Yokogawa Electric Corporation Copyright © Yokogawa Electric Corporation DCS Software Printer Package August, 2003

Yokogawa Electric Corporation

<ISD-MASP-S03012-003>Copyright © Yokogawa Electric Corporation<August 2003>

DCS Software Printer PackageAugust, 2003

DCS Software Printer PackagePage.2


What is Exaplog?

The Exaplog Event Analysis Package runs on Windows PC, which provides analysis methodologies of DCS historical files (plant operation records) to managers, engineers and senior operators related to plant production process improvement. Exaplog helps them improve production processes by allowing them to delete needless alarms and inefficient sequences and analyze various problems by trend graphs, pie charts and tables. As an event analysis tool, 150 and more sales actual results in the world.

This event analysis package “Exaplog” can become the substitution of the DCS message

printer.



Exaplog Software Printer

DCS MessagesPrinter

ControlStation

OperatorStation

DCS Software Printer

ControlStation

OperatorStation

Replace

Message Acquisiti

on Message Preservati

on

• A message is indicated in time series.• Exaplog visually displays the balance

between the Process request volume and the operator work volume of the processes.

• Exaplog displays the message per message type.

• Exaplog displays the message per tag type.

Message Visualizati

on



What is existing problems? (1)

The purchase of the hardware is difficult.

Exaplog runs on Windows PC that is easily obtainable.

When a message printer breaks down, it is difficult recently to obtain new hardware (printer and peripheral equipment).

Replace printer with Exaplog




Running Cost

In case of Exaplog software printer, it is unnecessary.

A running cost such as printer sheets, toner cartridge are necessity in addition to the introduction cost. And, the maintenance (such as the printer form supply, toner cartridge exchange) of the printer is necessary.





Space Saving

Exaplog can be set up anywhere , because Exaplog can run on even a notebook PC.

The place to keep a spare part and a printer form are necessary in addition to the place to set a printer.





Event Confirmation, Search and Analysis

Confirmation : The collected message can be seen on five PCs at the same time.Search : The message can be searched from the tag or time.Analysis : The occurrence cause of the trouble can be found out easily by the rich analytic function.

Confirmation : The message can be confirmed only by the printed sheet.Search : When a trouble occurred, it is difficult to search a specific message from the printed sheet.Analysis : When a trouble occurred, it is very difficult to find out an occurrence cause from the printed sheet.




Exaplog window components

The PLView displays DCS event data for 1 day in four windows.

EBT graph Window (When?)

Category Sort Window (What?)

Point ID Sort Window (Where?)

Message Summary Window



EBT (Event Balance Trend) Graph Window

Process RequestsProcess Requests

Operator’s ActionsOperator’s Actions

Process alarm, announciator message, etcProcess alarm, announciator message, etc

Set -point change, pump start/stop,Set -point change, pump start/stop,tag mode change, etc.tag mode change, etc.X-axis : time

Y-axis : number of events

Displays the balance between the number of process operational requirements (plus side) and the number of operation (minus side) in chronological order and take a close-up of the operational area needs improvement.

1

No. Pattern Type Suspected ProblemEBT Pattern Countermeasure

Balanced No urgent problemLong term analysis about seasonal change

2ExcessiveNotification

Unnecessary alarms/messages Retuning of alarm set values

Long term analysis about erosion/corrosion

Integration of redundant alarms/messagesRedundant alarms/messages

Masking of low priority alarms/messages

3ExcessiveOperation

Low automation rate Automation using DCS

Automation using Exapilot

Simplify operation sequence

Manual operation according to know-how

Complex operation sequence

4Operation WorkOverview

Lack of support function Navigation using Exapilot

Operation TrainingInsufficient Operation capability

5InadequateOperation

Human error Error detection using Exapilot

Introduction of advanced process controlUnstable process



Message Summary Window

Displays all event informationincluding not printed informationsuch as batch ID, station ID.



Category Sort Window

Here, events information is summarized as a pie graph,showing the distribution of each types of events.



Point ID Sort Window

Displays event identification names such as tag name and data type by the order of generating amount or by the ascending/descending order of identification names.



Event Analysis Tool

Scope In Filter– Allows you to display only a selected event, or zoom in

on a selected time span.

Exclude Filter– Allows you to delete a selected event from the display.

User can choose the message which you don’t want to indicate the message or you want to indicate by using these two filters, and only necessary information can be referred.



Actual Example (Chemical, USA)

9/09 Total Events: 5837 9/20 Total Events: 3041

BeforeBefore AfterAfter

Following improvements were identified quantitatively:– Identified repeated process alarm-messages which were ignored– Identified manual operations which can be automated– Discovered instances of alarm flooding– Identified areas for further improvement

(by using PID tuning and advanced control, etc.)

Reduce 45% DCS events in 10 Days Before:5837 events/day -> After:3041 events/day



PLSummary (Long Term EBT Software)

PLSummary displays a long term EBT graph which is helpful to reveal target data of analysis.

PLSummary provides the summary of event data matching with filters defined by PLView and visualizes it as long-term trend graph (7days, 14days and 31days).



Export Event Records

DCS event log data can be stored in HDD as a binary file to economize HDD resources. PLAdmin separates this to three binary files to realize quick sorting of information.Stored log data and analysis report can be converted to the CSV file which is a standard format of Microsoft Excel software.

export



System Configuration (CENTUM-XL)

One Exaplog package includes one Exaplog server license and four Exaplog client licenses.

Uses “RS81” RS-232C interface card Printer port

Client Function

Ethernet

KB51:RS-232C cable for Exaplog CENTUM-XL adapter

EFCSEFCD

HF-Bus

EOPSServer Function include Client Function as standard



System Configuration (XL)

MFCUMFCD

RL-Bus

MOPS

Uses “RS81” RS-232C interface card Printer port

Client Function

Ethernet

KB51:RS-232C cable for Exaplog XL adapter

Server Function include Client Function as standard

One Exaplog package includes one Exaplog server license and four Exaplog client licenses.



Exaplog Specifications (1)

Supported Platforms– CENTUM-XL : R12 or later– XL: R11 or later

Hardware Operating Environment– PC/AT (DOS/V) compatible– CPU : Pentium 800 MHz or faster (Windows X

P)Pentium 500 MHz or faster (Windows 200

0)– Memory : 256 MB or more (Windows XP)

128 MB or more (Windows 2000)– Disk capacity: 50 MB or greater free space– CRT display: 1024 x 768 or greater (min. 800 x

600)



Exaplog Specifications (2)

Software Operating Environment– Windows XP (Service Pack 1)– Windows 2000 Professional (Service Pack 4)– Windows 2000 Server Stand-alone server

(Service Pack 4)



Functional Limitations

The event data file can contain up to approximately 64,000 messages per day. If the number of importing events exceeded the limit, PLServer. The log records an error message, and subsequent events on the day are discarded. PLView can show up to 30,000 messages at a time. For showing more than 30,000 messages in a day, please apply filter operations. And if you want to expand this area, PLView can show up to 60,000 messages at a time.



Thank you for your attention.Thank you for your attention.

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Yokogawa Electric Corporation Copyright © Yokogawa Electric Corporation DCS Software Printer Package August, 2003