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January 29, 2013
Yokogawa Electric Corporation
Plant Energy Conservationby Cloud Computing & Data Analysis
All Rights Reserved, Copyright © GIPC 2013
1. Introduction of Yokogawa 2. Introduction of the previous best
practices3. 2012 Green IT initiative Introduction of the target company Schedule overview 2012 program contents Summary Contact information
Table of Contents
1
All Rights Reserved, Copyright © GIPC 2013
Introduction of Yokogawa
Name: Yokogawa Electric Corporation
Subsidiaries/Affiliates: 89 in 55 countries
(19 in Japan, 70 outside Japan)
Employees:
Installed nearly 24,000 control systems
As of March, 2012
Japan affiliates5,190
Global Total19,437
Overseas affiliates10,036
Yokogawa ElectricJapan 4,211
Our goal:Contribute to society through broad-ranging activities in the area of Measurement, Control and Information
ERP
MES
Digital Sensing Technology Process AnalyzersSafety system
Control System& Field devices
Distributed Control System
Advanced Process Control
Software/solutions
Operation Efficiency Improvement
Software/Solutions Plant Information Management System
Asset Diagnostics Software/Solutions
A suite of solution services for continual improvement
of plant productivity and energy efficiency
A large range of green products lineups
Advanced PLC
Network-based control system
Sustainable synergy
2
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What is VigilantPlant Services?
Help customers to realize “VigilantPlant” by improving the effectiveness of automation systems/products over the entire plant lifecycle
Provided based on a solution approach in consideration of the current stage of each client’s continuous improvement programs
PlantLife-cycle
PlantConstruction
Operation
PlantDecommi-ssioning
Plant ExpansionSystem Migration
Operation
Identify new improvement possibilities & prepare for solution implementation
Opportunity Identification Services TM
Solution Implementation Services TM
Lifecycle Effectiveness Services TM
Implement identified solution based on a best practice
Sustain the effectiveness of implemented solution through plant lifecycle
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VPS for Energy Conservation
Lifecycle Effectiveness Services
Power PlantAPCBTG
OptimizationBTG
Optimization
Systems/Packages for Solution
Implementation
Asset Asset PerformanceImprovement
FurnaceFurnaceEfficiency
Improvement
Regulatory Regulatory Control
Stabilization
Energy Monitoring System - For Entire Plant
Energy Monitoring System - For Process UnitsData Drilling Down
Data Drilling Down
Asset
maintenance
Asset management & maintenance
Plant wide utility optimization
Utility Section Production SectionProduction
Quality
Production/Operation/
Quality
Electricity
WaterSteamHeavy oil
Gas
Energy-supplying
Energy-receiving
Other Products Lineups Other Solutions LineupsEnergy Energy
conservation master planning
Wide variety of green products
Opportunity IdentificationVisualization by EnPIsmonitoring, Comparison & Further drilling down, taking measures
Analysis & SimulationAnalyze data, findopportunity, improvementplanning, benefit simulation
SolutionImplementationImplement New function, re-tuning, Control systemmodification
Operation & MaintenanceKeep benefit, Verification ofthe result
Plant Remote Analysis
4
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Regulatory Control Stabilization – Example 1.1
Manipulated Variable
PV MV
Process
SV(Set Point)
Cnt’l Parameters
Control Variable
DCS
Field Instruments
Cnt’l
PID
Control Loop
Energy Saving by RCS
①
①Retuning of PID parameters
②Reduced Set Point ⇒ Lower Energy
②
Set Point(After)
Additional Space
Deviation
Constraints
Set Point(Before)
Time
Process Variables Deviation=SV-PV
SV
How stable operation contributes “ Energy Conservation”
5
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Regulatory Control Stabilization – Example 1.2
Oscillations suppressed to 1/16⇒ Enabling Energy Conservation by set point changes
After
Potential for energy saving
SV Change
Before Optimization After
Before
Economical impactsExpected Savings
Test Plant (1 line) As COG 569,400 Nm3/yPotential (30 lines) 17,082,000 Nm3/y
Even a small step, impacts are large
14,519.7 t-CO2/yCOG: 0.85t-CO2/1,000Nm3 (METI Guideline)
A study of energy saving in a steel company in China
6
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Asset Performance Diagnostics – Example 2.1
Clear path to CBM(Condition based maintenance) Issues: As no heat performance monitoring tools are available
for hundreds of heat exchangers, maintenance targets and timings are listed up only on human experiences(TBM=Time based maintenance)
Solutions: Energy condition monitoring and analysis using asset performance diagnostics technology
7Heat exchanger(HEX)diagnostics systemHeat exchanger
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Asset Performance Diagnostics – Example 2.2
Future condition and best maintenance timings of four target HEXs were precisely forecasted using 1.5 year past data with advanced curve fitting technology for accurate predictions (=CBM)
Energy efficiency improvement (= Energy saving) HEX pumping power saving HEX heat transfer efficiency improvement Extraction of plant wide bad acting HEXs
Heat transferefficiency
Time
Turn around Turn around
Cleaned
Not Cleaned
Operationcycle
Current HEXperformance
Differenceof energyconsumption
Fig-1: Heat transfer efficiency deterioration by fouling
8Advanced curve fitting technology
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Naphtha flow
Dilution steamflow
Air
6 paths
(For decoking)
6 paths6 paths
Olefins (Ethylene, propylene, etc)
Released at decoking
Combustion air
Fuel gas
Ambient temperature
Tube metal temperature
Coil outlet temperatureCoil outlet pressure
Furnace temperature
6 paths/ 24 tubes
Coil inlet pressure
Furnace pressure
Coil inlet temperature
Exhaust CO2 density
Raw materials are supplied to metal tube.
Cokes are stacked at inner tube wall as production goes by and it deteriorate heat transfer efficiency , then finally tube metal temperature (TMT) reaches to the mechanical limit.
Hence periodic De-coking is performed every 45 days by stopping the furnace.
Decoking furnace is stopped but the plant is kept operating.
Furnace Decoking Optimization – Example 3.1
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Furnace Decoking Optimization – Example 3.2
A study to reduce energy usage by the improvement of asset performance in a petrochemical company in Thailand Solutions: Energy condition monitoring and analysis using asset
performance diagnostics technology Targets Ethylene cracking furnace coking tubes conditions (Fig-2) Actions Optimized utility supply for decoking process as per the coke
level of each coil tube
Coil-tubes
Rel
ativ
ely
clea
n tu
bes
Dirt
y tu
bes
Mod
erat
e di
rty tu
bes
Mod
erat
ely
dirty
tube
s
Steamand air flow
Steam and air flow
Rel
ativ
ely
clea
n tu
bes
Dirt
y tu
bes
Mod
erat
e di
rty tu
bes
Mod
erat
ely
dirty
tube
s
Coil-tubes
If coking tube dirtiness is measured, then…Energy conservation by variable steam feed would be available
Coking severity indices were measuredusing statistical diagnostics system
Worst 5 severely coking tubes
Before After
10
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Green IT Initiative 2012
Production volume
Ene
rgy
Con
sum
ptio
n
Reduction
Ene
rgy
Con
sum
ptio
nProduction volume
11
Application of emerging IT technology (Cloud Computing) Opportunity identification of cloud computing
applications Implementation of applications and demonstration
Application of advanced analytical technology Opportunity identification of advanced plant
analytical tools Implementation of analytical tools to actual plant
operation analysis
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Introduction of the Target Company
Target company: A company in process industry (Oil and Gas)
that has centralized engineering organization lots of travels for data monitoring and analysis are
required between the center and the sitesitem Overview
Targetcompany
A
Time of survey
June, 2012 – Dec,2012
Company overview
A company that operates process plants in Malaysia
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Schedule Overview
May to Sep Oct Nov Dec Jan Feb Mar
Jan 29
Seminar Presentation
Selection of Target CoCompany Visit 6/26 ~ 30Cloud Tool Development
Data Collection & Analysis
Site Visit for AnalysisInterim Reporting
Final Report Preparation
Final Report Submission
Financial $ Project Report
Item
CalendarFiscal Year 2012
12/3 7
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Project Outline
Remote Monitoring and Analysis of Plant Operation by Utilizing Cloud Technology Energy saving on
travels for site visit
Process Analysis for Identifying Energy Saving Opportunities
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Cloud Computing Architecture
Hybrid Cloud Model where Applications reside in the cloud and the database is hosted privately
Cloud Data Center
File server3rd Party Consultants
Customer Engineers
Engineering Center
Cloud Applications Authentication by live ID
Process Data
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Process Analytical Tools - Development -
• The following products and tools have been developed and/or customized
- Plant Wide Oscillation (Loop oscillation analysis)- (Loop diagnostics)- (Alarm & event analyzer for cloud) - Process analyzer (Statistical data analysis)- ^ (Loop tuning simulator)
Functional tests Connectivity tests Other crucial tests
Trial run at sites Customization
Step 1- Preparation Step 2- Verification Step 3- Implementation Planning of analysis
tools Develop prototypes
16
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Process Analytical Tools - Features -
Yokogawa Analyzer Client Unit: comparing trend charts of multi process variables. Good tool to analyze temporal behavior of variables
Statistical Analyzer: PPCL’s C Visual Explorer (CVE) provides a graphical representation of multi variables. Good tool to identify correlations between variables
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Identified Opportunities for CO2 Reduction
Reduction of business travels of engineers A company has centered engineers for servicing many
sites by minimum engineers Engineers at the center travels back and forth with sites
distributed in the country for process monitoring and analysis as much as 1000 man-times/year
In cloud environment engineers can analyze plant operation in remote without limitations of time and place as if they are sitting at the site
Reduction of process steam consumption Process analysis revealed variation in steam
consumption at the one process unit 20% of steam consumption could be saved by reducing
the flow as low as its minimum requirement
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Potential Energy Saving and CO2 Reduction
The identified potential reduction of CO2 emission by the proposed schemes is about 3,000 ton-CO2 per year
CO2 emission reduced by the proposed scheme Result details
Proposal
Reduction
Fuel Energy(KL/Y)
CO2 eq.
(ton/Y)
Monetary Effect
(MYR/US$)
Reduction
(%)
Cloud 10 27 400K / 130K
20
Process 1,000 2,700 4M /1.3M
20
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Summary
Cloud computing can trim unnecessary travels of customer engineers Security of data is still a major concern for a customer Needs more applications as SaaS to attract customers
Cloud computing makes it easier for 3rd party consultants such as Yokogawa to analyze plant data from remote place
Powerful process analytical tools are very effective for identifying process improvement opportunities Full lineup of tools for analyzing process dynamics is
preferable The government should stimulate private sectors
for promoting energy saving by incentives
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Contact Information
Yokogawa Electric Corporation:
2-9-32 Nakacho, Musashino, Tokyo 180-8750, JapanTEL: +81-422-52-5530http://www.yokogwa.com/
Yokogawa Electric (Malaysia) Sdn. Bhd.:No. 9 Jalan Industri PBP 3, Taman Industri Pusat Bandar Puchong, 47100 Puchong Selangor Darul Ehsan, MalaysiaTEL: +60-3-8064-9888