Procedural Automation (Exapilot)

MPA (Modular Procedural Automation)는 공정 플랜트의 절차 지식을 포착, 최적화 및 유지하면서 신뢰성, 유연성 및 라이프사이클 요구 사항을 충족시키는 유연한 방법을 제공합니다.

Product Overview

Industry Issues with Procedural Control in Process Operations

모든 유형의 공정 플랜트는 안전하고 효율적인 플랜트를 운영하는데 중요한 절차적 활동에 의해 주도됩니다. 이러한 절차 활동은 수동 SOP, 레거시 제어 시스템 및 수년간의 경험을 통해 얻은 문서화되지 않은 운영자 지식에 상주합니다. 경력사원의 퇴직률이 높아지면서 이러한 지식의 상당 부분이 신세대 기술자와 운전원에게 전수되지 않고 있습니다. 정확한 절차의 부적절한 가용성으로 인해 운영에 오류가 발생할 수 있습니다. 최적의 효율성과 안전에 대한 경계에 중점을 두어 운영 지식과 모범 사례가 기업에 포착 및 일관되고 정확하게 실행되는 것이 중요합니다.

업계 리더들은 절차 자동화에 관한 표준이 필요하다는 것을 인식하고 지속적인 프로세스 운영 자동화를 위한 절차의 설계 및 구현에 관한 표준, 권장 사례 및 기술 보고서를 개발하는 것이 목적인 ISA-106 위원회를 구성했습니다. 이 표준화 노력에 관련했으며 새로 부상하는 표준인 Modular Procedural Automation에서 다루는 문제를 해결하는 솔루션을 개발했습니다.

Documenting and Driving Best Practices

모듈형 절차 자동화는 컨설팅 전문 지식과 세계적 수준의 절차 제어 기능을 결합하여 다음과 같은 이점을 제공합니다.

  1. 공정 플랜트에서의 절차적 지식 및 제어의 캡처, 최적화, 유지
  2. 절차 신뢰성 및 유연성 요구사항을 만족하기 위해 플랜트 제어 시스템에서 적절한 수준의 절차를 구현
  3. 운전자 인터페이스 및 알람 시스템에 절차를 통합하여 상황 인식 향상

Capablities of Modular Procedural Automation

  1. Vigilant Procedure consulting and tools - 운영 요구 사항을 기반으로 제어 시스템 아키텍처에 프로시저 구현 모듈을 포함하는 동급 최고의 도구, 기능 및 컨설팅 전문성
  2. Knowledge Engineering - MPA 컨설턴트 및 엔지니어는 매뉴얼, 레거시 제어 시스템 또는 운전원의 머리 속에 현재 사용중인 절차를 캡처하고 문서화하는 전문가
  3. Modular Engineering - 새롭게 부상하는 ISA-106 표준 작업 및 개발 방법론을 기반으로 하는 표준 기반 설계는 절차 투자가 신뢰할 수 있고 운전원에게 적합하다는 것을 보장
  4. Advanced Decision Support Integration - 절차는 고성능 HMI 및 알람 시스템에 통합되어 운전원에게 모든 공정 조건 및 상태에서 높은 수준의 상황 인식을 제공
  5. Operator Simulation - 플랜트 운전원을 교육하여 비정상 조건에 대한 적절한 대응을 유도하고 공정 전환의 효율적인 실행을 위해 운전원 교육 시스템을 통합 및 batch 함으로써 MPA의 가치 향상

Exapilot Software

Exapilot disply image

Exapilot은 운영자가 플랜트 운영 절차를 단계별로 안내하는 온라인 탐색 도구입니다.

생산 제어 시스템이 산업 플랜트 운영을 자동화하더라도 운영자는 플랜트 스타트 업/셧 다운 및 제품 로드/등급/레시피 변경과 같은 비정상적인 프로세스에 수동으로 개입해야 합니다. Start-ups와 shutdowns는 몇 년에 한번 드물게 발생할 수 있습니다. 반면에 제품 전환은 일상적으로 발생할 수 있습니다.

숙련된 운영자는 이러한 절차의 모든 단계를 알고 있지만, 만약 그런 사람이 현장에서 즉시 사용할 수 있는 사람이 없으면 어떻게 됩니까? 미숙한 다른 운전자가 예기치 못한 사태가 발생했을 때 대응할 수 있을까?

Exapilot은 작업의 각 단계를 통해 작업자를 탐색하고 실수로 작업하는 것을 방지하며, 프로세스에서 위험한 비정상적인 상태가 감지되면 적절한 시기에 알람을 발생시킵니다. 운영 표준화는 제품 품질을 향상시키고, 생산주기 시간을 단축하며 일시적인 제품을 줄입니다. 이로 인해 유틸리티 비용이 절감되고 공장이 더 작은 인벤토리로 운영할 수 있습니다. Exapilot은 이 문제를 해결합니다. Exapilot은 최고의 운영자의 노하우를 사용하여 운영자가 전체 프로세스를 통해 완벽하게 탐색할 수 있는 표준화된 절차 흐름도로 변환합니다.

운전자 실수와 생산 손실을 제거함으로써 효율성이 향상되고 총 운영 비용이 절감됩니다.

Exapilot이 처음 출시된 이래 전 세계적으로 1,000개 이상의 라이센스가 판매되었으며 대부분의 사용자는 화학, 석유 화학, 석유 및 가스 산업입니다.

(1) Operating procedures represented as combinations of icons (during configuration)

Exapilot는 아이콘을 사용하여 표준 설비 작동 요소를 나타냅니다. 아이콘을 순서대로 batch하고 연결하여 표준 작동 절차를 만듭니다. 복잡한 절차를 나타내는 간단한 계층적 시퀀스를 만듭니다. Exapilot 구성에는 특별한 엔지니어링 기술이 필요하지 않습니다.

Exapilot display

(2) Avoid omitting steps (during operations)

프로세스의 각 단계에서 운영자가 다음에 취해야 할 조치를 나타내는 대화 상자가 화면에 표시됩니다. 인터록 시퀀스는 운전자가 단계를 생략하지 않도록 구성할 수 있습니다.

(3) Automate DCS operation and monitoring

밸브 개방, 램프 작동, 레벨 점검 및 펌프 기동/정지 절차가 자동화될 수 있습니다.

(4) Seamlessly connect with production control systems

Exapilot는 표준 OLE for Process Control(OPC) 인터페이스를 통해 생산 제어 시스템(PCS)에 끊김없는 연결을 제공합니다. PCS 엔지니어링은 필요하지 않습니다. Exapilot은 Yokogawa의 CENTUM 시리즈 PCS에 최적화되었지만 다른 회사의 DCS와 PLC 시스템도 지원됩니다.

(5) Document standard operation procedures (SOP)

Exapilot으로 작성된 Workflow는 SOP(표준 운영 절차)로 사용하기 위한 자체 문서 기능으로 출력할 수 있습니다.

(6) Use Exapilot as an operation simulator

테스트 모드에서 디버깅 기능을 사용하면 Exapilot을 조작 시뮬레이터로 사용할 수 있습니다. 플랜트 데이터를 Exapilot으로 실시간으로 가져와 실제 플랜트 운영을 방해하지 않고 시뮬레이션을 실행할 수 있습니다.

(7) Make more effective use of your most skilled operators

Exapilot을 사용하여 비표준 작업을 자동화하면 숙련된 운전자가 플랜트 전체에서 운영 절차를 향상시키고 최적화하는데 더 많은 시간을 할애할 수 있습니다. 이를 통해 효율성이 향상되고 운영비가 절감됩니다.

Exapilot Release Information

The latest Release Information

R3.98 (August, 2018)
  1. New operation environment support
    Windows Server 2016 Standard (64-bit)
  2. Yokogawa Virtualization platform support
  3. Event Driven unit procedure enhancement

Revision 3.95 or earlier

R3.95 (January 2013)
  1. Windows 7 Professional Edition SP1 (32-bit) supported for Exapilot client only.
  2. Security function enhanced using Windows user authentication mode
  3. PCS output confirmation function enhanced.
  4. Operation comment input function added.
R3.90 (September 2011)
  1. New software environments added
    Windows Server 2008 R2 Standard Edition SP1 (64-bit)
    Windows 7 Professional Edition SP1 (64-bit)
    Microsoft Office 2010
  2. Common IT security tool with CENTUM VP R5.01 added
    A user can select suitable security level from the standard or legacy model. These IT security levels are common throughout Yokogawa system products, and it enables Exapilot to have the same IT security as the CENTUM VP. (Exapilot R3.90's IT security tool is as the same as CENUM VP R5.01.)
R3.80 (September 2010)
  1. New self-documentation function (optional)
    Enables users to export all of Exapilot's main procedure settings (procedure flow, unit procedure definition information, system information, and additional comments) to a Microsoft Word file. This gives users greater freedom and convenience in how they use Exapilot data, allowing them, for example, to produce SOPs and management documents.
  2. Enhancements in builder window functions.
    New rich text format (RTF) editor, page setup, and grid line display functions give users increased flexibility in how they edit and print out Exapilot procedure flowcharts.
R3.70 (December 2009)
  1. Windows Server 2008 and Windows Vista Business Edition SP2 support added
  2. IT security enhanced
  3. Operator error prevention functions added
R3.60.10 (May 2009)
  1. Sub-procedure online maintenance
  2. Windows Vista Business Edition SP2 support added Addition of ActiveX component message window component 2 for display of CENTUM VP HIS graphics in Windows Vista
R3.60 (August 2008)
  1. Support of CENTUM VP R4.01 added
  2. Matrix search unit procedure added
  3. Builder window function improved, for better operability
  4. Support of Microsoft Windows Vista Business Edition SP1 added
R3.50 (November 2007)
  1. Comment display and copy functions for main procedure view in builder window added
  2. Search function for connector unit procedure added
  3. Intelligent mouse function for builder window added
  4. Support of daylight savings time added
  5. Active-X component, MS-Excel link unit procedure, and MS-Excel add-in support with Microsoft Excel 2007 added
R3.40 (February 2006)
  1. Hierarchically arranged user procedure module added
  2. Matrix variables added
  3. Parameter declaration unit procedure function improved
  4. Local variable access from other units enabled
  5. OPC server/cache read method adopted
  6. Addition of user-created application icons to palette tab enabled ActiveX components and MS-Excel add-in components added
  7. ActiveX components (simplified trend/chart, data input function, sorting & coloring of grid components, simultaneous execution of button components, area monitoring function by monitoring area variables) added
R3.30 (January 2005)
  1. Operation and builder windows enhanced
  2. Utility functions enhanced
  3. Now compatible with TSE (remote operation) functions
  4. Advanced alarm function option enhanced
  5. MS-Excel link unit procedure option added
  6. ActiveX components added
R3.20 (January 2004)
  1. ActiveX components and MS-Excel add-in components added
  2. Unit procedure (regression calculation) added
  3. Unit procedure options (VB script unit and e-mail communication) added
  4. Unit procedure functions (confirmation message, case judgment, area judgment, enhanced search and replacement) enhanced
  5. 21 CFR Part11 compliant inspection evidence function added
  6. New security function added
  7. Support of Exaopc OPC server redundancy function added
R3.01 (March 2003)
  1. Windows XP support added
  2. Advanced alarm function enhanced
  3. Standard and optional unit procedures added

Revision 2

R2.20 (November 2002)
  1. Dynamic message, dynamic generic name, and text box with hyperlink functions added
  2. Advanced alarm function option added
R2.10 (April 2002)
  1. Exapilot package names changed to Professional, Standard, Office, and For HIS
  2. New expansion and multi-run options added
  3. Event wait, message window, watchdog timer, and graphics features added
R2.01 (May 2001)
  1. Windows 2000 support added

Revision 1

R1.10 (February 2001)
  1. Security, multiple OPC server connection, historical report, procedure flow printing, character variable, and DCS tag existence-checking functions enhanced
R1.03 (January 2000)
  1. Exapilot Lite and Super Lite added to package lineup
R0 (January 2000)
  1. Exapilot operation efficiency improvement package for Windows NT released
Overview:

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.

Overview:

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.

Overview:
  • 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.
Overview:
  • 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)
Overview:
  • 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.
Overview:
  • 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.
Overview:
  • Exapilot contributes to safety, reduces cost, and retains operational know-how.
Overview:
  • 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.
Overview:
  • 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.
Overview:
  • Configuration of complicated procedures in Exapilot leads to operational excellence.
  • DENKA wanted to standardize the operation, reduce workload and prevent operator errors.
Overview:
  • Easy-to-understand sequence programs' creation
  • An entire programming system built by operators
  • Operator workloads reduction
Overview:
  • 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.
Overview:
  • 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.
Overview:
  • 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.
Overview:
  • 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.
Overview:
  • Exapilot was introduced to maximize operational efficiency at an experimental refining facility.
  • To prevent operator errors, it was essential to standardize operating procedures.
Overview:

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.

Overview:

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.

Overview:

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.

Overview:

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.

Overview:

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. 

Overview:

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.

Overview:

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

Overview:

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

Overview:

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.

업종:
Yokogawa Technical Report
Overview:

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.

업종:
Overview:

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.

업종:
Yokogawa Technical Report
Overview:

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.

Yokogawa Technical Report
Overview:

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.

Yokogawa Technical Report
Overview:

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.

업종:
Overview:

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.

기술 및 솔루션, 요꼬가와에 대한 자세한 정보를 찾고 계십니까?


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