Bulletin 43D02A03-02EN

Plant Asset Effectiveness Optimization Service

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With the increasing demand for energy that has accompanied the economic growth of newly industrialized nations, companies need to find every possible way to add value and max out the efficiency of their production processes. And they must find a way to do this without doing harm to the environment and while complying with stringent HSE regulations.

Yokogawa has solutions for a sustainable future that solve the issues you face with your plant assets. We can detect problems at an early stage and put forth proposals that show you the way forward to achieving concrete improvements. We make it possible for you to slash your plant asset operating and maintenance costs while reducing both energy consumption and carbon emissions.

Optimized Operationsand

Maintenance

Improve the productivity of your plant assets

The challenges for management and field operators- Increasing availability- Improving efficiency- Reducing maintenance and operating costs- Saving energy

Yokogawa helps you

The three steps have proven effective in optimizing the efficiency of plant assets.

Choose any one of these steps, depending on the condition of your plant assets, as your entry

point for using our state-of-the-art diagnostics and services. In this, Yokogawa will work with you in a

collaborative effort to get the maximum possible productivity out of your plant assets.

SEE clearly, with a birds-eye view, the condition of your plant assets by providing diagnostic solutions

KNOW in advance what must be done to optimize these plant assets by providing information-intensive service solutions that precisely detect and analyze their conditions

ACT with agility to implement proposals that resolve specific issues and achieve improvements

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03Field Digital Device Diagnostics

Control Valve and Control Loop Diagnostics

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Asset Performance Diagnostics

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Field Digital Device Diagnostics for accurate measurement and control

recognized. By using both PRM and KPI Report, Mitsubishi was actually able to spot a failure in a critical temperature transmitter that was connected to the safety system and could take corrective action before this could cause a plant shutdown.

Based on the information gathered from field devices, KPI reports are generated that help to visualize which device or interface process is likely to experience an abnormality.

A condition- and risk-based maintenance and operation approach

- Easier to prioritize maintenance work.- Make the best use of your maintenance expenditures.- Optimize Process operation.

Take your plant into the digital era to make more efficient use of your devices

- Our field digital device diagnostics show how to eliminate the root causes of inaccuracy in measurement and control.

- The monitoring of the conditions of all your field devices enables a condition-based maintenance (CBM) approach.

The Challenges The Solutions

Get maximum benefits from field digital technology over the entire plant lifecycle

- Have an exact, quantitative grasp of your field device conditions.- Improve asset reliability by being able to analyze and solve bad actors.

Isn’t it time for a more efficient maintenance approachusing field digital technology?

Yokogawa’s InsightSuiteAE enabled us to easily grasp the device health and early detect problems that Mitsubishi maintenance engineers hadn’t

JapanMitsubishi Chemical Corporation

Case Study

Our Services

The Benefits

- Critical maintenance targets highlighted

Maintenance workflow with PRM

Field Asset KPI Report

Field Asset KPI Report

Using our know-how and expertise, we offer field digital baseline tuning and consulting services to correct the problems identified in the KPI reports.

Consulting services

Consulting reports present proposals on how to make use of device information, which may include the use of PRM to optimize the daily maintenance workflow.

Maintenance optimization

Knowing exactly what is happening with your field devicesUsually there are so many devices from a variety of vendors and it is difficult for any one operator to monitor their health. An easy to implement and time saving solution must be found.

Making sure that essential know-how is not lostWith the retirement of your most experienced operators, you stand the risk of losing the knowledge and expertise needed to properly maintain field devices.

Reducing maintenance time and costsIt is a waste of time and money to check devices that are functioning normally, which is what often happens with time-based maintenance (TBM). A more effective approach is needed that allows you to know exactly when maintenance should be performed.

Visualize field device and process interface conditionsAutomatically generated key performance indicator (KPI) reports provide numeric data that make it possible to spot at a glance which devices are generating alarms and in need of maintenance.

Maximize use of field digital informationCombined with field digital baseline tuning, our consulting services show you how to maximize the availability of your field devices.

Identify targets and establish an efficient maintenance workflow

Our KPI and consulting reports show you how to prioritize your maintenance activities. A condition- and risk-based maintenance workflow reduces maintenance time and costs.

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Control valve and control loop conditions are clearly displayed so that operators can quickly spot abnormalities.

Accurate and effective maintenance planning

- Sophisticated diagnostics give you a quick and accurate grasp of device conditions.- It is easy to determine what remedial steps must be taken.

- Our control loop and control valve diagnostics help address problems that destabilize measurement and control.

- An effective alarm management system ensures that the right information is delivered to the right person at the right time so that proactive maintenance steps can be taken.

Spot hidden problems

- Never again overlook the signs of an unstable control loop.

Improved asset reliability

- Minimize failures by carrying out tuning and preventive maintenance.- Reduce energy consumption and maintenance costs.

Thai Acrylic Fibre Co., Ltd.

Our Services

The Benefits

(daily/weekly/monthly)

( Upper )Controllability deviation trend

( Lower ) Average valve movement

Controllability trend data

Control valve and control loop monitoring

Daily/weekly/monthly controllability trend data can be monitored online, allowing operators to quickly make predictions and take remedial actions.

Trend monitoring and prediction

Control valve and control loop diagnostics help identify the root causes of instability in control loops.

Root cause analysis

Being able to monitor control valves from multiple vendorsChecking control valves can be time consuming, and it can be very difficult to uniformly monitor the condition of devices from multiple vendors.

Easily identifying unstable control loopsMonitoring control loops spread out over a wide area can be difficult, and it can take a considerable amount of time to pinpoint the bad actors.

Promptly solving problems

There is a need to devise and implement a maintenance approach that makes it possible to quickly resolve problems.

Using diagnostics to identify problematic control valves at a glanceEven with multiple vendors’ control valves, it is possible to monitor how effectively they are being controlled and to promptly identify any problems.

Combining diagnostics of control valves and control loops with the monitoring of sensorsThe combination of diagnostics and extensive monitoring make it easy to identify problems occurring over a wide area.

Improved efficiency of maintenance workflowDiagnostics and consulting reports facilitate the planning of an optimized maintenance approach.

With the help of Tune VP, tuning simulator tool, it was possible to eliminate the higher set point and control the temperature without any quality issues. After control valve recalibration / servicing, the average amplitude was reduced to less than 5% which resulted into lesser requirement of instrument air.In two production lines out of five, it is estimated that annual steam saving is approx. 3,100 tons.

InsightSuiteAE has been continuously monitoring the entire dryer section of the plant. The average temperature set point was found to be maintained at 6% higher and the maximum control valve movement was observed to be 12%.

Control Valve and Control Loop Diagnostics for stable operation

Detecting and resolving issues to stabilize operations at your plantThe Challenges The Solutions

Case Study

Have you been looking for a more effective approach tocontrol valve and control loop maintenance?

Thailand

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Online monitoring gives you immediate access to asset health information.

Optimizing maintenance for each asset

- Based on asset conditions and the need to minimize energy costs, you can know exactly when maintenance should be performed.

- We use sophisticated diagnostics to analyze your assets and propose an optimal maintenance approach that will help reduce your energy consumption.

- We identify how efficiently your plant is using energy and show you a maintenance approach that will improve productivity.

Online, real-time monitoring

- Easily track asset conditions and performance. - Reduce maintenance costs even as the number of assets increases.- Detect abnormalities and be able to promptly respond in the event of sudden failure.

ThailandRayong Olefins Co., Ltd.

Our Services

The BenefitsPerformancemonitoring

Heat exchanger diagnostics

Real-time monitoring of asset health

Time-series data makes it possible to predict future performance.Prediction of future performance

Our diagnostic and consulting services help you map out an optimum maintenance approach.

Maintenance planning support

Protecting the environmentThere is a need to lessen our impact on the environment and achieve a sustainable society through measures that include the reduction of CO2 emissions.

Reducing energy costsPlant operators need to know how to optimize plant operations and maintenance (O&M) to improve energy efficiency and reduce energy costs.

Effectively reducing energy consumptionIt is difficult and time consuming to effectively monitor all of a plant’s assets and map out an effective maintenance approach that will save energy.

A maintenance approach that focuses on reducing energy consumptionOur comprehensive solutions improve energy efficiency while ensuring a stable and environmentally friendly O&M.

Measurement of energy efficiencyWe can visualize present and future energy consumption to prepare a precise and effective maintenance plan.

Predicting when maintenance needs to be performedAn online system efficiently monitors the status of many different field assets. It enables a condition-based maintenance approach that extends the service life of individual devices by ensuring that they receive the most appropriate maintenance.

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E241A/B Fouling Prediction Diagnostics

Recovered Cleaning Index after Cleaning

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Energy saving in hot fuild = 44.6 E06 kWhEnergy saving in pumping = 1.7 E06 kWh

Raw DataFitted Data

Performanceprediction

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criticality and expected time to failure. In the furnace section, the formation of coke on the coils can be precisely monitored using fault monitoring diagnostics that check for normal operating conditions and report on any deviations in real time. The information on the severity of coke formation is also utilized to optimize the decoking procedure during the decoking cycle.

InsightSuiteAE, heat exchanger diagnostics identified that badly fouled heat exchangers were impacting performance. With its failure prediction diagnostics, the maintenance team was able to prioritize a maintenance list based on estimations of

Asset Performance Diagnostics for increased efficiency

Mapping out a path that will improve asset performance and save energyThe Challenges The Solutions

Case Study

Why not consider a new maintenance approach that saves energy and reduces your lifecycle costs?

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Three Introductory

Steps

VigilantPlant ServicesTM is a suite of comprehensive services that enable Yokogawa’s VigilantPlant concept, helping manufactures achieve safe, reliable, environmentally friendly and profitable plant operations. From design through project execution, operations and maintenance, VigilantPlant Services support manufactures to achieve ongoing Operational Excellence over the plant lifecycle.

- Field Digital Device Diagnostics - Control Valve and Control Loop Diagnostics - Asset Performance Diagnostics

Field Digital

Analog

Yokogawa helps you improve plant asset efficiency for optimized maintenance and operation. We contribute to your plant asset management, realizing energy and cost savings.

InsightSuiteAE is a part of Solution Implementation Services under VigilantPlant Services. We provide InsightSuiteAE

service solutions for monitoring, diagnosing, and optimizing your plant assets.

Solution Implementation ServicesTM

Lifecycle Effectiveness ServicesTM

Opportunity Identification ServicesTM

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Based on a wealth of industry experience and leading-edge technology, Yokogawa provides a range of value-added service solutions for monitoring, diagnosing, and optimizing your plant assets. As your partner throughout the plant lifecycle, we make sure that your plant assets operate at peak efficiency while working to minimize your maintenance costs.

The Clear Path to Asset Effectiveness Optimization

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YOKOGAWA CORPORATION OF AMERICA2 Dart Road, Newnan, Georgia 30265, USA http://www.yokogawa.com/us/

YOKOGAWA EUROPE B.V. Euroweg 2, 3825 HD Amersfoort, The Netherlands http://www.yokogawa.com/eu/

YOKOGAWA ENGINEERING ASIA PTE. LTD.5 Bedok South Road, Singapore 469270, Singaporehttp://www.yokogawa.com/sg/

YOKOGAWA CHINA CO., LTD. 3F Tower D Cartelo Crocodile BuildingNo. 568 West Tianshan Road, Shanghai 200335, Chinahttp://www.yokogawa.com/cn/

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TrademarksAll brand or product names of Yokogawa Electric Corporation in this bulletin are trademarks or registered trademarks of Yokogawa ElectricCorporation. All other company brand or product names in this bulletin are trademarks or registered trademarks of their respective holders.

[Ed:01/b] Printed in Japan, 007(KP)