[L1.1.9] R&D for Construction of Remote Support Technology in the Equipment Control Department (Remote support system group) Shibaura 401 Laboratory Goi 402 Laboratory Yokkaichi 402 Laboratory Ikunori Nagai, Masaru Sakon, Katsunori Abe Michio Ishizaki, Katsumi Nakazawa, Ryoichi Ino Kazutoshi Nakamura, Yasuki Tsuruoka, Junichiro Shimoda 1. R&D Objectives In order to realize improvements in safety control and stabilized operations at refinery plants, it is essential to bolster the support functions of staffers at locations other than the plant operations department who engage in planning and implementation of plant maintenance and new expansion or renovation construction, etc. So as to carry out these activities, staffers combine and use various types of data centering on operational data (that is, flow volume, temperature and pressure of fluids normally flowing in and between plant equipment) but including the properties and yields of each oil type, as well as the operational condition of each plant equipment, operational time periods, frequencies and maintenance history. At times, huge volumes of data, accumulated over a number of years, are retrieved, investigated, analyzed and used in future forecasting. Against this backdrop, together with the spread of computers for storing data, there has been a shift away from the main frame computer to multiple server computers. Because of this, data is now divided up among each server computer, whereas in the past, all or most of it was stored inside a single, main-frame computer. Consequently, for users who obtain all types of data from diverse sources, the process of gathering data has gradually become very burdensome. Hence it is conjectured that there would be greater efficiency in data collection and analysis if software could be created and provided in subroutine format, software which searches and retrieves while linking data from databases in multiple computers in response to the demands of users in remote areas, software which also enables retrieved data to be seen in plant pipe drawings (hereinafter P&I) and as virtual images in remote areas. The following benefits are expected from developing such technology. -Diversification in data analysis could be targeted through greater freedom and swifter action in data searching. -It would be easy to grasp plant conditions in remote areas thanks to virtual reproduction of P&I. -It would be possible to make quick responses for equipment maintenance thanks to dynamic linkage of related data at the frame online, data which thus far has been difficult to obtain, such as data on P&I, on properties and on maintenance. -It would be possible to establish linkages among simulations of equipment renovations, test operations, etc. 1
Another target is to reduce the number of personnel required at the manufacturing department and the maintenance department. Multiple refineries (local) Maintenance information DB Operation data Properties data In-company network Remote site (company home office) Reduction of the number of Staff Confirmation of plant silhouette Collection of process data from virtual model through visual operations Investigation of new buildings, additions, renovations, etc. Collection of mechanical data for process simulation Confirmation of equipment maintenance data Virtual modeling machine Plant Virtual plant model Figure 1-1: Image of Completed R&D 2
2. R&D Contents 2.1 R&D Completion Schedule Table 2.1-1: R&D Completion Schedule Table Item Fiscal year JFY 1999 JFY 2000 JFY 2001 JFY 2002 First term 1.System overall design 2.Link DB design 3.Link software development Second term 1.Design of virtualization system 2.Investigation of P&I virtualization 3.Design of virtualization DB 4.Development of virtualization software 5.System evaluation So that database access technology for retrieving data from a multiple number of databases at different locations can be separated from technology for visual representation of retrieved data, making it easy to understand, the present research is divided into two periods for covering each step in development. 2.2 Outline of Research Equipment In conjunction with the present research, the equipment indicated below was prepared in JFY2001 and is now being used in R&D. (1) Operation control server (computer) A relational database (Oracle) is loaded onto this server, other related databases required for research are built onto it, and the server is then used in research on virtualization. In addition, the server is connected to a similar server installed at the Goi 402 Laboratory; image transmission technology via WAN is then investigated, and soft functions are verified. (2) Data collection server IP21 (InfoPlus. 21: real-time database for collecting plant data) is loaded onto this server, which then holds data on plant operation. The server is connected to an operations control server and used for the development of data linkage technology. 3
Yokkaichi 402 Laboratory Goi 402 Laboratory Operation control server Operation control server Link software research Data collection server Virtuali -zation research plant data Figure 2.2-1: Equipment Composition Outline Drawing 2.3 R&D Contents in JFY2001 (1) Creation of data link software (a) INI file design and fabrication As a means of searching each item in a database, the key components at the time of searching are standardized. Correlations established between these components and key items in a practical database are rendered as files. Schemes with these files are then designed and fabricated. (b) Design and construction of software general applications Setting data, etc. are prepared as files and placed outside so that the data link software created can be easily transported to other systems and can be easily maintained. Concurrently, tools are designed and fabricated so that files can be easily created and preserved. (2) Data link software verification (a) Manual preparations Manuals for the data link software created and for setup file maintenance software, established for general applications, are prepared together with other documents. (b) Software verification Operations of the data link software created are verified. 4
(c) Types of database handled The types of databases handled are divided into ranks. One rank is a database with functions which can be used by simply giving definitions. Another rank is a database which can be used when the interface subroutine provided by the database has been installed. (d) Comparison of special features of other realization methods In the data link software, communications are implemented by ODBC and frame display by Excel, but other mediums such as the Web are also possible. The reasons why the present method was used are considered and the contents of a comparative investigation are gathered and arranged. (3) Design of virtualization system (a) Computer installation A computer was installed at the Yokkaichi 402 Laboratory for research purposes and a fundamental database was constructed. (b) System resources design System resources were designed so that construction of virtualization system software can be accomplished easily enough, as can operation of software under each environment or set of conditions. (4) Investigation of virtualization technology (a) Survey of CAD software market The market for typical CAD software handling drawings was surveyed so as to investigate types of image or converted files, conditions for network response, etc. (b) Survey of image communications technology Because images contain large volumes of data, much time is required to transmit them as such and this is inefficient. Accordingly, the market was surveyed to see how images are transmitted efficiently at present, to serve as a reference in the development of image transmission software. (5) Design of virtualization database (a) Design of plant operation database A database was designed to store plant operations data, process data, properties data, etc., all of which are displayed through links to images. 5
3. R&D Results 3.1 Creation of Data Link Software (1) INI file design and fabrication Each item in each database stored within the server is given a name, and in this way, users typically can judge which items they want to collect. This naming method, however, differs slightly depending on the database, or even if the same name is used, the contents denoted are different. A person could see such differences easily, but in the world of software, recognizing these differences is extremely difficult. Since the purpose of the present software is to make it possible for users to easily obtain targeted data without being very conscious of database location or structure, this problem cannot be ignored. An investigation was thus made to determine the minimum extent to which definitions, etc., must be established in advance in order for software to be able to make distinctions by itself. This item was selected and software was designed for handling data as INI files. Server Identifier SouchiMaster SouchiMaster SouchiCode SouchiName SectionMaster Figure 3.1-1: INI File INI file structure was designed and fabricated in association with a typical database, including tests. (2) Design and construction of software for general applicability The data link software created is of the prototype format. (This means that the format contains only basic functions considered necessary. It is the software format typically run at the software engineering level, and it is completed up to the stage just prior to release to users.) This prototype format is difficult for users to employ as such. What is more, because this software was created under the computer system environment used at the Laboratory, a number of system coefficients and environmental definitions must be changed before it can be used with a different system. Because these system coefficients, etc., are already incorporated into present-day software to some extent, considerable knowledge of computer systems is required to make changes using this software format. It cannot be easily employed by other users, and it is deficient in general applicability. 6
Accordingly, software was designed and constructed for wider general applicability by preparing these system coefficients and environment definitions in file format (setup file), to be stored externally. Operation control server Data colle -ction server Maintenance server PHD is for the future Table, column information Server side Master information Data Data Data Data collection application Definition file Client side Location information Read in file Maintenance Setup file Setup file maintenance tool for data collection application (Excel AddIn) Ranking of setup file maintenance tool for data collection application General applicability is improved by retrieving to the exterior as a file, information which must be changed in accordance with the environment in which software is used. Tools are prepared for the creation of setup files. Figure 3.1-2: Setup file Design In addition, dedicated creation tools (e.g., frames) were established so that a user without much knowledge of computer systems can establish and/or define setup files. Handling convenience was escalated by incorporating these tools as add-in buttons into the data collection frame (Excel frame). 7
Setup file maintenance frame (main) DB server setup frame Location information list frame DB server information Table column information Location information Setup file Location information file etc. Figure 3.1-3: Design of Setup file Creation Tool Figure 3.1-4: Tool Add-in to Excel 3.2 Data Link Software Verification (1) Manual creation Each of the following operation manuals was prepared covering the data link software created. 8
Data link software manual Data link software installation manual Setup file creation tool manual (2) Software verification Data collection time period and other indicators of basic performance by the data link software created were verified. Respecting data collection time period, measurements were taken with special reference to data volumes and to differences in environment via LAN or WAN. Results were favorable and it was concluded that the software has adequate practical applicability. (1) Collection time versus data volume (mean value of 5 collections) i) Small volume: about 7,000 cases (10 tag, one month)... 12 seconds ii) Large volume: about 88,000 cases (10 tag, one year)... 2 minutes, 32 seconds (2) Collection time versus environment differences (mean value of 5 collections) 10 tag one month 10 tag one year i) LOCAL 18 seconds 2 minutes 33 seconds ii) LAN 26 seconds 3 minutes 40 seconds iii) WAN 35 seconds 5 minutes 33 seconds Note: Local : Collected with server terminal containing data LAN : Data collected via LAN within compound WAN : Data in server at Goi 402 Laboratory (Ichihara City, Chiba Prefecture) is collected via WAN at Shibaura 401 Laboratory (Minato-ward, Tokyo). A portion of the measurements taken at this time appears in the next figure. Changes in data collection times by time period Time involved in data collection (mean value) Elapsed time Data collection time period (month) Figure 3.2-1: Measurements of Data Collection Time Periods 9
(3) Types of database handled Because the ODBC is used in the communications software for collecting data with data link software, the databases handled are limited to ones that support ODBC. The figure below presents the status of this software support for a typical database used as an online database in support of ODBC. Target database Features Database name Development/sales source Oracle Oracle Co. Defacto standard RDB Connection possible? Remarks Response by priority because of results with de facto standard used from the start of research. InfoPlus21 AspenTech Co. PIMS package Response by priority because of results with de facto standard used from the start of research. SQL Server Microsoft Co. RDB Problem with reliability from the start of research. At present, reliability is improving. Connection is possible. PHD Yamatake Co., LTD. PIMS package Response is possible. PI OSI Software Co./ System Plaza Co., LTD. PIMS package Representative PIMS package. Response possible with small renovation. Exaquantum Yokogawa Electric Co., LTD. PIMS package Sales in 2001. Response possible with small renovation. SynfoWARE Fujitsu Co., LTD. RDB/R-OLAP tool Problem with safty from the start of research. Survey required. InfoMIX IBM/Fujitsu Co., LTD. RDB(UNIX) Survey required. Figure 3.2-2: Range of Databases Handled (4) Comparison with special features of other methods In the interest of freedom in software development and ease in editing after data has been collected, Excel was selected for the data link software platform. The contents of a comparative investigation made at this time are given in the table below. 10
Coefficient Excel Dedicated application Web Emulator Data collection Performance 2 4 Optimum speed is not 6 This application is the 0 Suitable for display 2 Optimum speed is obtained because communications are via ODBC to secure general applicability. fastest because it was specialized for the database. only. Not good for file manipulation after data collection. Overhead is required for using software after it has been downloaded. not obtained because communications are via ODBC to secure general applicability. Overhead is also required for emulator connection. Stability 3 9 Stability is extremely 3 There are restrictions 9 Browser is abundant 9 Very high stability high with each OS version because the maker is the same as the OS maker. on OS version. in general applicability, and stability is extremely high with each OS because manipulations are carried out at the server, not the client. version. Freedom in development 1 3 Functions can be easily expanded by the user. 1 Mastering a dedicated editor is required. 0 Complex operations cannot be performed. 2 Functions cannot be expanded for individual users. Functions cannot (Environment be expanded for changes are made individual users. for all clients collectively.) Operability 3 9 This is office 3 Mastering a 6 Applications are 6 Emulator startup is software, and there is little time and labor for special education. dedicated editor is required. at the server side, and only at the server side is control necessary required but after startup, everything is the same as with Excel. Data analysis 4 12 Manipulation and interpretation of collected data as such are possible 0 Complex analytical operations cannot be performed. 0 Analysis is burdensome. 12 Manipulation and interpretation of collected data as such are possible. Maintenance 1 3 This is office software 3 No special problems 3 Applications are 3 Only at the server and there are no special problems. because of the package. at the server side, and only at the side is maintenance necessary. server side is maintenance necessary. Version 2 4 Version dependency 2 There are restrictions 6 Applications are at 6 Only at the server control is low but version control is required for each client. on the OS version and version control is required in each application. the server side, and only at the server side is version control necessary side is maintenance necessary. Comprehen -sive point 44 18 24 40 Figure 3.2-3: Comparison with Special Features of Other Methods 3.3 Design of Virtualization System (1) Computer installation A server for software development and for process data collection and preservation was installed in the computer room at the Yokkaichi 402 Laboratory. 11
Figure 3.3-1: Photo of Servers (2) System resource design System resources were designed as necessary for research. These were summarized on specifications sheets and installed in server/client computers. Major specifications are as follows. (i) Server : or process data storage : PIMS (Plant Information Management System) : or process data storage : IP21 (InfoPlus.21) : Oracle data base : RDBMS (Relational DataBase Management System) : Communications support tool : Openway/FT etc. (ii) Client PC : Process data display : Aspen Process Explorer : Process data collection : ODBC, SQLplus : Oracle data collection : SQLnet : Image and data display : Office97 etc. 3.4 Investigation of Virtualization Technology (1) Survey of CAD software market CAD is present in typical software for handling drawings that are the subject of virtualization. CAD is provided by numerous makers and it comes in a huge number of versions. In research, the market was surveyed with key emphasis put on those software versions compatible with networks. Attention was focused on about 20 typical versions (those having large market share and those with software maintenance). Next, respecting these versions, system environments, including file types handled and corresponding OS, were investigated, and preparations were made for designing specifications of software for virtualization. 12
Product Developer Network OS DB Type ensxpres NS Solution Web DocuWorks Document filing system FINALFILING Integrated diagram management system Ridoc Document System FUJI XEROX Matsushita Electric Industrial Mitsubishi Electric C/S C/S Win2000, NT4.0 Win95 to 2000, NT4.0 Unix, WinNT4.0 Unix, WinNT4.0 Multidocument Data format Compatibility with A0 size Oracle Diagram Free Document Oracle Document PDF ASSISTMICRO Web Win2000 Own DB A3? RICHO EDMICS2000 FUJI XEROX C/S Raku-Raku Document WebCaby Sumitomo Electric Industries Hitachi Microsoft Win2000, Unix Diagram Web Document PDF Win2000, NT4.0 MS SQL Diagram Tiff Figure 3.4-1: CAD Software Market Survey (2) Survey of image communications technology In order to investigate image communications technology, first the market for existing object tools was surveyed. From among the items surveyed, attention was focused on the following three software versions in consideration of abundance in corresponding image software versions, simplicity, and level of familiarity. AutoVue WiseVIEW 2D Jizaigan (Software for Multi-format file Viewer) 1 Web (IE,NS) (IE,NS) (IE,NS) 2 File format 190 or above 200 versions 3 AutoCAD 4 Word 5 Excel 6 Tiff 7 ME-10 8 Powerpoint 9 Markup 10 Remarks Total is covered including CAD. Limit response for CAD Mainly documents and image. It is good only with AutoCAD version5. CAD is weak. Figure 3.4-2: Survey of Image Display Software Market What is more, OLE (function subroutine) was released to the public, and it was decided that AutoVue would be used as the object tool for image communications because it is extremely convenient for add-in of special functions as required for the present research. 13
OLE (function subroutine) released to the public Good with many image files Good performance Few restrictions on hardware or OS Image virtualization software (Developed in JFY2002) Data link software (Developed in JFY2001) Image search Data search collection Image communications Data communications Image display Data display Image data rendezvous display Figure 3.4-3: Location of AutoVue 3.5 Design of Virtualization Database (1) Design of plant operation database A database for processes, etc., that link and display images was designed and constructed. Figure 3.5-1: Database Design Sheet 4. Synopsis No special issues or problems were encountered. Research conducted this fiscal year will be continued in the next fiscal year, covering virtualization of second-term P&I drawings, etc, and high-speed transfer communications. Copyright 2002 Petroleum Energy Center. All rights reserved. 14