Plant Asset Effectiveness
Optimization Service
Bulletin 43D02A03-02EN
Improve the productivity of your plant assets
Optimized Operations
and
Maintenance
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.
step
03
step
Asset
Performance
Diagnostics
Choose any one of these steps, depending on
Control Valve and
Control Loop
Diagnostics
02
step
The three steps have proven effective in
optimizing the efficiency of plant assets.
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.
01
Field Digital
Device
Diagnostics
SEE clearly, with a
birds-eye view, the
condition of your plant
assets by providing
diagnostic solutions
Yokogawa helps you
SEE
CLEARLY
ACT
WITH AGILITY
ACT with agility to
implement proposals
that resolve specific
issues and achieve
improvements
KNOW
IN ADVANCE
The challenges
for management and field operators
1
Increasing availability
Improving efficiency
Reducing maintenance and operating costs
Saving energy
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
2
SEE
CLEARLY
Field Digital Device Diagnostics
ACT
WITH AGILITY
for accurate measurement and control
KNOW
IN ADVANCE
Case Study
Mitsubishi Chemical Corporation
step
01
Japan
Yokogawa’s InsightSuiteAE
enabled us to easily grasp the
device health and early detect
problems that Mitsubishi
maintenance engineers hadn’t
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.
Isn’t it time for a more efficient maintenance approach
using field digital technology?
The Challenges
The Solutions
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.
3
Knowing exactly what is happening
with your field devices
Visualize field device and process
interface conditions
Usually 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.
Automatically 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.
Making sure that essential
know-how is not lost
Maximize use of
field digital information
With the retirement of your most experienced
operators, you stand the risk of losing the
knowledge and expertise needed to properly
maintain field devices.
Combined with field digital baseline tuning, our
consulting services show you how to maximize
the availability of your field devices.
Our Services
Field Asset KPI Report
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.
Consulting services
Using our know-how and expertise, we offer field digital baseline
tuning and consulting services to correct the problems identified
in the KPI reports.
Field Asset KPI Report
- Critical maintenance targets highlighted
Maintenance optimization
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.
The Benefits
Reducing maintenance time
and costs
Identify targets and establish an
efficient maintenance workflow
It 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.
Our KPI and consulting reports show you how to
prioritize your maintenance activities. A conditionand risk-based maintenance workflow reduces
maintenance time and costs.
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.
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.
Maintenance workflow with PRM
4
Control Valve and Control Loop Diagnostics
for stable operation
Case Study
Thai Acrylic Fibre Co., Ltd.
step
02
Thailand
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%.
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.
Have you been looking for a more effective approach to
control valve and control loop maintenance?
The Challenges
The Solutions
Detecting and resolving issues to stabilize operations at your plant
- 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.
Being able to monitor control
valves from multiple vendors
Using diagnostics to identify problematic
control valves at a glance
Checking control valves can be time consuming,
and it can be very difficult to uniformly monitor
the condition of devices from multiple vendors.
Even with multiple vendors’ control valves, it is
possible to monitor how effectively they are being
controlled and to promptly identify any problems.
Our Services
Control valve and control loop monitoring
Control valve and control loop conditions are clearly displayed so
that operators can quickly spot abnormalities.
Trend monitoring and prediction
Easily identifying unstable
control loops
Monitoring 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.
Combining diagnostics of
control valves and control loops
with the monitoring of sensors
The combination of diagnostics and extensive
monitoring make it easy to identify problems
occurring over a wide area.
Daily/weekly/monthly controllability trend data can be monitored
online, allowing operators to quickly make predictions and take
remedial actions.
Root cause analysis
Controllability trend data
(daily/weekly/monthly)
Control valve and control loop diagnostics help identify the root
causes of instability in control loops.
The Benefits
Spot hidden problems
Promptly solving problems
There is a need to devise and implement a
maintenance approach that makes it possible to
quickly resolve problems.
Improved efficiency of
maintenance workflow
Diagnostics and consulting reports facilitate the
planning of an optimized maintenance approach.
- 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.
Accurate and effective maintenance planning
5
- Sophisticated diagnostics give you a quick and
accurate grasp of device conditions.
- It is easy to determine what remedial steps must be taken.
( Upper )
Controllability
deviation trend
( Lower )
Average valve
movement
6
SEE
CLEARLY
Asset Performance Diagnostics
ACT
WITH AGILITY
for increased efficiency
KNOW
IN ADVANCE
Case Study
Rayong Olefins Co., Ltd.
step
03
Thailand
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
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.
Why not consider a new maintenance approach that
saves energy and reduces your lifecycle costs?
The Challenges
The Solutions
Mapping out a path that will improve asset performance and save energy
- 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.
Protecting the environment
There is a need to lessen our impact on the
environment and achieve a sustainable society
through measures that include the reduction of
CO2 emissions.
A maintenance approach that focuses
on reducing energy consumption
Our comprehensive solutions improve energy
efficiency while ensuring a stable and
environmentally friendly O&M.
Our Services
Real-time monitoring of asset health
Online monitoring gives you immediate access to asset health
information.
Prediction of future performance
Time-series data makes it possible to predict future performance.
Reducing energy costs
Measurement of energy efficiency
Plant operators need to know how to optimize
plant operations and maintenance (O&M) to
improve energy efficiency and reduce energy
costs.
We can visualize present and future energy
consumption to prepare a precise and effective
maintenance plan.
Effectively reducing energy
consumption
Predicting when maintenance
needs to be performed
It 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.
An 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.
Maintenance planning support
Our diagnostic and consulting services help you map out an
optimum maintenance approach.
Heat exchanger diagnostics
The Benefits
Performance
monitoring
Optimizing maintenance for each asset
E241A/B Fouling Prediction Diagnostics
1
Raw Data
Fitted Data
0.9
Recovered Cleaning Index after Cleaning
Predided cleaning data if cleaning was carried
0.7
Energy saving in hot fuild = 44.6 E06 kWh
Energy saving in pumping = 1.7 E06 kWh
0.6
Planned Shutdown for Cleaning
Cleanliness Index
0.8
0.5
0.4
Recommended Cleaning Threshold
0.3
Online, real-time monitoring
0.2
0.1
0
Jun08
Oct08
Mar09
Periodic
maintenance
7
- Based on asset conditions and the need to minimize
energy costs, you can know exactly when
maintenance should be performed.
1st
Aug09
Jan10
Jun10
Nov10
Apr11
Sep11
Feb12
Periodic
Data
maintenance
2nd
Jul12
Dec12
May13
Oct13
Performance
prediction
- 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.
8
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
Yokogawa helps you improve plant asset efficiency for
optimized maintenance and operation. We contribute to your
plant asset management, realizing energy and cost savings.
1
2
3
step
Opportunity Identification
ServicesTM
s t e p
Solution Implementation
ServicesTM
InsightSuiteAE is a part of Solution Implementation Services
under VigilantPlant Services. We provide InsightSuiteAE
service solutions for monitoring, diagnosing, and
optimizing your plant assets.
Three
Introductory
Steps
step
Lifecycle Effectiveness
ServicesTM
Field Digital
Analog
9
10
The Clear Path to Asset Effectiveness Optimization
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.
YOKOGAWA ELECTRIC CORPORATION
World Headquarters
9-32, Nakacho 2-chome, Musashino-shi, Tokyo 180-8750, Japan
http://www.yokogawa.com/
Represented by:
YOKOGAWA CORPORATION OF AMERICA
2 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, Singapore
http://www.yokogawa.com/sg/
YOKOGAWA CHINA CO., LTD.
3F Tower D Cartelo Crocodile Building
No. 568 West Tianshan Road, Shanghai 200335, China
http://www.yokogawa.com/cn/
YOKOGAWA MIDDLE EAST B.S.C.(c)
P.O. Box 10070, Manama
Building 577, Road 2516, Busaiteen 225, Muharraq, Bahrain
http://www.yokogawa.com/bh/
Trademarks
All brand or product names of Yokogawa Electric Corporation in this bulletin are trademarks or registered trademarks of Yokogawa Electric
Corporation. All other company brand or product names in this bulletin are trademarks or registered trademarks of their respective holders.
Subject to change without notice
All Rights Reserved. Copyright © 2010, Yokogawa Electric Corporation
[Ed:01/b]
Printed in Japan, 007(KP)