modular procedural automation

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Modular Procedural Automation

Yokogawa Users Group

October 2012

Yokogawa Users GroupCopyright © Yokogawa Electric CorporationOctober 2012

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Modular Procedural Automation (MPA)

What is MPA?

Consulting Methodology

How to select the right tool for the jobExaPilot exam les

Centum VP examples


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Capturing Procedural Best Practices

A B C

D

E F

Operator A’s Procedure

Best-Practices

Operator B’s ProcedureA

B1 C

D1 E F

A

D

E F

B2 D2

A B C

D1

E F

Operator C’s Procedure Capture the Best

Procedure from all

D2 Combine into a Best

Practice Procedure


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Capturing Procedural Best Practices

(1) Check base tank level LI100.PV >= 50%(2) Start pump P-101(3) Check pump status feedback

Capture Operator

Knowled e!

(4) Confirm field operator to open hand valve HV100

<Condition icon>

Check LI100.PV>=50

<Block mode setting icon>

P101.MODE to AUTO

<Condition icon>

Check P101.PV = 2

<Confirmation icon>

HV100 Open<Guidance message icon>

P101 start finished

<Output to DCS icon>

P101.CSV to 2 (Start )

<Pause icon>

Pause this sequence

YES YES

Original SOPOriginal SOP

NONO

NO

YES

Know-how

<Condition icon>

Check P101.ALRM = NR

(NR means Normal)

<Out ut to DCS icon>

<Alarm message icon>

P101 start error

-


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P101.CSV to 0 (Stop)arm message con

Preparation error

u pu o con

FIC100.SV to 20t/h

mer con

Wait 10 minu tes



Procedural control- Modularization of code

- Transition from - Transition fromProduct mix B to

Product mix B Product mix C

Ad ust tem SP Ad ust refluxRam as flow

Adjust temp SP Ramp gas flow

Adjust temp SP Adjust reflux Adjust reflux

us r n e

Adjust Air Inlet

Reduce Steam


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6



Consulting Site Visit

Look for opportunities for improvement (major “pain”points)

Site visit pre-work

Plant walkthrough

Interview checklists with

• Management

• Operations

• Other functions

Initial review meeting/ on-site report

Prioritize and recommend best solutions


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Tool Selection

• What determines if the MPAapplication should beim lemented in the controller?

Fault tolerance (high reliabilityrequired?)

Safety/environmental risks

Execution speed requirements

Level of automation available

Procedure implementation andlifecycle cost

Operating philosophy

Incremental

implementation/modification ofprocedures


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Yokogawa MPA Tools

• n t nstrument unct on oc

– Within the redundant FCS Controller

– Based on ISA88 structure SFC

– Supports state-based control – Allows the use of modular generic sequences/tags/code

–

• Exapilot –

– User-friendly flowcharting

– Allows for modular sub-procedures

– Capable of manipulating instruments – Generates operator messages/confirmations/data entry

– Works with an control s stem OPC


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Basic MPA Architecture

ExaPILOT

Procedure

Builder

E-NETMPAServer &

HistorianExa

Integrated

Operator

Display

Server

V net

FCS01FCS02

Unit Instruments


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Design Components


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Ethylene Furnace Example

Plant Area

Unit

urnace urnace

Furnace 5Furnace 4Furnace 3


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Ethylene Furnace Example

Plant Area

Unit QUENCH TOWER

Discharge

29

DECOKE DRUM

Heater

Air & Fuel Input

Device


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State Transition Diagram

State Available

Commands

Operator-

Initiated?

Description

Cracking Decoke

Stop

Yes

Yes

The furnace is in full production.

Coking deposits are being

monitored.

Decokin Standb No Cokin de osits are bein removed

Pause

Stop

No/Yes

Yes

from the coils. At the end of

process, the status is automatically

changed to Standby. If an

abnormal condition occurs, the

status is automatically changed to

ause.

Stopped Crack

Decoke

Yes

Yes

Furnace is taken out of service for

maintenance. Cracking or Decoking

can be selected by the operator.

Stop Yes

into Cracking from Decoking.

Paused Decoke Yes Operator can pause the Decoking at

any time and resume it.


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Map Procedures to States


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Exapilot MPA Example


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Exapilot – Interface with Graphics


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Centum Unit Instrument Example


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Example of Unit-based Procedure:

− Utilities Check (check of utilities valves,instrumentation, etc.)

− , ,flow check, etc.)

− Purification Process (manual valves open check,etc.)

− By-product Recovery Process (temperaturechecks, etc.)

− Separation Process (scrubber circulation, pHcheck, etc.)

• Possible States of the Train XYZ• WAIT

• READY FOR START

• START-UP

• RUNNING

• STOP


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Unit Instruments – Generic Functions


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MPA - Where to Start?

• – to another that requires a discrete set of activities – Startups / Shutdowns

– Crude Switches

– Grade Changes

– Cleaning / Regeneration

• Find Justifications based on: – Safety & Exposure

– Productivity –

– Knowledge Capture

• – Use the best tool for the job

– Get users involved (buy-in and better results)

– Create Templates


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Modular Procedural Automation - Applications

• Wednesday 10-31-2012, Technology Session Track 2

- Wayne Hawkins, Chevron

“Modular Procedural Automation in Gulf of”

- Zahra Kerkan Shell

“Modular Design Approach to Subsea MCS”

- Exhibit Area – Exapilot Demo


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Modular Procedural Automation - Summary

• onsu t ng et o o ogy – Capture best practices

– Modular

• Available Today

• ISA-106 Upcoming Standard

– -,

• Tool Selection

– Exapilot – Unit Instrument Function Block


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