Friday, December 20, 2013

The Art of DBDOC - Live Specs and NVRAM Failure

Summary

NVRAM failure can be a big problem.  Doing a DBDOC Live Loop Annotation fetching the block specifications will fail if the NVRAM has failed.  This could be useful information to you.

Details

A client reported that DBDOC Hyperview could not fetch the specs of a block.  In fact, the specs could not be fetched in any block in that module.  This is shown in this image.  Live data could be fetched - only the reporting of the specifications was affected.


However, fetching specs worked fine in other modules.  The example in a clone of the problem one, as you can see.


What could cause this problem? 

The next two images show the difference between working and failing module status fetches. 




Guess what?  The problem module shows NVRAM failure status: Fail.  The one that is working says: Good.

From the Client

"I believe a NVRAM failure will prevent looking at any of the configuration."

Subsequent Perspective

"The module will continue to operate with an NVRAM error because a copy of the configuration is held in SRAM and executes from there. The next time the module is reset it will not startup but will fail.

"This module had failed earlier and was hard initialized during an outage and did not show the errors, but has NVRAM failure now."

New INFI 90 "art" has been crafted.  This is the first time we know of that the module status fetch we created has been used to solve a problem.

FC 222 and 223 Can Have Severe Exception Report Problems

Summary

If you have FC 222 and FC 223 blocks, you should check for the following problems:

  1. FC 222 S8 defaulted to 0.0 and FC 223 S9 defaulted to 0.0 which causes continuous exception reports if the block is tagged in any HMI.
  2. Spare FC 222 and FC 223 blocks tagged but not used which cause absolutely wasted continous exception reports.
  3. FC 222 and FC 223 blocks with all the significant change specifications set to 1, even when this value is not appropriate.

Details

At a client site, DBDOC was responsible for uncovering a significant loading problem involving FC 222 - Analog In/Channel that has been causing significant loading of the node communication capability. It turns out that FC 223 - Analog Out/Channel has the same problem. Here is an outline of the problem:
  • site has significant number of FC 222 S8 and FC 223 S9 blocks at default value of 0 significant change
  • even worse, many of these have "spare" tags identifying unused blocks brought into the HMI by exception report
  • the result is exception reports generated by the node at once per second, many utterly wasted, and the rest far too sensitive to be valid.
  • examination of other systems shows that some have all default values replaced, although there is clearly no understanding that the value is in engineering units (like FC 177) not in percent
DBDOC tools including the Significant Change Report and the extraction of all specifications made it easy to look for the problems once they were conceptualized.

In the site in question, a power plant installation, the bulk of the FC 222 blocks were done relatively recently, taking advantage of modern INFI 90 hardware.

There are 573 FC 222 blocks with default significant change of 0. Our tests with DBDOC Watch Window easily proved that each of these blocks, either if imported or in the HMI tag database, generated an exception report every Tmin seconds, that is, every second. In fact, 92 more FC 222 blocks had non-default significant change, because they had been properly configured.

What about these 665 FC 222 and FC 223 blocks?
  • One had no tag, but was imported by an AI/L block, so it is generating an exception report anyhow.
  • 196 were named spare blocks, none used in graphics or PI, so196 XR's per second wasted.
  • The other 469 blocks were giving an XR every second.
The PCU distribution of the load was:
  • PCU 2 - 640
  • PCU 3 - 16
  • PCU 4 - 8
  • PCU 5 - 1
There actually were 2181 tags defined in PCU 2, which means that every Tmax of 60 seconds, each generated an XR. Thus, the base XR load was:
  • 573 per second from default FC 222 blocks
  • (2181 - 573) / 60 = 27 per second from the other tags
That is, the base XR load on the node is 600 XRs per second. It is a good thing this system has NIS 21 / NIS 22 communication cards. As it is, this showed that the average communication CPU usage in the node of about 50% was a valid figure.

Why worry about this?

554 of the 640 tags and export blocks had default significant change. If the defaulted FC 222 blocks had 1% significant change, the base load would nominally be 2181 / 60 sec or 36 XRs / sec. Allocating 600 XRs per second nominally would allow the analog tags to be increased in sensitivity by a factor of 20, with less load on the system than there is now.

This investigation also brought our attention to FC 223, the Analog Out/Channel block, which also has a default significant change of 0.

Guess what? There are 80 of these in PCU 2. They all have the default 0 significant change, so they are generating 1 exception report per second. 31 of them are spare blocks, so that load is doing nothing.
Bottom line is that, unbeknownst to our client, the exception report loading on the node included:
  • 96 analog in and 31 analog out spares giving 127 utterly wasted XRs per second
  • 469 analog in and 49 analog out tagged blocks giving 518 very, very, precise values every second.
  • 26 XRs per second from the other 1536 "low class" tags, most at default significant change.
Thus, the load was about 600 XRs per second. If the spare tags were deleted and the defaulted ones set to 1% significant change, the load would be 518 / 60 per second (typically) or 9.

This node would generate 35 XRs per second as currently tuned. There is lots of XR capability to improve its tags and history data using the capacity that is nearly completely wasted right now.

How many other nodes with FC 222 and FC 223 blocks have this bad situation?

The good:
  • Large Australian power plant has 10663. One has default significant change. It is also not tagged.
  • Large Canadian power plant has 1610. None of the 161 that have 0 significant change is tagged.
  • Large American power plant has 1312, none of which is defaulted.
  • Medium size Canadian power plant has 192, all with sig change set to 1.
The bad:
  • Large Australian process plant has 66 with default values. 16 are tagged, which is a meaningful load.
The ugly:
  • These small American power plants with all values defaulted at 0 and over one-third tagged but spare.
  • Small American power plant with 88 of 754 with default 0. 86 of these have tags, so they are a load. 21 are spares, so they are a wasted load.
  • Medium size Canadian process plant has 496, all at default 0. 216 are in PCU 171 and 280 in PCU 172. Every one is generating one XR per second.
  • Medium size American process plant has 559 FC 222, of which 368 are tagged with significant change 0. No spare ones are tagged.
It is clear that the significant change specifications and tags for all FC 222 and FC 223 blocks should be examined. The load can be large, and it can be a waste of a precious resource, even stalling or losing exception reports.

Postscript

The general situation with FC 222 and FC 223 blocks that are not defaulted is to have the significant change specification set to 1, no matter what the span.  This is probably an error, too, suggesting that the work was done under the misconception that the specification is a percentage value, rather than an EU one.  1 in a span of 5 is 20%, whereas 1 in a span of 1000 is 0.1%.  Since both appeared in the same system, with the only value used being 1, it is likely the values should be studied even when they are all not defaulted.

Monitoring Exception Report Performance

Are Dated Design Compromises Affecting Your HMI and History Data Precision?

In many INFI 90 systems, there is a significant loss of continuity between the system implementation and its current use and performance.  The experts that made the original decisions are long gone, with no documentation and justification for many decisions that were made.

How can you find out if the system performance tuning decisions made are still valid?  Why is it possible that the way things were done years ago is no longer valid?  

Systems have gone from NET 90 to INFI 90 (plant loop to INFI loop).  Additionally, the PCU now has much higher communication performance available in the form of the NIS21/NPM22 pair.  The old hardware could only generate (in a PCU) 400 exception reports (XRs) per second, whereas the new hardware can do many times that number.

What are the ramifications for INFI 90 systems?  Can limitations decided on long ago be backed off? Are the decisions made long ago still valid now after you spent all that money on new communication modules?

Especially if you have PCUs with new NIS21/NPM22 communication modules, you are very likely to have the ability to generate much more fine-grained data for your HMI / consoles and for your history system, essentially for free.  The capability is there.  Why not use it?  If your system has older hardware, it may have been set up so conservatively that there is actually lots of capacity available you can avail yourself of, too.

Here is my humble sketch of how you would use spare blocks (hopefully) and a lightly loaded module to monitor the performance of your system from the perspective of timeliness or delay of exception reports.

1. In a Module to be Monitored, Create An Exception Report Generated Once Per Second

The first outrageous suggestion is that you generate an exception report from the seconds value in any module you wish to monitor.  The sketch shows this.






To be able to stop the exception reports, you would simply put a transfer block and an ON/OFF block between block 22 and S1 of the AO/L block.  This would allow you to turn on the exception reports only when you wished to check.  However, it is very difficult to imagine that adding one exception report per second per module will really make a significant difference.

You can see that, as 1 second is more than 1% of 100, an exception report will be generated every second. The objective of this logic is to use the added load for good benefit.  You will have the seconds value in Loop 1, PCU 10, Module 4 available as an exception report.

2. Create Your Time Standard in Lightly Loaded Safely Manipulable Module

The rest of the implementation uses a lightly loaded module that you can manipulate safely.  Since the objective of this work is to increase the precision of a lot of data in the system, you have to decide if the effort is worthwhile, of course.

In most systems, the time is synchronized around the loop.  Do you know it works for sure?  If it does not, you will find out when you go further.  The second bit of logic, in the lightly loaded module (Loop 1, PCU 5, Module 4 in the example), simply puts an Output Reference on the seconds value in that module.





You can see that the value on the OREF "10504 SECONDS" ought to be pretty close to any other SECONDS value in the whole system.

3. Create an Exception Report Import and Comparison Logic

All that is needed now is to import the seconds value from the module being monitored and compare it to the reference value in our lightly loaded module.  Probably 5 seconds for an alarm is horribly high, but normal monitoring techniques will tell you easily enough how tight you can get the test.  If you define the tag "11004 SECONDS LAG" (or "11004_SECONDS_LAG"), you can get an alarm whenever the exception report is delayed (or simply log it).




Of course, your imagination is the limit.  You can send the difference to an AO/L block and monitor that using your historian.  You can filter and average and remove jitter if that is needed.  The sky's the limit!

Note how easily you could monitor all the modules this way that are purported to be heavily loaded.  The only significant work involves the lightly loaded module that you can manipulate safely.

4. Ramifications for Improved HMI and History Data

What happens if you find that there is no delay?  You also might have implemented the technique in the post "Monitoring Node Communication CPU Load" and found that your node CPU usage is very minimal.

The most important limitation in existing INFI 90 systems is the Significant Change specification.  This number tells either a percent of span (AO/L blocks, Station blocks) or an actual EGU value (FC 177, 222, 223) that triggers a new exception report.  Traditionally, 1% is the default value used to try to keep the load managed.  Is this still valid, if you have no exception report generation delay and idle communication modules?

If you have proven that you have excess communication capacity, you can start improving (reducing) the significant change specifications of important or too coarse tags to get better data to the operators, engineers and executives.  You can be sure that you have lots of capacity by keeping the CPU load reasonable (but higher than the minimal level found in many modern systems).  You have a direct test and warning if you are getting delays in the generation of exception reports.

5. Negative Ramifications of Current INFI 90 Practice with respect to Significant Change

In case you wonder, or have to justify even thinking about the monitoring suggested here, you will want to look closely at my post Improved Tag and History Data Precision in INFI 90 Systems.  It will give you "grist for the mill" as you try to make the data originating in your system better.  It will show you that there usually is a lot of room for significant improvement.

Improved Tag and History Data Precision in INFI 90 Systems

INFI 90 is based on the concept of Exception Reports (XRs) that reduce the communication load needed to get good values to HMI systems, historians, OPC servers and to be used in other parts of the system.  Analog values have a "significant change specification" to prevent load from analog values that are not changing significantly.

History

This history is approximate, as told to me by gurus over the past years.  

Net 90 and INFI 90 started with a 1 MBaud plant loop communication ring, plus the impediment that a single XR was sent for each enrolled user.  These two factors made it easy to overload the capacity of the system.

Infi Loop introduced both a 10 MBaud communication ring and a protocol that allowed multiple destinations on the ring for an XR, so the load caused by an exception report no longer changed if more consoles used the tag, for example.

Pragma

Practical considerations were developed to avoid the loss of exception reports in the early systems, and developed further as the systems got both bigger and faster.  Bigger, of course, meant more load, but faster meant more capability.  Initially, the practical suggestion and default was that a change of 1% of span in and analog value was a good compromise.  Sensors were often enough not very accurate and it seemed logical.

The Modern World

In the modern world, there are aspects you should take into account:
  1. INFI 90 communication capability increases have not usually been translated into more precise data.
  2. Sensors have often changed from 2 1/2 digits to 3 1/2 digits, ten times as precise.
  3. Techniques now exist to easily monitor exception report delay and communication loading.
  4. Decisions based on data that is not sensitive enough are made regularly, probably with affecting your plant negatively at times.  This applies to both console operations and historical data.
A Case Study

In a plant, examining the DBDOC Significant Change Report, we noted a flow rate with a span of 7000 and default 1% significant change.  Because it was being imported into another module by exception report, we could study the suitability of the significant change setting.

There were 23 exception reports in the period shown, 18 of them at Tmax of 75 seconds.

Here are some salient aspects of the raw and imported values:

  • Raw value is the pink line.
  • Imported value is the blue stepped line.
  • Working range is under 400.
  • Tmax is 75 seconds, and all positive-going exception reports were caused by the timeout.
  • The negative-going exception reports were triggered by the drop of 70 before 75 seconds had elapsed.
The green sections show where the imported exception report value was less than the actual value.  The orange ones show where it was greater.  Interestingly enough (to me, anyhow), I had joked in front of clients about how bad it would be to be integrating exactly this sort of a variable.  You would find the accountants for the customer very happy when you told them you had used the blue step function to decide how much they should pay.  They would pay fast, and not quibble.

Out of curiosity, I estimated the performance using 0.1% significant change.  I did this by simply taking the raw value as a start and making a pseudo-XR when the value increased or decreased by 7.0 or more.  This gave me an estimate of how the imported values would look and what the performance would be.  The number of exception reports would have been about 140 in 1420 seconds, or about 6 per minute.  Only one period of 75 seconds went by when there would not have been a significant change. 

What does this look like from a numerical perspective?

Significant Change       1%      0.1%

Mean error            -8.1      -1.3
% of full span       -0.12%    -0.02%
% of working range   -2.02%    -0.34%

Mean error magnitude  29.0       3.5
% of full span        0.41%     0.05%
% of working range    7.24%     0.87%

The Bottom Line

By using the data available through DBDOC Watch Window (or Composer Trending, or any other block value monitoring package), you can see that it is perfectly possible for an exception reported value to be handled in a way that could be problematical.  The data comes from an exception report import block, but applies to every value on every graphic, and to every historical value in every INFI 90 system.

At a small cost in increased exception reports, using capacity that can be verified as being available safely, process values can be much more precise.  The full analysis that is done here is not necessary.  What you need to do is simply:
  • Identify imported values, tags and historical data that needs more precision
  • Monitor the node communication loading
  • Where there is capacity, use it by making the significant change specification tighter
The improvements in console, history and perhaps control and shutdowns will be significant.  You probably have the capacity to do this right now.

DBDOC and Spare Blocks

Sometimes, you have to find a spare block and the spare blocks / boneyard sheets have not been maintained.   DBDOC can make this task systematic and as easy as possible. We plan to add a feature one day to directly identify unused blocks, which will be even nicer.  Keep those cards and letters coming, folks!

Start with the Table of Contents - Miscellaneous Indices chapter.  Click on Function Codes.  In the Index to all Function Codes, click on the Function Code 30 entry to get to the list of all FC 30 blocks in your system.


You are now at a list of all the FC 30 blocks in the system.  Scroll down the list until you get to the module you want, in this case, Loop 11, PCU 10, Module 2 (Module 11,10,02 in DBDOC terms) and click on the highlighted entry to call up that block.  You will see the block in the CLD or CAD sheet, usually with a line showing it is (probably) used.  If you turn on "attributes" with the "A" key, you will see if the block has a tag. You should, at least for a start, assume that it is used if it has a tag or if it has an output reference.

The example shows that the first block is tagged "1-TI-2241" and that it has a line carrying its value someplace to boot.  Probably used, eh?


Now you simply walk through the FC 30 blocks with the "L" key ("shift L" to go up).  The same functionality is given by  andin the icons.

When you get to one that has no line and no tag, you have found a candidate spare block.


Clicking on the block number (1501) brings up the index of all the places in the world where this block is purported to be used, hopefully only its source right here.  This one certainly seems to be unused.


It makes sense to be satisfied that you have a good enough DBDOC build that you can count on the fact the block is not used.  For example, it is possible that it is imported by some other project, and you did not build all the projects together in your DBDOC build.  If that could be the case, you should do further analysis.

However, no other tools can get you this far this fast.  We are always ready to help you be sure you have a good DBDOC build that resolves everything.  You have a candidate spare block and it really did not take very long.

What do you do if you walk right through Module 11,10,02 without finding a spare?  You can go back through the blocks and click on the output block number, looking for blocks that are not used in any graphics.  Although these might be in your history system, you can go after that usage and perhaps find that the block can be re-purposed with no problem.


When you are walking through the blocks checking for how they are used, the key sequence is easy enough to do semi-automatically:
  • click on output block number
  • back-space to get back to the function code index
  • type "L" (or "l") to get to the next linked block and repeat
There are, of course, other ways to do this.  It is very nice when all spare blocks get put into boneyard pages.  However, that is not always the case.  When you have to find one and see how it is used or not, this DBDOC technique will certainly help you.




Thursday, December 19, 2013

Monitoring Node Communication CPU Load

INFI 90 systems are characterized by PCUs that are Nodes on a Ring.  Traditional systems include a NIS/NPM pair that handles the communication between the Modules on the PCU/Node and the rest of the system.  The performance of this interface can be monitored trivially using WatchWindow in DBDOC Hyperview.

Note that ABB Technical Bulletin TB1999054A gives details on the various performance statistics available from a node.  It also specifically mentions that this capability was introduced in INNPM01 firmware revision C.1, so it is not available in older versions.  It being at least a decade and a half since that firmware revision was introduced, let's hope nobody will be disappointed by not being able to do this.

Using DBDOC Watch Window to Monitor Communication CPU Usage

To see what percent of the communication module's processing power is being used, you simply monitor Loop L, PCU P, Module 0, Block 11.  The example shows Loop 1 PCU 4 being monitored and the monitoring of Loop 1 PCU 6 being defined.


Notes about this monitoring:

  1. This fetch is never done in turbo mode, so you only have 10 to 15 values per second available, and these are shared with all your other Hyperview users.  
  2. Running for one or two "Tmax" periods for exception report flushing should give you a good picture.
  3. Turn off the Watch Window data collection by clicking on the green clock icon when you have a picture of the loading.
  4. If you do a save of a module in the PCU while you are monitoring, you will get an idea of the maximum communication loading possible in the node.


Interpretation of the Data

Experimentation has shown that CPU loading above 90% shows a situation where exception reports (XRs) can be delayed or lost.  This is the bad side.

What about if you find the loading very low - under 10%? This is the good side. We believe this means you have a lot more exception report generation capability than you are using. Your system is capable of significantly better performance with respect to tighter values for the HMI and for the history system. Pushing the communication usage out of the idling range will potentially be very beneficial.

You might refer to Improved Tag and History Data Precision in INFI 90 Systems for more on what you can do to understand what you might be suffering from and how to get more out of your system.


Results

We would be happy to get a copy of the Watch Window data, which is in a .CSV file that is created by the monitoring.


Disclaimer

The monitoring indicated has been done on dozens of DBDOC systems with no known problems.  It is the same monitoring as done by Process Portal B and gets the same result (of course).  Monitoring only one block makes the load as minimal as possible.  However, if you have any question or hesitation, your consultation with your ABB support specialist should give you more insight.  We are very willing to work with your experts.

Wednesday, December 18, 2013

Function Code Quantity

A client wrote:
     "Can DBDOC tell me how many Function Code 156s we have in our project?"

The answer is:
     For sure!  Let us count the ways. 


1.  In DBDOC Hyperview, under Miscellaneous Indices, click Function Codes and then Function Code 156. This will give you a list of all of the blocks in your system that are function code 156. The blocks are numbered, so you can just scroll to the end of the list for a count.


2.  FC156.dbf in the Exports subfolder has all the FC156 blocks and all the specs, even the compiled input block numbers (and FCnnn.dbf has the same thing for the FC nnn blocks).


3.  File FCLIST.TXT in the build folder lists all the function codes used in the project and how many of each that there are.


4.  The MHD Module Info section of a module will tell you how many are in that module.  This can make module CPU loading possible to estimate.


5.  MASTER.DB is an SQLite database that has all the Function Code information and a lot more. SQLite tools will allow you to open the file, examine the records and do queries.


The bottom line is that DBDOC has a great deal of capability built in that most of our users never find, so they do not tap the resource they have available.  We have tried to do things that are not possible easily with existing tools, if they are possible at all.

Happily, one more site is now turned on to the capability.  

Over the last half year, I have presented Advanced DBDOC workshops and Hyperview training sessions totalling 23 days at 13 sites.  Without exception, the DCS teams found a mess of useful things in DBDOC that they had not guessed were provided.

Tuesday, November 12, 2013

Error example: The case of the not quite identical clones.

This is the story of one error in a system with two approximately cloned units.
 
The error message is simple.  It says that a FC 36 8 input qualified or (QOR) block does not have enough inputs wired to be able to trigger a "1".
 
Image 1 shows the following DBDOC aspects of the error message, starting from the Error Browser.
  • A - The error is selected in the Error Browser.  Note it is the only error of this type.
  • B - Clicking on it brings up the detailed description, plus the location on the sheet where the error is found (Image 2).
  • C - Note how Error Browser makes new detailed error documentation available to the user.
  • D - The documentation called up by asking for "Complete error documentation".
  • E - The documentation showing explanation and example (not from this system, of course).
Image 1
  
Image 2 shows how Error Browser brought up the flagged block in the sheet.
  • F - The block number is highlighted, and the block index available to show where it is used.
  • G - The specifications show S9 is 8.  With only 6 inputs, the output can never be 1.
Note, however, that this is a clone of another unit, which did not have the error. 
  • H - The text of the reference on this output, which we can search for in the other unit.
Image 2
 
Image 3 shows how Hyperview text searching finds the reference text to resolve this question.
  • I - Search for the (case insensitive) text of the reference on the sheet with the error.
  • J - Go to the result in the first unit.
  • K - Here is what you find.
  • L - The logic in the first unit was originally a rung block - FC 111.  
Image 3
 
The error, it turns out, was introduced when the rung block was changed into AND logic implemented with the FC 36 block, but incorrectly.  There is a good reason not to have cloned errors. 
 
Cloning is beautiful - it replicates tested, working logic.  When a message or error is noted, it would be expected to be in all similar instances.  If a message is not replicated, it can mean:
  1. the error was fixed in another copy
  2. the error has not yet been made in the other copy
  3. the copy is not an exact clone
The error in this example is in the third category, logic that is not exactly the same in the clone.  Watch out for situations like this!
 

Monday, November 4, 2013

News from New Zealand


Since arriving Sunday evening we have had a very busy week. Monday was spent driving from  Auckland to New Plymouth by roads that twisted, turned and climbed. There are other highways that go more directly but we enjoy the challenging ones, if there is time. The scenery was spectacular, as you can see from some of the pictures. From a historical view point, many (if not all) of the green treeless hills (mountains) you see were treed in about 1850.

On Tuesday and Wednesday we worked with contractors and clients. We will have a good relationship with the three plants in the future.  On Thursday and today we have had great touring days. We are a couple of 100 km from New Plymouth, but have not started going north. Again, the scenery has been spectacular.   Next Monday and Tuesday we will spend two days doing DBDOC workshop and training sessions at client  sites. 


The "Cabbage Tree."  Geoff commented that this
must be the tree made famous by Dr. Suess.
Sunday driving on the eastern coastal highway 35 from Gisborne to Opotiki we saw miles of sandy beaches. The British explorer, Captain Cook’s cabin boy, Young Nick, sighted a piece of land (now called Young Nick’s Head)  near Gisborne in 1769. This was the start of Britain’s relationship with New Zealand. We travelled north-east along  the coast towards Opotiki. Noon lunch was a picnic overlooking a wide, sandy beach with rolling surf and bright blue water.

Inland there were many farms with thousands of sheep, cattle and occasional herds of horses. The countryside was covered with lush green grass and occasional groves of trees. There were large volcanic shaped hills everywhere, an the occasional plateau of grass. An interesting tree is the cabbage tree, which has clumps of leaves that look like  cabbages on their branches.

As part of the day we met on the road two steers and a cow. Our car came to a stop. The cow gingerly walked by on the other side of the road. The steers took a second look, thought for a while and then decided to follow her lead.

As they passed by, we slowly moved forward.

A short time later we met a herd of 50 or 60 sheep. We moved slowly forward. Then we saw the source of their movement, a small truck was slowly moving behind them, herding them down the highway. Hopefully, the procession did not have far to go.

An hour further down the road we met two spirited horses, who had just opened the latch on their pasture gate and were enjoying a run down the grassy ditch. Next, we were treated to great seaward views over The Bay of Plenty. It is a natural U-shaped harbour.

The rest of the drive was less eventful, and by evening we arrived at our B&B. Here we were treated to a great steak supper to complete the day. Tomorrow will start two days of DBDOC workshop and training sessions at Tasman Paper.

Thursday, October 31, 2013

Happy Halloween


There was a lot of candy eating at GMCL today.   A selection of the best dressed GMCL staff, from left to right: Jen, Keith, Sarah, Roxana, Rob, and Linda.

DBDOC and Taglist Maintenance

Why is this worth talking about?  Many systems are burdened with numerous "stub" taglists, archives and everything under the sun.  People try to make sense of them, but there is nothing systematic.  The techniques available using DBDOC will let you unburden your system of deadwood, leaving useful information that is cross-checked.  Some sites give up on the process, but this prevents them from having a good cross-check on the HMI because they create logic and thus tags in the EWS.

INFI 90 HMI systems can be separated into these classes:
  • Master taglists in the HMI - 800xA, SPlus, PGP, PPB, Conductor NT and PCView
  • EWS contains the HMI taglists - Conductor VMS and WinSODG
As sites have moved to more modern HMI systems, reconciling the taglists in the EWS to match the master taglists in the HMI systems becomes important.  Here is how to do this using DBDOC.
  • Identify the actual taglists used by the consoles.  You should be building them in DBDOC already.
  • Identify the taglists in Composer or WinTools that need reconciliation.
  • Build as many subprojects as needed to have simple parallel lists of tags.
DBDOC has numerous resources for supporting taglist work if you need more:
  • Extracted SQLite database containing all the tags built into the project
  • Individual DBF files for the taglists from both EWS and HMI systems
  • Combined taglists of Composer and WinCAD tags
There can be significant benefits to keeping the HMI and EWS taglists synchronized.  We would be happy to help you understand the data DBDOC makes available to you and how to take advantage of it. 

Friday, October 25, 2013

Thoughts on 10.5

The most important feature in DBDOC 10.5 for everyone with INFI 90 is the Error Browser. We continue to find issues that cannot be found any other way, as we have done for the past seventeen years. Now, finally, we let the user examine, comprehend and resolve our messages. You will hide many, but mark some for attention. When you rebuild the DBDOC document, new issues will be highlighted. Things you have hidden will stay hidden. Finally, you can converge to a system with no significant errors.

We continue our search for a system with more than 200 sheets that has no errors worth fixing. So far, only systems that have used DBDOC and heeded our messages are even close.

AutoCAD 2012 is now supported as well as previous versions. XLS file support has been extended to handle more and wider columns.

Of course, we finally have released initial support for ABB SPlus Graphics, 800xA PG2 and IET800 CIU. You will still get the most data out of your INFI 90 system for DBDOC with the least load out using a conventional CIU with RoviSys OPC90Server Turbo. An unprecedented 100 values per second at 10 GMI fetches can be achieved.

Why an Error Browser?

I have now presented the new Error Browser by building DBDOC Version 10.5 at six Australian DBDOC sites this past four weeks. The response has been universally ecstatic.

Severe errors were relatively easy to work with before Error Browser. The messages highlighted things that were clearly wrong, whether or not they were actual problems. Every site with DBDOC worked over the error messages, because we find significant things that can bite.

However, we find many things that are "wrong" and that might cause problems, but that are likely to just be cosmetic. Looking for needles in haystacks (and they are there) could not be justified. Actual errors thus were missed. Furthermore, conscientious DCS people end up with a whole mess of things to be ignored for reasons including the following:
  • Logic, graphics and tags simply not used - by far the most usual reason for an otherwise significant error to be ignored.
  • Logic cannot be fixed without a shutdown - making notes on the CLD or CAD sheet and documenting problems that cannot be fixed without a cold reload is often necessary.
  • Issue is cosmetic - the error stems from a systematic approach like using a macro with functionality that is not needed in all instances.
Until now, the error messages we presented the DBDOC users came back each rebuild. Until the system configuration, graphics or tags could be changed, they were seen again and again.
 
The real strength of Error Browser, however, shows up in the messages we have traditionally called "CHECK" ones. They simply could not reasonably be examined and analyzed before. Now they can.
 
Error Browser makes it a whole new ball game. Sometimes all the messages in a particular class can be hidden as unworthy of further attention. The easy ability to walk through hundreds of messages can make it possible to find the few that need attention. Mark them all as hidden, walk through, star the ones that need attention, in fact, and unhide them. Clients reduced hundreds of mostly innocuous messages to a few nocuous ones (is nocuous the opposite of innocuous, I wonder).
 
Error Browser was first requested by a client in 2002. It is now here. My experience in Australia, with good DBDOC clients, is that it is not too late. The INFI 90 sites without DBDOC need it more than ever, because system integrity now is achievable on top of fast, effective, read-only fault-finding and trouble-shooting (Australians do fault-finding).
 

Friday, October 18, 2013

DBDOC 10.5 is ready to go!

I'm happy to report that we are finally in the process of actually burning DBDOC 10.5 DVDs at the office, so if you're expecting one, it should be arriving soon.  This release has been a long haul, but it contains some very interesting new features (along with plenty of general improvements and bug fixes as usual).

If you need it RIGHT NOW, you can download DBDOC 10.5 here.

DBDOC 10.5 contains beta-level support for PGP, SPlus and 800xA PG2 systems.  These are in the final stages of testing and integration, and will be added to the official release version in November.  If you have one of these systems, and would like to test drive this support before then, let us know.  We implement the support for these systems substantially by reverse engineering example files from clients, so the more trial users we have, the sooner our support will become complete.

Another major new feature in 10.5 is the Error Browser.  For the first time, the configuration errors identified by DBDOC while compiling a project file can be presented interactively by the Hyperview browser.  Although this error information has always been generated during builds, previously the only way of getting at it was to manually search the error text files produced, or build them into the M14 directly with a second build pass, a somewhat unwieldy method. 

In any case, there was no particularly easy way for the uninitiated to identify errors of interest and hide the irrelevant ones.

All this has now changed.   The Error Browser not only makes it easy to organize errors in a variety of useful ways (by severity, by document, by subsystem, by module, just to name a few), but also to flag errors, explicitly mark them as having been reviewed, and hide errors or entire categories of errors when they are not of interest.  The errors presented in the Error Browser link to specific location in the main project file, and there is built in error documentation to make the task of sorting and evaluating errors as easy as possible.

With this initial version of the Error Browser, individual users will be able to mark off errors for themselves, but shared error review is planned for the next DBDOC release.  It will then be possible for multiple users to collectively review and hide errors.

Other new features in 10.5 will be explored in upcoming posts.  Check out the official "What's New" document for an overview.

Tuesday, October 1, 2013

Lamb, Kangaroo and Pavlova

Charlton Fuentes and Geoff Michaels at DBDOC
training session at Queensland Alumina.
We have just finished two days of DBDOC advanced workshop sessions at Gladstone.

Children have been enjoying their spring break from school this week and next. I was just offered and ate a delicious ripe tomato. As spring turns to summer, the tomato season is over in Queensland just as it is in southern California six months earlier. The summer season is too hot for plants like tomatoes to thrive.

Last night we visited with friends, and had a lovely home prepared meal of lamb and kangaroo. The meal was finished with a delicious Australian dessert of Pavlova and fresh fruit. I also found out there are several snowboarding and skiing resorts in southern Australia, open in their winter season (May to August).

Tomorrow is a driving day as we go further south. Geoff enjoys driving. Driving on the other side of the road seems to come naturally for him. We will be traveling through kangaroo country, so we are looking forward to see one or more as we drive by.

Saturday, September 28, 2013

Sugar Cane Train

It is Saturday noon, and we are in Bowen. 

As we drove south from Cairns we passed from tropical bush to Gum trees, dried grass and large fields of sugar cane. The sugar cane is in bloom and ready to cut. Often along the road are railway tracks. Sugar cane trains are used to transport the cane to the mills.

Tony Porter at Airlie Beach
Sugar Cane Train
We spent a lovely day on Friday with long time DBDOC customer Tony Porter as we looked around Bowen and then we went for a late lunch at a nearby beach. For supper we went to a Chinese restaurant, The Cove, on a beach facing the Pacific Ocean. It was lovely to watch the sun dip under the horizon as we had supper.

This afternoon we started down the coast to Mackay for another night's stay before we get to Gladstone on Sunday night. On the way we passed many more fields of sugar cane, and finally a sugar cane train. See the pictures with the cane mill in the background.

People here do not seem to drive these distances often, although the roads are paved, two lane roads with frequent passing lanes. The people are very friendly, and it reminds me of rural communities in western Canada.

Tuesday, September 24, 2013

"Manual Mode" Hyperview Training

About half hour ago the power failed. I do not know if it is temporary or long term. It is amazing the quiet that settles on a work space when the white noise is turned off. It is fun to watch people try to stay busy without their computers. Geoff is now conducting his Hyperview class using voice and the Chapters One and Two of the Hyperview Manual. No overhead or PCs to confuse anyone.

Sunday, September 22, 2013

Tropical Workshop


Arrival at Gove Operations.

This is our first day at Gove Operations in Australia's Northern Territory. Last night we flew from Cairns to Gove, a two hour flight. Imagine our surprise, when a hot complimentary supper was served to everyone in economy. Definitely a thing of the past in North America. The weather here is very pleasant, 22 to 28C - day and night.

This morning, Geoff has started discussing advanced DBDOC workshop topics with the maintainers of the system. Tomorrow and Wednesday, the mornings will be spent with the technical staff reviewing and introducing

Hyperview topics. The afternoons will be spent on further advanced DBDOC topics such as error review, uses of Watch Window and inclusion of AutoCAD in the build. Everyone is enthusiastic about DBDOC.

The site is extremely safety conscious. This is the first time I am wearing steel toed boots, as well as everyone else in the IT office area (where I have a work space).

 

Saturday, September 21, 2013

A Change from Canada

We are finally in Australia and enjoying the beautiful weather. Our flight from Guam was delayed five hours. We were scheduled to leave at seven in the evening and arrive in Cairns, Queensland at midnight. However, a violent storm at Saipan (an island forty-five flight minutes from Guam) pinned the plane down and it returned to Guam at midnight. Hence, we arrived in Cairns at five am, arriving at our hotel at least three hours before our ten am checkout time!

However, from there things started to look up.


We moved Friday afternoon to a beachfront apartment on Trinity beach. Here we have remained on Friday and Saturday nights. During the day on Saturday we drove to and visited the tropical rain forest north of Cairns -- a great day. Now Sunday we are preparing for our flight to Gove and out first week of DBDOC workshops and training.


A picture only an engineer could love. We crossed a large river as we approached the Daintree Tropical Rain Forest.  The ferry winched itself across the river and back.  This is a picture of the cable mechanism.


A look out view over the forest as it extended down the slope towards the ocean.

Thursday, September 19, 2013

Rain in Guam

Today we are in Guam. Yesterday, we flew from Vancouver to Tokyo and spent about six hours in the United Airlines lounge. A meal on the plane was typical Japanese, a nice introduction to Japan. The lounge was an extremely large and pleasant place, where I enjoyed a three hour nap, all the sushi I wanted, chicken fingers, and a delicious vegetable soup. All the staff were very helpful. Internet connections were easy and good. We were able to keep in touch with the office and our clients.

After a good night /morning at Guam we are waiting to go to Cairns Australia this evening. A significant rainstorm rages outside our hotel. We have just found our flight is an hour late but going. We will soon take the shuttle to the airport.

We are at the airport. As we drove along, there was lots of water on the streets. The storm is supposed to last for two to three days. This is still the northern hemisphere and winter is coming. Nice looking place, but a good place to be leaving, given the weather. Tomorrow morning starts our stay in Australia. We have heard from many clients, and we are anxious to start that part of our trip.

No Jet Lag

Worked out beautifully.  We arrived here at Guam at 2 AM and negotiated late checkout at 2 PM.  I just went to sleep for another couple of hours, in fact.  We will have no jet lag when we get to Australia. 
Raining here, so our plans to wander about and find something interesting collapse to Plan B - chill, sleep and go on at 6 PM to Australia. 

Tuesday, September 17, 2013

DBDOC Around the World

DBDOC has taken us traveling than once over the past fifteen years or so, but it's rare for us to be in both Australia and Europe on the same trip. However this is an exceptional three month round the world adventure, about three parts DBDOC training and consulting and one vacation.

We are getting ready to leave Canada for Australia and New Zealand. Tuesday morning we leave through Vancouver, for Japan and then Australia. We have a challenging and enjoyable schedule ahead of us.

We will be starting in Cairns and Gove, and then moving down the coast to Gladstone and Pittsworth. We look forward to working with clients in these places.

Before we leave the Cairns area we will have the chance to spend a day in the Daintree area, a tropical reserve. There will also be a weekend at the beach. And visits with several friends.

By October 8th, we will be in the Sydney area for a week, ending up with spending Sunday and Monday (October 13 and 14) with friends in Canberra, the capital of Australia.