程序自动化(Exapilot)

在满足可靠性、灵活性和生命周期成本方面的要求的同时,模块化流程自动化(MPA)提供灵活的方法来获取、优化和维持过程工厂中的流程知识。

产品概述

过程操作中流程管理的工业问题

所有类型的过程工厂都是以实现安全和效率的关键过程活动为主。这些过程活动来源于许多领域,包括手动SOP、现有的控制系统以及操作员多年来获得的隐性知识。由于资深操作人员的退休率高,新一代的工程师和操作员未掌握这些知识。操作程序的准确性不足会导致操作错误。通过强调工厂以优化效率运行以及时刻关注安全问题,关键在于企业获得操作知识和最佳实践,并持续、准确地执行。

行业领导者已经认识到自动化程序需要标准,并成立了ISA-106委员会。该委员会用于创建标准、推荐的操作规范以及流程设计和执行方面的技术报告,以实现持续过程操作的自动化。横河电机努力参与该标准化进程,并提出了解决方案,可以解决新兴标准—模块化的流程自动化中的问题。

文档化并驱动最佳实践

模块化的程序自动化将咨询的专业知识与世界级的流程管理能力相结合,以便:

  1. 在过程工厂中获取、优化和维持流程知识和控制。
  2. 在工厂控制系统中以适当的级别执行流程,以满足流程的可靠性和灵活性要求。
  3. 将流程集成到操作员界面和报警系统中,提高态势感知能力。

模块化流程自动化的功能

  1. Vigilant程序咨询和工具 - 根据操作要求,将程序执行模块的工具、功能和咨询专家功能内置到控制系统结构中。
  2. 知识工程 - 无论是在手动的现有控制系统还是在操作员的心中,MPA顾问和工程师都是获取和记录当前使用程序的专家。
  3. 模块化的工程 – 在新兴ISA-106标准作业和研发方法方面,基于标准的设计可以确保用户的程序性投资始终可靠且适合操作人员。
  4. 先进的决策支持整合 - 将程序集成到高性能的HMI和报警系统中,可以在所有过程条件和状态下为操作员提供高层次的态势感知能力。
  5. 操作员模拟 - 通过整合和部署操作员培训系统来提高MPA的价值,以培训工厂操作员对异常条件和过程转换的有效执行做出适当的反应。

Exapilot软件

Exapilot disply image

Exapilot是一款在线导航工具,可以指导操作员逐步进行工厂运行操作步骤。

虽然生产控制系统使工业工厂的大部分运行实现了自动化,但是操作员仍然需要手动对非常规过程进行干预,如工厂开车/停车和产品装载/分级/配方变化等。虽然开车和停车操作不常发生,甚至几年才进行一次,但是几乎每天都会进行产品切换。

经验丰富的操作员清楚地掌握了这些过程的每个步骤,但是如果他们不在现场的话该怎么办?发生意外情况时,缺乏经验的操作员能否处理?

Exapilot可以解决这些问题。Exapilot可以指导操作员每一步操作,防止操作员出错,甚至能够在检测到过程危险情况时及时报警。标准化的操作提高了产品质量,缩短了生产周期,并且减少了过渡产品。这样不仅降低了公用设施的成本,而且工厂还能够以更少的投入运行。Exapilot将优秀操作员的专门知识转化为标准化的步骤流程图,操作员可以在整个过程中充分利用该流程图进行导航。

通过减少操作员失误和生产损失,提高了效率,降低了整体运行成本。

自从Exapilot发布后,已经出售了1000多个软件许可。其中,大多数用户来自化工、石化和石油天然气行业。

(1) 用组合图标表示操作流程(组态期间)

Exapilot使用图标表示标准的工厂运行组件。只需定位并按照顺序连接图标即可创建标准的操作流程。创建简单的分级结构即可表示复杂的流程。无需专业工程技能即可配置Exapilot。

Exapilot display

(2) 避免遗漏步骤(操作期间)

对于过程的每一步,画面上都会显示对话框,指导操作员进行下一步操作。可以配置互锁顺序,防止操作员遗漏步骤。

(3) 将DCS操作和监视自动化

可以将阀门打开、斜坡测试、液位检查以及泵的启停等过程自动化。

(4) 与生产控制系统无缝连接

Exapilot通过过程连接(OPC)接口的标准OLE与生产控制系统(PCS)无缝连接,而无需PCS工程。Exapilot已经针对横河电机的CENTUM系列PCS进行优化,但同时也支持其他公司的DCS和PLC系统。

(5) 将标准操作程序文档化(SOP)

可以通过自文档化功能打印Exapilot创建的工作流,用作标准操作程序(SOP)。

(6) 将Exapilot用作运行仿真器

通过在试用模式中使用调试功能,可以将Exapilot用作运行仿真器。无需中断实际的工厂运行即可将工厂数据实时导入Exapilot进行模拟。

(7) 充分发挥经验丰富操作员的作用

使用Exapilot将非标准操作自动化,经验丰富的操作员便可以花费更多的时间来增强和优化用户整个工厂的操作流程。这样可以提高效率,降低运行成本。

Exapilot版本信息

最新版本信息

R3.98 (2018年8月)
  1. 新运行环境支持Windows Server 2016 Standard (64位)
  2. 支持横河电机可视化平台
  3. 强化事件驱动单元程序

3.95版及更早版本

R3.95 (2013年1月)
  1. Windows 7 Professional SP1 (32位),仅支持Exapilot客户端。
  2. 采用Windows用户身份验证模式增强安全功能。
  3. 加强PCS输出确认功能。
  4. 新增操作批注输入功能。
R3.90 (2011年9月)
  1. 新增软件环境
    Windows Server 2008 R2 Standard Edition SP1 (64位)
    Windows 7 Professional Edition SP1 (64位)
    Microsoft Office 2010
  2. 新增CENTUM VP R5.01通用IT安全工具
    用户可以从标准或原有型号选择适合的安全级别。这些IT安全级别在所有横河电机系统产品中通用,并且使Exapilot与CENTUM VP具有相同的IT安全性。(Exapilot R3.90的IT安全工具与CENUM VP R5.01的相同。)
R3.80 (2010年9月)
  1. 新增自文档化功能(可选)
    用户可以将Exapilot的所有主程序设定(流程工作流、单元程序定义信息、系统信息和附加批注)导出为Microsoft Word文件。这样用户便可以更自由、更方便地使用Exapilot数据,如创建SOP和管理文档。
  2. 强化组态画面功能
    新增富文本格式(RTF)编辑器、页面设定和网格线显示功能,用户可以更灵活地编辑和打印Exapilot流程作业图。
R3.70 (2009年12月)
  1. 新增支持Windows Server 2008和Windows Vista Business Edition SP2
  2. 增强IT安全性
  3. 新增操作员错误预防功能
R3.60.10 (2009年5月)
  1. 子流程在线维护
  2. 新增支持Windows Vista Business Edition SP2
    附加ActiveX组件信息画面组件2,在Windows Vista中显示CENTUM VP HIS图形
R3.60 (2008年8月
  1. 新增支持CENTUM VP R4.01
  2. 新增矩阵搜索单元程序
  3. 改善组态画面功能、操作性更好
  4. 新增支持Microsoft Windows Vista Business Edition SP1
R3.50 (2007年11月)
  1. 新增在组态画面主程序显示批注和拷贝功能
  2. 新增连接单元程序的搜索功能
  3. 新增组态画面的智能鼠标功能
  4. 新增支持夏时制
  5. 新增Active-X组件、MS-Excel连接单元程序、Microsoft Excel 2007 MS-Excel插件
R3.40 (2006年2月)
  1. 新增继承用户原有程序模块
  2. 新增矩阵变量
  3. 改善参数声明单元程序功能
  4. 实现从其他机器访问本地变量
  5. 采用OPC服务器/缓冲读取方法
  6. 新增ActiveX组件和MS-Excel附加组件,用户可以在工具栏创建应用程序图标。
  7. 新增ActiveX组件(简易趋势/图表、数据输入功能、网格排序&上色组件、按钮同步执行组件、通过监视区域变量进行区域监视的功能)
R3.30 (2005年1月)
  1. 强化操作和组态画面
  2. 强化实用性功能
  3. 兼容TSE (远程操作)功能
  4. 强化先进报警功能可选项
  5. 新增MS-Excel链接单元程序可选项
  6. 新增ActiveX组件
R3.20 (2004年1月)
  1. 新增ActiveX组件和MS-Excel插件
  2. 新增单元程序(回归计算)
  3. 新增单元程序可选项(VB脚本单元和e-mail通信)
  4. 强化单元程序功能(确认信息、案例判断、区域判断、强化搜索和替换)
  5. 新增符合21 CFR Part11标准的检查证据功能
  6. 新增安全功能
  7. 新增Exaopc OPC服务器冗余功能
R3.01 (2003年3月)
  1. 新增支持Windows XP
  2. 强化先进报警功能
  3. 新增标准和可选的单元程序

版本2

R2.20 (2002年11月)
  1. 新增动态信息、动态署名和带超链接的文本框功能
  2. 新增先进报警功能可选项
R2.10 (2002年4月)
  1. Exapilot软件包更名为专业、标准、办公,并用于HIS。
  2. 新增扩展和多运行可选项
  3. 新增事件等待、信息窗口、看门狗定时器和图形特性
R2.01 (2001年5月)
  1. 新增支持Windows 2000

版本1

R1.10 (2001年2月)
  1. 强化安全、多OPC服务器连接、历史报告、工序流程打印、DCS位号存在检查功能
R1.03 (2000年1月)
  1. 产品系列中新增Exapilot Lite和Super Lite
R0 (2000年1月)
  1. 发布适用于Windows NT的Exapilot操作效率改善软件包
概述:

Samsung Petrochemical Co. Ltd. (SPCL), a major Korean petrochemical company, produces 700,000 tons per year of purified terephthalic acid (PTA) at its Daesan plant. PTA, a white powder substance that is produced by oxidizing and refining para-xylene, is a precursor to polyethylene terephthalate (PET), a polyester material that has excellent thermal resistance and wear resistance and is widely used as a substitute for natural cotton fibers and in film packaging, beverage bottles, tire cords, paints, adhesives, and other applications.

行业:
概述:

INPEX Corporation (INPEX) is Japan's biggest oil and gas development company and is involved in all aspects of this business, from research to exploration, production, and sales. INPEX is engaged in projects all over the world, in a total of 29 countries, including Japan, where it operates a gas production plant near Oyazawa, a town in Niigata prefecture.

概述:
  • Exapilot was built up as e-SOP system based on the standard operating procedures and the know-how of experienced operators.
  • e-SOP system improved the quality and productivity in the performance chemical plant in China.
概述:
  • Provided a better way to transfer its manufacturing know-how to the next generation
  • Reduced energy consumption and operator workload by implementing Advanced Process Control (APC) and Advanced Operator Assistance (AOA)
概述:
  • Based on a careful review of all operational procedures and operator roles and configured new SOPs in Exapilot.
  • As a result, SFC has been able to reduce operator workload, improve product quality, and reduce production losses.
概述:
  • At the company's Ulsan resin plant, six Exaquantum servers were connected to CENTUM CS 3000 and other vendor's systems.
  • KKPC needed to expand its SBC capabilities and improve production efficiency at its plants.
概述:
  • Exapilot contributes to safety, reduces cost, and retains operational know-how.
概述:
  • Exapilot smoothly starts up and shuts down the world's biggest experimental distillation unit.
  • Data visualization is the key, giving operators a complete understanding of what is is going on in the process, in real time.
概述:
  • Up to 90% of all manual tasks can now be carried out automatically.
  • Increasing productivity by means of partially automated start-up and load change procedures.
概述:
  • Configuration of complicated procedures in Exapilot leads to operational excellence.
  • DENKA wanted to standardize the operation, reduce workload and prevent operator errors.
行业:
概述:
  • Easy-to-understand sequence programs' creation
  • An entire programming system built by operators
  • Operator workloads reduction
概述:
  • Stable regeneration of butane driers and effective start-up of sulfur recovery plant.
  • Exapilot contributes to operational consistency and procedure management in large refinery plant.
行业:
概述:
  • Exapilot improves operations and reduces energy use at PTT Khanom Gas Separation Plant #4.
  • This is a real solution package and a good tool for the plan-do-check-act (PDCA) cycle to achieve operational excellence in the plant.
概述:
  • Exapilot is Effectively Applied to Polypropylene Plant and Optimizes Operation, Cost Savings.
  • By using Yokogawa's Exapilot, Safripol were able to eliminate product variations and kept the operations consistent.
概述:
  • Kaneka Corporation has urgently needed to implement countermeasures that would reduce this facility's energy costs.
  • Optimization of control strategy helps BTG plant save energy and operate more efficiently.
概述:
  • Exapilot was introduced to maximize operational efficiency at an experimental refining facility.
  • To prevent operator errors, it was essential to standardize operating procedures.
概述:

This paper shows how to improve distillation operations by focusing on procedure automation. It will review the importance of using procedures in distillation operations and highlights the collaboration work underway between Fractionation Research Inc. (FRI) and Yokogawa Corporation to improve procedural operations.

概述:

Operational error is the single biggest reason for unscheduled shutdowns in process plants, causing several millions of dollars in damages and losses per year. Combine this with an aging skilled workforce leaving the work place, with inexperienced people to replace them, and there is no doubt that process plants face a challenging problem.

概述:

Yokogawa has come a long way in making its message clear to the world of process automation. Last year, the company embarked on a full-scale global marketing campaign to make customers aware of the company's focus on system reliability, security, dependability, and robustness. Dubbed "Vigilance", the campaign created a unified message for the company and greatly helped expand awareness of the Yokogawa brand and corporate philosophy.

概述:

The world of process automation is governed by procedures. While we like to refer to the process industries as being largely "continuous", this could not be further from the truth. Process manufacturing is constantly in flux.

概述:

July 2011

Process plants are run according to operational procedures. These procedures consist of a set of tasks that are executed in a consistent manner to achieve a specific objective, such as starting up, shutting down or transitioning a unit as part of making a product. 

概述:

Process plants require operational procedures in order to produce products. These procedures consist of a set of tasks that are executed in a consistent manner to achieve a specific objective such as starting up or shutting down, or transitioning to a different product. The level of detail, purpose and frequency of use of these procedures varies by process, company and site—but in all cases these procedures should be the basis for plant operations.

概述:

ARC believes that by implementing procedural automation, many process plants can minimize variability to help ensure smooth, efficient, and safe state transitions.

概述:

Manual operations live on and even thrive in largely automated process plants, and they are often the cause of safety incidents.

By Maurice Wilkins, VP Strategic Technology Marketing Center, Yokogawa Corporation of America
Marcus Tennant, Senior Principal Technology Strategist, Yokogawa Corporation of America

概述:

Large process industry companies have recently started building plants with world-class safety and profitability to reinforce their competitive edge in the global market. As for plant operations, support functions for improving operators' plant operation skills and for extending operators' maximum capability are required to the DCS so that an operator can expand the area of plant monitoring or operate a plant with higher cost- consciousness.

行业:
概述:

In 1999, Yokogawa Electric Corporation formed an alliance with Shell Global Solutions International B.V. (SGSI) in Advanced Process Control (APC), and both companies have since jointly developed products. This alliance successfully combined SGSI's experience gained through more than 800 projects in more than 30 years and Yokogawa's great deal of experience with the process control market, and strengthened the scheme to provide the APC technology.

行业:
概述:

In recent years, safety and profitability have become ever more important in the process industry due to fierce global competition. Greater emphasis is being placed on highly efficient plant operation for reducing the increasing energy bill.

行业:
横河技报
概述:

Recently, standardization of procedural automation of manual operations has been promoted mainly by the International Society of Automation (ISA), and the functional requirements necessary for automation are being studied by the ISA106 committee in the US.

概述:

For a coal fired power generation plant (hereafter referred to as "BTG facilities," in which "BTG" stands for boiler, steam turbine, and generator) supplying power to a large-scale production plant, the CO2 emissions from such facilities are a critical issue today.

横河技报
概述:

Remarkable progress in information technology has led to open architecture systems and networking in the manufacturing industry. In such industry, remote monitoring systems based on public communication lines or the Internet, and or collaboration of control, information, and corporate systems based on standardized interfaces such as OLE for Process Control (OPC) are now widely used via networks.

行业:
概述:

Due to emerging competitors from the rapidly growing countries such as India and China and the global economic downturn triggered by the Lehman shock, many companies in the process industries are struggling to survive the severe global competition.

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