The Newsletter of Yokogawa in Australasia
Third Quarter 2009
The Energy Brix
power plant in
Morwell, Vic.
Zenith Award for Energy Brix
and Yokogawa
The Foundation in Australia
3
2
Automation Replacement
Completed at Large
Onshore Oilfield
4
Integration Made Easy
5
Integrating DCS & SCADA
Migrating to Centum usung SIOS
Product Releases
7
Photograph by Luke Shortal
1
6
State of the Art Analysis
A Century of Excellence
Expert Safety Training
News Tid Bits
8
Zenith Award for
Energy Brix and Yokogawa
Yokogawa Australia and our customer
Energy Brix Australia Corporation (EBAC)
have won the 2009 PACE Zenith Award in
the Transport, Power and Infrastructure
category. This is the third year in a row
that a Yokogawa Australia project has
been a finalist in the Zenith Awards.
This year’s award was for the project to
modernise the control systems at the
Energy Brix power station in Morwell,
Victoria. Completed in 2008, the project
was successful in:
reducing station operating costs
generating additional power for export
improving plant operating flexibility
providing modern conditions for plant
operators
reducing station
maintenance costs
operating
and
improving plant emissions.
“This project was quite remarkable for
the complexity and innovation of the
engineering involved in installing 21st
Continued on page 2
Product Releases
century
control
systems
technology onto older plant,” said
John Hewitt, Managing Director
of Yokogawa Australia. “Not only
has the project increased the
reliability of the electricity
supply, it has done so while
The Yokogawa DL9000/DL9700/9500 series and SB5000,
simultaneously
improving
with the LXI compliant Ethernet option (/C9 or /C12)
protection of the plant,
installed, are now fully compliant with LXI Class C.
LXI (Lan eXtensions for Instrumentation) is a reducing maintenance costs
communication platform for test and measurementand optimising the use of
instruments, built on LAN technology. It provides raw fuels.”
steam range and a low pressure
condensing turbine.This complex interactive configuration contrasts with most
modern plants, where boilers and
turbines are installed as unit plants in a
much simpler one-to-one arrangement.
LXI Support for Yokogawa Digital Oscilloscopes, MSOs and Serial Bus Analysers
Yokogawa has been providimproved transfer speeds with enhanced
ing control systems for power
usability and lower cost than traditional
plants for many years. However,
instrument interfaces. It’s easy to migrate
Energy Brix presented some
over from traditional GPIB systems, because
LXI utilises existing technologies such asunique challenges, particularly for
Peter Morrow, General Manager of
Yokogawa’s younger engineers.
VXI-11 or IVI.
EBAC (left) and Philip Nicholson,
MoreEngineer
than 20 of
test
and measurement
Some of them were working for the
Principal
Yokogawa
manufacturers
provide LXI
first time with a power plant equipped
Australia
(centre) accepted
thecompliant products,
PACE
Award
fromof
Jeremy
andZenith
the total
number
supported products
withissteam ranges and pass-out turbines
Needham
Mitsubishi
Electric,
alreadyof
above
1100. As
a new communication
— where all boilers feed a common
sponsors
of the
Transport, Power
platform
for applications
requiring high transfer
steam range supplying multiple turbines,
and Infrastructure category.
speed, low cost and usability, LXI will become
some of which then supply a process
more widespread in the future and Yokogawa
will be including this feature on many more
new products.
One significant achievement of the
project was the automated optimisation
of energy used for total plant operation,
replacing what had been a much more
manual approach.This was made possible
by the installation of digital controllers on
the turbines and load sharing controllers
on the boilers.
The PACE Zenith Awards were
established in 2004 by Process Control
and Engineering (PACE) magazine to
publicly recognise companies that show
leadership
in
engineering
and
technological excellence and innovation.
The awards are presented annually, with a
record number of entries received in
2009. Yokogawa projects have previously
won awards in 2005, 2007 and 2008.
The Foundation in Australia
The Fieldbus Foundation visited Australia within the region and the rest of the
Main Benefits of Foundation
in August to meet with local equipment world.
of liquids
Fieldbus Technology
suppliers, with a view to establishing an
Mr Hisashi Sasajima, Vice President for
reduced
wiring and installation
Yokogawa
has developed
a retractable
fitting
available
electrodes with PG 13.5mm
Australian
Marketing
Committee
to pro- sensor
Asia Pacific, and Mr Shane
Parr,pH
Chairman
costs
that the
offersfeatures
a flexibleand
approach
to online
analytical
or DIN
connections, as well as
mote
benefits
of liquid
of the Asia Pacific thread
Executive
Advisory
measurements
in
a
wide
range
of
process
industries.
reduced
control/equipment room
Yokogawa’s
SC4A
conductivity
and ISC40
Foundation Fieldbus to the local market. Council, visited Australia to share the
space
(no
marshalling)
inductive
conductivity
sensors
(with
a
The
Yokogawa
PR10
has
been
designed
for
online
The Foundation has been championed Foundation’s vision.
built-in
protection
cage
for
the
latter).
process
applications
where
the
sensor
has
to
be
easy integration with asset
in Australia for many years by the
All delegates to the meeting were
management systems
removed
safely
without
interrupting
process
continuity
For
dissolved
oxygen
measurements,
Foundation Fieldbus End Users’ Council, enthusiastic and agreed to the formation
– in anaerobic,
toxic orfeels
pressurised
environments, for
the Yokogawa-Hamilton
Visiferm,
saving in operations and
however
the Foundation
that a sepof a Marketing Committee.
Mr Tom Rolton
example.
The
PR10
is
suited
to
pH,
ORP,
conductivity,
maintenance
through superior
Oxyferm
and
Oxygold
sensors
can be
arate Marketing Committee would pro- of Emerson was elected Chairman of the
diagnostic availability
inductive
conductivity
and
dissolved
oxygen
installed.
These
sensors
are
vide a supplementary function and more Committee. He will be assisted by
measurements.
in nitrogen
focussed
approach to promotion of the Committee memberstypically
Shaun used
Loesch
of
blanketing
applications,
The
unit
is
available
with
a
wide
range
of
adaptors,
technology. Such a structure is similar to ABB, Lindsay Hadland of Yokogawa, and
where the optional flush
valves and
flanges,
and the
insertion Andrew
depth can
thatball
existing
in many
other
countries
Siabe
of Rockwell.
port will allow regular
adjusted to achieve optimum measurement conditions.
moisturising of the sensor to
Total disassembly without interruption to the process is
Local suppliers meet with
prevent the membrane from Fieldbus Foundation executives.
possible when the ball valve is closed, and safe
drying out.
retraction is possible at pressures up to 5barG.
Retractable sensor fitting for analytical measurement
For ease of maintenance, a scraper is built in, and
maintenance time is further reduced because fewer
O-rings are needed for a good process seal. An optional
flush port makes it easy to keep pH and dissolved
oxygen sensors moist and clean, and also provides
access for calibration.
The PR10 will accommodate most commercially
2
6
Applications for the Yokogawa
PR10 include the chemical
industry, power plants, pulp and
paper manufacture, water and
effluent treatment,
pharmaceuticals and the
semiconductor industry.
Automation
State
of the replacement
art analysis completed at Western
Europe’s largest onshore oilfield
Delta Electricity has ordered two
Yokogawa generator analyser panels for
installation at its Munmorah Power Station
Yokogawa UK has successfully completed
on the NSW Central Coast.
a full replacement of the control and
At thissystems
plant, hydrogen
to
2) is used
safety
for BP’s(HWytch
Farm
cool
the
generators.
The
merits
of
H
as
a
2
oilfield project in Dorset.
coolant are its capacity to cool while
Developed by BP,Wytch Farm is Western
causing only minimal drag or friction
Europe’s largest onshore oil field, with
between the generators’ moving parts,
estimated recoverable reserves of 480
thus increasing efficiency. The potential
million barrels. It is located in one of the
downside, however, is that if the H2
most environmentally sensitive areas of
becomes mixed with oxygen, it can
the UK.
become explosive, and thus a significant
The Wytch Farm oilfield comprises
safety hazard.
three separate oil reservoirs that lie under
In normal operation, the gas blanket
Poole Harbour and Poole Bay in Dorset
inside the generator is monitored to
on the south coast of England. The
ensure that the H2 is pure. When the
operation, comprising a central oil
generator needs to be shut down for
gathering station and a number of remote
maintenance, the hydrogen is removed by
well sites, was established in the early
flushing it out with carbon dioxide (CO2);
1980s, and the recently completed
the CO2, in turn, is flushed out with
automation replacement project was part
breathable air so that access to the
of a development plan that will enable its
generator is safe. When the generator is
operational life to be extended.
put back into service, the process is
Yokogawa was selected by BP as the
reversed: air is flushed out with CO2,
main automation contractor (MAC) for
then the CO2 is swept away with H2.The
the project, and the Yokogawa project
process is referred to as the Generator
team worked closely with the BP team
Purge Cycle.
during the project implementation. The
major challenges were the initial
definition of the project scope and
requirements in a front-end engineering
and
(FEED)
It included
Rota design
Yokogawa
will study.
be celebrating
100a
site
survey,
document
verification,
years of production of high quality
changeover
and interface
with
flowmeters planning
for industrial
applications
existing
infrastructure.
This
was
followed
next month. Founded as Deutsche
by the implementation of a smooth hot
cutover to the new integrated
control
An RAMC02
and safety system Rotameter
during the
from Rota
commissioning phase.
Using traditional gas analysis
techniques, three separate analysers
would be needed to monitor all stages
During the FEED phase, the Yokogawa
of operation and the purge cycle.
FEED team was resident at Wytch Farm for
But, using state of the art
site survey work, liaising with the BP
technology from Yokogawa, only a
engineers and collecting the engineering
single
GD402 GastoDensity
Analyser
data necessary
complete
the is
FEED
required.
Delta
however
chose
use
before commencement of theto detailed
two
analysers
for operational
reasons.
design.
A one-team
approach
by BP
The
GD402
is
exceptionally
stable
and by
and Yokogawa was achieved
reliable
andthe
is becoming
the choice ofin an
managing
business relationship
the
power
generation
industry for and
open,
performance-focused
these
applications.
collaborative
manner.
In
conjunction
with Delta,with
“Yokogawa
worked collaboratively
Yokogawa
has
designed,
the on-site BP team through
the many
manufactured,
commissioned
and and
challenges of the FEED phase
documented
a
complete
process
subsequent design, build and test phases,
analyser
that on
enables
deliveringsystem
the system
time,” the
said Ian
operation
and
purge
cycle
for
the
Bennett, project manager, Automation
two
Munmorah
350
Excellence,
at BP Wytch
Farm.MW
“Lessons
generators
to
be
measured.
Thethose
have been learned, especially
system
waswith
designed
so that it
associated
the preparation
of the
minimises the effects of oil and
moisture in the sample stream. Pressure
measurement was included to provide
compensation for changes in operating
pressure
in
the
generator
cooling hydrogen; such compensation
loop
diagrams
and
subsequent
commissioning phase, which will benefit
the management and planning of future
retrofit projects. We commend Yokogawa
for the open and honest way they have
accepted responsibility in taking the
lessons process forward.”
BP confirmed its satisfaction in the
way Yokogawa completed the Wytch
Farm distributed control system (DCS)
and safety instrumented system (SIS)
upgrade
project.
Key
project
performance achievements included:
100% health, safety, security, and
environment performance; no plant shutdown as a result of the project; on-time
delivery; a smooth and safe changeover
to the new system; a ‘one team’ approach
with the client project team; and a high
The analyser system installed at the
level of customer satisfaction.
Munmorah Power Station.
Wytch
Farm
is Western
can be performed
by the
GD402
Analyser.
Europe’s largest
The first system was installed and comonshore oil field.
missioned in June and a second identical
system has now been delivered.
Celebrating a century of excellence
The integrated controlYokogawa.
and safety
system is based on the Yokogawa CENTUM
CS 3000-Vnet/IP distributed control
system, the ProSafe-RS safety system for
emergency shutdown and burner
management, and STARDOM networkbased controllers for use as remote
terminal units.
This project replaced the existing
control system, safety system, dual
redundant
PLC
system, process
automation controllers, and SCADA/RTU
previously used to monitor and control
the gathering and processing operations.
Rotawerke in the German town of
Aachen in 1909, Rota Yokogawa became
part of theYokogawa Electric Corporation
in 1995.
Wytch Farm
The early years of the business were
focussed on production of the recentlyinvented Rotameter, a float-based
flowmeter. The company was so
successful that ‘Rotameter’ is often used
as a generic term for any flowmeter of
this kind, not just Yokogawa’s.
Today, Rota Yokogawa continues as
the company’s worldwide centre of
excellence for flowmeters, which
now
include
mass
flow
measurement using the Coriolis
principle as well as Rotameters.
Manufacturing floor space has
recently been enlarged by 40% with
the opening of one of the most modern
and innovative production lines of its
kind. Production has also been
increasingly automated with sizeable
investment in production equipment,
robots and automated test rigs. Further
investment of tens of millions of Euros is
planned in buildings and plant in the next
few years.
Today, Rota Yokogawa develops and
manufactures high-quality flowmeters
based on five measuring principles: floats,
magnetic-inductive, vortex flowmeters,
Coriolis and differential head. Calibrations
are carried out in the company’s own
DKD-certified facility, which also provides
a calibration service to other companies.
With outstanding products and an
excellent business performance in recent
years, Rota Yokogawa is in good shape for
the future. The continuous development
of new and existing measuring devices
will ensure that customers around the
world are supplied with top quality
Yokogawa flowmeters.
Photo courtesy of BP
Zenith Award for Energy Brix and Yokogawa cont'd
7
3
Communications Special Feature
Integration made easy
Process users have always found
themselves with automation and control
equipment from a number of different
manufacturers in their plant, be it
packaged with the original process
equipment supply or necessary for their
special purpose application.
Examples may include a turbine
controller from the turbine manufacturer
and intelligent electrical devices
associated with the electrical switchgear.
In other cases, the original plant builder
may not have been sufficiently
disciplined
to
specify
common
automation equipment. And in still other
cases, the user has elected to implement
a best-in-class type of unit application
solution.
For whatever reason, it has always been
necessary for the main automation
system supplier to have to communicate
with, or integrate, control equipment
from a number of different suppliers into
the overall control system.
Yokogawa
has
handled
these
communications issues quietly and without fuss for many years. Few systems
would have ever been supplied in the
early days of CENTUM without at least
one RS232 serial interface being
installed.
Modbus over serial link was generally
preferred over custom serial protocols,
Profibus was and still is popular with
equipment of European extraction,
Modbus over Ethernet is still a favourite,
and OPC over Ethernet is the current
communication system of choice today.
CENTUM generally interfaces to
third-party equipment via one of three
physical connection mechanisms:
1. a communications card in the Controller
– serial, Profibus, Foundation Fieldbus or
Ethernet
2. a Generic Subsystem Gateway (GSGW)
station on the control network, which
acts as an OPC client to third-party OPC
servers for the purpose of integration to
subsystems
3. a System Integration OPC Client Station
(SIOS) on the control network for largevolume, high-performance integration to
peer-level systems
4
Integrating DCS and SCADA using SIOS
DCS and SCADA have always been mutually opposing control system architectures. Each has its advantages and disadvantages and each is applied to different
types of applications. Until now, it hasn’t
been possible to realise the advantages of
both architectures within a single system.
SIOS is the most
recently
released
product, and forms a
very convenient and
easy to implement
methodology
for
communicating via
OPC DA and A&E with
other vendors’ higherlevel systems – including foreign DCS-type
control systems. It allows
co-existence of Yokogawa and
competitors’ control systems on
the same plant, and can facilitate
migration of older style foreign legacy
DCSs to the latest CENTUM VP system.
Yokogawa Australia has tested SIOS on
integration with a competitive DCS
system with good results. SIOS has also
found extensive use globally in integrating
Yokogawa’s STARDOM network control
system and remote terminal units with
CENTUM.
Both SIOS and GSGW run on a generic
PC hardware platform containing
Reference Interfaces
(Partial List)
ABB – drives, IEDs, GCs, etc
Allen-Bradley – PLC5, SLC5,
ControlLogix
Amdel
ATMOS Leak Detection
ASi-Bus
BentlyNevada
Bristol Babcock RTU
Contrec Counters and Batchers
Danfoss VSD
Enraf
FMC Subsea
Foxboro – GC, tank gauges
Gastech – fire & gas sensors
GE – PLCs, Multilin, Mark IV, Mark V
Harris RTU
HIMA
Honeywell
Modicon – 584, 984, Quantum
Outokumpu Courier
ProFace touch panels
Schneider Telemechanique
Siemens – S5, S7, 1135. VSD
Square D
Toshiba – PLC, VSD
Triconex
Woodward Governor
CENTUM Vnet/IP communication cards.
SIOS can handle 100,000 data points
with 4,000 tags in GSGW. GSGW can
handle OPC-DA only, while SIOS can
accommodate OPC-A&E alarm and
events message traffic as well.
No matter which Yokogawa integration solution is adopted, the end result
for the operator is complete
transparency of information from
across the plant
Communications
Glossary of Terms
RS232 – serial connection
standard
Modbus – defacto standard serial
protocol
OPC – OLE for Process Control –
international std comms protocols
across Ethernet
Profibus – a suite of field and
network protocols originating in
Europe
Ethernet – standard office and
industrial network technology
Foundation Fieldbus –
international standard fieldbus
technology
OPC-DA – OPC Data Acquisition
protocol
OPC-A&E – OPC Alarm & Events
protocol
database and function block style programming. In addition, the level of availability, redundancy and reliability in hardware and software make this the clear
choice for critical applications.
system and are immediately available to
the user as standard CENTUM-style faceplates on the operator station. The operator is not aware of the source of the data
for the faceplate.
Now, Yokogawa is blurring the boundaries of the two architectures with the
integration of the STARDOM SCADA system with the CENTUM VP DCS. Using
SIOS (System Integration OPC client
Station), all STARDOM variables and function blocks are automatically mapped
into the CENTUM DCS, providing seamless and transparent connection between
the two systems.
The STARDOM control family includes
the FCN and FCJ high performance PLC
type controllers and the FCN-RTU for
remote applications. Programmed using
the IEC 61131-3 suite of programming
languages and supplied with a wide range
of communication options, the STARDOM
controllers are suitable for remote and
PLC type applications. The FAST/TOOLS
SCADA HMI provides a high performance
user interface to the STARDOM controllers for a highly integrated SCADA system.
Because of the transparent nature of the
connection between the systems, full
CENTUM connectivity can be realised,
including peer-to-peer communication
between controllers across the two systems, alarm monitoring, trending, monitoring and operation. The user can monitor
and operate entirely through the CENTUM
HIS operator station. However, the FAST/
TOOLS SCADA HMI can also be connected for local monitoring and operations of
the STARDOM controllers in remote locations as required.
The Yokogawa CENTUM VP DCS provides high integrity control of medium to
large processing sites. Being a DCS, engineering is greatly reduced by the single
The SIOS gateway provides seamless
integration between STARDOM and
CENTUM. Tags created in STARDOM are
automatically recognised by the CENTUM
Now the full benefits of both DCS and
SCADA can be realised within a single
system using the Yokogawa CENTUM and
STARDOM technologies.
Migrating to Centum using SIOS
If you are considering upgrading your old
DCS and it is not a Yokogawa system, then
you may have a problem.
One of Yokogawa’s basic design philosophies in developing latest technology
DCS is to ensure full backwards compatibility with previous systems. This means
that any generation of Yokogawa’s DCS
will integrate seamlessly with any other
generation, which protects your investment and ensures minimal downtime
with each upgrade process. However, it’s
a philosophy that is not typically adopted
by other equipment providers.
The good news is that Yokogawa is
now applying its expertise in systems
migration not only to legacy Yokogawa
systems, but also to systems from just
about any vendor, using a range of technologies.
When replacing the field control hardware, downtime can be minimised by
keeping the existing terminal boards.This
saves a considerable amount of time in
rewiring and testing and reduces errors
in the changeover process. Yokogawa
provides a range of cables and interposing boards for interfacing between
Yokogawa I/O modules and a range of
different vendors’ terminal boards.
The operator monitors and operates
through the standard Yokogawa faceplate
without being aware of the fact that the
associated functions are located in the
other control system.
Sometimes it is not feasible to change
over the system in one go. It may be desirable to run the new system in parallel
with the legacy system for a period of
time. Yokogawa provides a range of integration options that allow the legacy system to be seamlessly integrated into the
Yokogawa CENTUM system.
By this method, SIOS seamlessly integrates variables and function blocks from
the legacy system into the Yokogawa
CENTUM system. As a result, standard
Yokogawa functions such as peer-to-peer
communication between controllers
across the two systems, alarm detection,
trending, operation and monitoring can
be performed without regard for the
source of the data.
The SIOS (System Integration OPC client Station) is an OPC based gateway that
interfaces to OPC servers and maps variables and function blocks from another
system to the Yokogawa CENTUM VP system. For example, a PID function block in
a Honeywell DCS can be mapped to a
Yokogawa PID function block faceplate.
The SIOS will read the parameters from
the Honeywell PID function block and
convert the variables into the correct format for the Yokogawa PID function block.
5
Product Releases
century
control
systems
technology onto older plant,” said
John Hewitt, Managing Director
of Yokogawa Australia. “Not only
has the project increased the
reliability of the electricity
supply, it has done so while
The Yokogawa DL9000/DL9700/9500 series and SB5000,
simultaneously
improving
with the LXI compliant Ethernet option (/C9 or /C12)
protection of the plant,
installed, are now fully compliant with LXI Class C.
LXI (Lan eXtensions for Instrumentation) is a reducing maintenance costs
communication platform for test and measurementand optimising the use of
instruments, built on LAN technology. It provides raw fuels.”
steam range and a low pressure
condensing turbine.This complex interactive configuration contrasts with most
modern plants, where boilers and
turbines are installed as unit plants in a
much simpler one-to-one arrangement.
LXI Support for Yokogawa Digital Oscilloscopes, MSOs and Serial Bus Analysers
Yokogawa has been providimproved transfer speeds with enhanced
ing control systems for power
usability and lower cost than traditional
plants for many years. However,
instrument interfaces. It’s easy to migrate
Energy Brix presented some
over from traditional GPIB systems, because
LXI utilises existing technologies such asunique challenges, particularly for
Peter Morrow, General Manager of
Yokogawa’s younger engineers.
VXI-11 or IVI.
EBAC (left) and Philip Nicholson,
MoreEngineer
than 20 of
test
and measurement
Some of them were working for the
Principal
Yokogawa
manufacturers
provide LXI
first time with a power plant equipped
Australia
(centre) accepted
thecompliant products,
PACE
Award
fromof
Jeremy
andZenith
the total
number
supported products
withissteam ranges and pass-out turbines
Needham
Mitsubishi
Electric,
alreadyof
above
1100. As
a new communication
— where all boilers feed a common
sponsors
of the
Transport, Power
platform
for applications
requiring high transfer
steam range supplying multiple turbines,
and Infrastructure category.
speed, low cost and usability, LXI will become
some of which then supply a process
more widespread in the future and Yokogawa
will be including this feature on many more
new products.
One significant achievement of the
project was the automated optimisation
of energy used for total plant operation,
replacing what had been a much more
manual approach.This was made possible
by the installation of digital controllers on
the turbines and load sharing controllers
on the boilers.
The PACE Zenith Awards were
established in 2004 by Process Control
and Engineering (PACE) magazine to
publicly recognise companies that show
leadership
in
engineering
and
technological excellence and innovation.
The awards are presented annually, with a
record number of entries received in
2009. Yokogawa projects have previously
won awards in 2005, 2007 and 2008.
The Foundation in Australia
The Fieldbus Foundation visited Australia within the region and the rest of the
Main Benefits of Foundation
in August to meet with local equipment world.
of liquids
Fieldbus Technology
suppliers, with a view to establishing an
Mr Hisashi Sasajima, Vice President for
reduced
wiring and installation
Yokogawa
has developed
a retractable
fitting
available
electrodes with PG 13.5mm
Australian
Marketing
Committee
to pro- sensor
Asia Pacific, and Mr Shane
Parr,pH
Chairman
costs
that the
offersfeatures
a flexibleand
approach
to online
analytical
or DIN
connections, as well as
mote
benefits
of liquid
of the Asia Pacific thread
Executive
Advisory
measurements
in
a
wide
range
of
process
industries.
reduced
control/equipment room
Yokogawa’s
SC4A
conductivity
and ISC40
Foundation Fieldbus to the local market. Council, visited Australia to share the
space
(no
marshalling)
inductive
conductivity
sensors
(with
a
The
Yokogawa
PR10
has
been
designed
for
online
The Foundation has been championed Foundation’s vision.
built-in
protection
cage
for
the
latter).
process
applications
where
the
sensor
has
to
be
easy integration with asset
in Australia for many years by the
All delegates to the meeting were
management systems
removed
safely
without
interrupting
process
continuity
For
dissolved
oxygen
measurements,
Foundation Fieldbus End Users’ Council, enthusiastic and agreed to the formation
– in anaerobic,
toxic orfeels
pressurised
environments, for
the Yokogawa-Hamilton
Visiferm,
saving in operations and
however
the Foundation
that a sepof a Marketing Committee.
Mr Tom Rolton
example.
The
PR10
is
suited
to
pH,
ORP,
conductivity,
maintenance
through superior
Oxyferm
and
Oxygold
sensors
can be
arate Marketing Committee would pro- of Emerson was elected Chairman of the
diagnostic availability
inductive
conductivity
and
dissolved
oxygen
installed.
These
sensors
are
vide a supplementary function and more Committee. He will be assisted by
measurements.
in nitrogen
focussed
approach to promotion of the Committee memberstypically
Shaun used
Loesch
of
blanketing
applications,
The
unit
is
available
with
a
wide
range
of
adaptors,
technology. Such a structure is similar to ABB, Lindsay Hadland of Yokogawa, and
where the optional flush
valves and
flanges,
and the
insertion Andrew
depth can
thatball
existing
in many
other
countries
Siabe
of Rockwell.
port will allow regular
adjusted to achieve optimum measurement conditions.
moisturising of the sensor to
Total disassembly without interruption to the process is
Local suppliers meet with
prevent the membrane from Fieldbus Foundation executives.
possible when the ball valve is closed, and safe
drying out.
retraction is possible at pressures up to 5barG.
Retractable sensor fitting for analytical measurement
For ease of maintenance, a scraper is built in, and
maintenance time is further reduced because fewer
O-rings are needed for a good process seal. An optional
flush port makes it easy to keep pH and dissolved
oxygen sensors moist and clean, and also provides
access for calibration.
The PR10 will accommodate most commercially
2
6
Applications for the Yokogawa
PR10 include the chemical
industry, power plants, pulp and
paper manufacture, water and
effluent treatment,
pharmaceuticals and the
semiconductor industry.
Automation
State
of the replacement
art analysis completed at Western
Europe’s largest onshore oilfield
Delta Electricity has ordered two
Yokogawa generator analyser panels for
installation at its Munmorah Power Station
Yokogawa UK has successfully completed
on the NSW Central Coast.
a full replacement of the control and
At thissystems
plant, hydrogen
to
2) is used
safety
for BP’s(HWytch
Farm
cool
the
generators.
The
merits
of
H
as
a
2
oilfield project in Dorset.
coolant are its capacity to cool while
Developed by BP,Wytch Farm is Western
causing only minimal drag or friction
Europe’s largest onshore oil field, with
between the generators’ moving parts,
estimated recoverable reserves of 480
thus increasing efficiency. The potential
million barrels. It is located in one of the
downside, however, is that if the H2
most environmentally sensitive areas of
becomes mixed with oxygen, it can
the UK.
become explosive, and thus a significant
The Wytch Farm oilfield comprises
safety hazard.
three separate oil reservoirs that lie under
In normal operation, the gas blanket
Poole Harbour and Poole Bay in Dorset
inside the generator is monitored to
on the south coast of England. The
ensure that the H2 is pure. When the
operation, comprising a central oil
generator needs to be shut down for
gathering station and a number of remote
maintenance, the hydrogen is removed by
well sites, was established in the early
flushing it out with carbon dioxide (CO2);
1980s, and the recently completed
the CO2, in turn, is flushed out with
automation replacement project was part
breathable air so that access to the
of a development plan that will enable its
generator is safe. When the generator is
operational life to be extended.
put back into service, the process is
Yokogawa was selected by BP as the
reversed: air is flushed out with CO2,
main automation contractor (MAC) for
then the CO2 is swept away with H2.The
the project, and the Yokogawa project
process is referred to as the Generator
team worked closely with the BP team
Purge Cycle.
during the project implementation. The
major challenges were the initial
definition of the project scope and
requirements in a front-end engineering
and
(FEED)
It included
Rotadesign
Yokogawa
will study.
be celebrating
100a
site
survey,
document
verification,
years of production of high quality
changeover
and interface
with
flowmeters planning
for industrial
applications
existing
infrastructure.
This
was
followed
next month. Founded as Deutsche
by the implementation of a smooth hot
cutover to the new integrated
control
An RAMC02
and safety system Rotameter
during the
from Rota
commissioning phase.
Using traditional gas analysis
techniques, three separate analysers
would be needed to monitor all stages
During the FEED phase, the Yokogawa
of operation and the purge cycle.
FEED team was resident at Wytch Farm for
But, using state of the art
site survey work, liaising with the BP
technology from Yokogawa, only a
engineers and collecting the engineering
single
GD402 GastoDensity
Analyser
data necessary
complete
the is
FEED
required.
Delta
however
chose
use
before commencement of theto detailed
two
analysers
for operational
reasons.
design.
A one-team
approach
by BP
The
GD402
is
exceptionally
stable
and by
and Yokogawa was achieved
reliable
andthe
is becoming
the choice ofin an
managing
business relationship
the
power
generation
industry for and
open,
performance-focused
these
applications.
collaborative
manner.
In
conjunction
with Delta,with
“Yokogawa
worked collaboratively
Yokogawa
has
designed,
the on-site BP team through
the many
manufactured,
commissioned
and and
challenges of the FEED phase
documented
a
complete
process
subsequent design, build and test phases,
analyser
that on
enables
deliveringsystem
the system
time,” the
said Ian
operation
and
purge
cycle
for
the
Bennett, project manager, Automation
two
Munmorah
350
Excellence,
at BP Wytch
Farm.MW
“Lessons
generators
to
be
measured.
Thethose
have been learned, especially
system
waswith
designed
so that it
associated
the preparation
of the
minimises the effects of oil and
moisture in the sample stream. Pressure
measurement was included to provide
compensation for changes in operating
pressure
in
the
generator
cooling hydrogen; such compensation
loop
diagrams
and
subsequent
commissioning phase, which will benefit
the management and planning of future
retrofit projects. We commend Yokogawa
for the open and honest way they have
accepted responsibility in taking the
lessons process forward.”
BP confirmed its satisfaction in the
way Yokogawa completed the Wytch
Farm distributed control system (DCS)
and safety instrumented system (SIS)
upgrade
project.
Key
project
performance achievements included:
100% health, safety, security, and
environment performance; no plant shutdown as a result of the project; on-time
delivery; a smooth and safe changeover
to the new system; a ‘one team’ approach
with the client project team; and a high
The analyser system installed at the
level of customer satisfaction.
Munmorah Power Station.
Wytch
Farm
is Western
can be performed
by the
GD402
Analyser.
Europe’s largest
The first system was installed and comonshore oil field.
missioned in June and a second identical
system has now been delivered.
Celebrating a century of excellence
The integrated controlYokogawa.
and safety
system is based on the Yokogawa CENTUM
CS 3000-Vnet/IP distributed control
system, the ProSafe-RS safety system for
emergency shutdown and burner
management, and STARDOM networkbased controllers for use as remote
terminal units.
This project replaced the existing
control system, safety system, dual
redundant
PLC
system, process
automation controllers, and SCADA/RTU
previously used to monitor and control
the gathering and processing operations.
Rotawerke in the German town of
Aachen in 1909, Rota Yokogawa became
part of theYokogawa Electric Corporation
in 1995.
Wytch Farm
The early years of the business were
focussed on production of the recentlyinvented Rotameter, a float-based
flowmeter. The company was so
successful that ‘Rotameter’ is often used
as a generic term for any flowmeter of
this kind, not just Yokogawa’s.
Today, Rota Yokogawa continues as
the company’s worldwide centre of
excellence for flowmeters, which
now
include
mass
flow
measurement using the Coriolis
principle as well as Rotameters.
Manufacturing floor space has
recently been enlarged by 40% with
the opening of one of the most modern
and innovative production lines of its
kind. Production has also been
increasingly automated with sizeable
investment in production equipment,
robots and automated test rigs. Further
investment of tens of millions of Euros is
planned in buildings and plant in the next
few years.
Today, Rota Yokogawa develops and
manufactures high-quality flowmeters
based on five measuring principles: floats,
magnetic-inductive, vortex flowmeters,
Coriolis and differential head. Calibrations
are carried out in the company’s own
DKD-certified facility, which also provides
a calibration service to other companies.
With outstanding products and an
excellent business performance in recent
years, Rota Yokogawa is in good shape for
the future. The continuous development
of new and existing measuring devices
will ensure that customers around the
world are supplied with top quality
Yokogawa flowmeters.
Photo courtesy of BP
Zenith Award for Energy Brix and Yokogawa cont'd
7
3
Expert Safety Training
to reapply to TÜV Rheinland for
revalidation. Suitable evidence of
continuing experience and education
must be submitted.
Did you know that Yokogawa has been
authorised by TÜV Rheinland to
conduct Safety Training, and at the end
of the training, subject to successfully
passing an examination, attendees
receive a certificate from TÜV Reinland
certifying them as a TÜV Functional
Safety Engineer?
Yokogawa has three TÜV certified
Functional Safety Expert trainers who
are able to conduct the training course
on a world-wide basis, and to date, over
10 courses have been completed and
many others scheduled.
Successful students also have the right
to use the TÜV logo on their business
cards and correspondence, and will be
listed on the TÜV website as FS
Engineers.
equivalent engineering experience. The
cumulative pass rate to date has been just
under 70% of students attempting the
examination. Any student who does not
pass may re-sit it within one year of their
first attempt.
The course comprises three and a
Yokogawa is planning to run a course
half days of training lectures, followed
in Australia within the next six months.
by a four hour examination. Prerequisites
Readers may submit expressions of
To celebrate the release of FieldMate R1.03, Yokogawa is offering readers
include three years’ functional safety
interest in attending the course to
of Connections a special price on FieldMate
and Yokogawa hand-held
experience and a bachelor degree or
inquiries@au.yokogawa.com
communication products on orders
placed by August 31, 2008.
Each certificate is valid for five years,
after which time the FS Engineer needs
News Tid Bits
Yokogawa New Zealand has been selected
by Environment Canterbury (ECan) as an
ol systems and
ntract to supply contr
co
a
n
wo
s
ha
a
gaw
nt
Yoko
nt in Vietnam. The pla
Vung Ang 1 power pla
l
na
instrumentation for the
tio
era
ed to be op
its, with the first plann
un
W
0M
60
o
tw
ve
ha
built
will
ce, the plant is being
in the Ha Tihn provin
a
by mid-2012. Situated
gaw
tnam). The Yoko
d Gas Group (Petrovie
for the Vietnam Oil an
million.
ated value of US$16.6
contract has an estim
This month marks the 10th anniversary of the introduction of
Yokogawa’s DAQstation, which replaced paper chart recorders with
digital data acquisition and display stations in control rooms around
the world. Revolutionary at the time, the DAQstation was a stepping
stone to a full-blown DCS; it visually mimicked what chart recorders
had provided but added a lot more functionality. The DAQstation has
evolved to provide additional functionality, with the latest model, the
DXAdvanced R3, offering user-customisable display screens and an
intelligent annunciator system with data display and recording
functions that can replace common annunciator lamp panels.
Yokogawa’s WT3000-2A and WT210 digital power
meters are now certified to carry out the standby power tests specified in
the new IEC 62301 standard. Key parameters whose limits are specified in
IEC 62301 are total harmonic distortion (THD), crest factor, accuracy,
resolution and stability at different power levels, and the ability to record
true average power over a period of more than five minutes
Authorised Water Meter Equipment
Supplier for the Rakaia Selwyn
Groundwater Zone. The two Yokogawa
flowmeters that have been approved by
ECan meet the needs of farmers who are
now required as part of their water
consent to install approved water meters to
measure their irrigation water take.
report
Yokogawa has published its annual
31,
for the financial year ended March
the
ded
inclu
2009. Highlights of the year
strengthening of product lineup in
launch
response to market needs, with the
system
of a new manufacturing execution
d
rove
imp
platform that contributes to
ase of
production efficiency, and the rele
ption
sum
highly durable, low power con
e
control and monitoring modules. Mor
l
stria
than 60% of sales in the indu
e
automation and control business wer
made outside Japan.
YOKOGAWA AUSTRALASIAN NETWORK
National toll free number:
1300 558 965
Sydney: 02 8870 1100, Adelaide: 08 8415 2600, Brisbane: 07 3902 6600, Melbourne: 03 8804 8800
Newcastle: 02 4016 2100, Perth: 08 6465 6600, Gladstone: 07 4972 6044, Townsville: 07 4779 9155
Auckland: 09 255 0496, Christchurch: 03 348 0066, New Plymouth: 027 667 7226
Internet: www.yokogawa.com/au Email inquiries: inquiries@au.yokogawa.com
8
Contributors to this issue: Megan Fisher, John Kemp, Simon Lillie, Philip Nicholson,
Paul Twigg, David Walker, Mike Wallis
Editor: Lindsay Hadland