Incident Analysis

Plant trips can happen at any time for any number of reasons, even in the best controlled and most stable of production processes. This disruption to production and subsequent re-startup can cost tens and even hundreds of thousands of dollars while also seriously impacting product delivery and customer satisfaction. Often the root cause of such trips is rarely identified, resulting in recurrence over prolonged periods of time. Yokogawa has developed a tried and proven incident analysis service which provides for:

- Experienced consultants who will help determine the optimum incident analysis environment to ensure that trip data is captured effectively
- Real-time monitoring of trip events using the defined model
- Capture of a complete history of key trends/events leading up to and after the trip
- Analysis of trip data to assist in root cause identification and system optimization/tuning

Yokogawa's incident analysis service provides an all-encompassing solution that considers the root cause of trips from all aspects of the production environment including:

- Process control systems
- Safety systems
- Fire and gas detection systems
- Rotating machinery
- Operator actions


This plant wide analysis helps to identify dependencies within and between systems/practices/procedures, allowing the root cause of trips across individual system boundaries to be detected and reported. This approach provides a valuable insight into the elimination of future trips and ultimately leads to a safer and more efficient production asset.

Yokogawa's incident analysis service is based on standardized Six Sigma DMAIC methodology. This provides clear and effective steps to achieve a defined target while ensuring consistent and high levels of service quality.

	Define coverage, unit, plant, site Identify systems to be integrated  - DCS, SCADA, PLC  - ESD, F&G  - Condition monitoring Define integration requirements  - OPC, ASCII, SQL,….  - Time synchronization issues  - Custom interface design Agree on monitoring period Agree on remote access Develop KPIs for event information
	Implement historian data collection Configure and test all subsystem interfaces
	Collect and integrate system event data Review plant segregation Identify trip conditions Identify key tag data to be collected
	Set up initial trip detection rules Define and implement enhanced reports Develop KPIs for event information Deploy OLAP based analysis
	Review trip data Identify common causes  - Maintenance related  - Operational  - Planning  - Inter-plant incidents Implement change and improvements Refine trip analysis

*1: OLAP: online analytical processing
*2: Training services for incident analysis and troubleshooting can also be provided.