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

Copyright © Yokogawa Electric Corporation DCS Software Printer Package Page.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.

Copyright © Yokogawa Electric Corporation DCS Software Printer Package Page.3 Exaplog Software Printer DCS Messages Printer Control Station Operator Station DCS Software Printer Control Station Operator Station Replace Message Acquisition Message Preservation 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 Visualization

Copyright © Yokogawa Electric Corporation DCS Software Printer Package Page.4 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

Copyright © Yokogawa Electric Corporation DCS Software Printer Package Page.5 What is existing problems? (2) 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. Replace printer with Exaplog

Copyright © Yokogawa Electric Corporation DCS Software Printer Package Page.6 What is existing problems? (3) 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. Replace printer with Exaplog

Copyright © Yokogawa Electric Corporation DCS Software Printer Package Page.7 What is existing problems? (4) 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. Replace printer with Exaplog

Copyright © Yokogawa Electric Corporation DCS Software Printer Package Page.8 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

Copyright © Yokogawa Electric Corporation DCS Software Printer Package Page.9 EBT (Event Balance Trend) Graph Window Process Requests Operator’s Actions Process alarm, announciator message, etc Set -point change, pump start/stop, 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 TypeSuspected ProblemEBT PatternCountermeasure BalancedNo urgent problem Long term analysis about seasonal change 2 Excessive Notification Unnecessary alarms/messagesRetuning of alarm set values Long term analysis about erosion/corrosion Integration of redundant alarms/messages Redundant alarms/messages Masking of low priority alarms/messages 3 Excessive Operation Low automation rateAutomation using DCS Automation using Exapilot Simplify operation sequence Manual operation according to know-how Complex operation sequence 4 Operation Work Overview Lack of support functionNavigation using Exapilot Operation TrainingInsufficient Operation capability 5 Inadequate Operation Human errorError detection using Exapilot Introduction of advanced process controlUnstable process

Copyright © Yokogawa Electric Corporation DCS Software Printer Package Page.10 Message Summary Window Displays all event information including not printed information such as batch ID, station ID.

Copyright © Yokogawa Electric Corporation DCS Software Printer Package Page.11 Category Sort Window Here, events information is summarized as a pie graph, showing the distribution of each types of events.

Copyright © Yokogawa Electric Corporation DCS Software Printer Package Page.12 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.

Copyright © Yokogawa Electric Corporation DCS Software Printer Package Page.13 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.

Copyright © Yokogawa Electric Corporation DCS Software Printer Package Page.14 Actual Example (Chemical, USA) 9/09 Total Events: 58379/20 Total Events: 3041 BeforeAfter 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

Copyright © Yokogawa Electric Corporation DCS Software Printer Package Page.15 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).

Copyright © Yokogawa Electric Corporation DCS Software Printer Package Page.16 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

Copyright © Yokogawa Electric Corporation DCS Software Printer Package Page.17 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 EFCS EFCD HF-Bus EOPS Server Function include Client Function as standard

Copyright © Yokogawa Electric Corporation DCS Software Printer Package Page.18 System Configuration (  XL) MFCU MFCD 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.

Copyright © Yokogawa Electric Corporation DCS Software Printer Package Page.19 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 XP) Pentium 500 MHz or faster (Windows 2000) –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)

Copyright © Yokogawa Electric Corporation DCS Software Printer Package Page.20 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)

Copyright © Yokogawa Electric Corporation DCS Software Printer Package Page.21 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.

Copyright © Yokogawa Electric Corporation DCS Software Printer Package Page.22 Thank you for your attention.