermal-flow characteristics in a pyrolysis reactor of a gas scrubber designed based on similitude theory

· 저자

송형운,윤종혁,김영배

In this study, the thermal and flow characteristics in the reactor were examined through experiments and numerical analysis using a small-scale model of simplified pyrolysis reactor. Furthermore, a prototype model of pyrolysis reactor was designed through analysis result of small-scale model based on the similitude theory. The results of this study can be used as basic data for analyzing thermal and flow characteristics in a variety of scrubber systems. Implications: This study investigated and suggested a methodology for designing a pyrolysis reactor of the gas scrubber to overcome the design failure by using the concept of similarity, which can use the results from one system to explain phenomena in another system.

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