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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
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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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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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Questions?
hank you.
Yokogawa Users Group
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