Yokogawa is leading the evolution of supervisory control and data acquisition (SCADA) systems to advanced automation and information visualization solutions that span global enterprises. Our SCADA applications combine high-performance, high-availability, broad scalability and platform independence in a manner that maximizes return-on investment (ROI) while minimizing the total cost of ownership (TCO) over the entire system lifecycle.
Originating as the Flexible Advanced System Techniques (FAST) project, FAST/TOOLS today is a comprehensive, fully-integrated SCADA application suite. Powerful and flexible, FAST/TOOLS serves installations ranging from 50-point unit processes to multimillion-point offshore production and pipeline systems that extend over thousands of miles.
EPMS provides a comprehensive series of standard software applications which are integrated within the FAST/TOOLS real-time system platform to facilitate management of hydrocarbon liquids pipelines and natural gas pipelines.
When Rangitata Diversion Race (RDR) Management took steps to improve visibility and performance for their historic irrigation scheme in New Zealand’s South Island, they selected a Yokogawa solution comprising FAST/TOOLS SCADA and Stardom RTU’s as platforms upon which operational excellence for future could be established.
New Zealand has been considered an agricultural country since the 19th century, when the introduction of refrigerated transport allowed its sheep and dairy industries to expand providing meat, wool, butter, and other agricultural products both locally and overseas. Throughout the 20th and into the 21st century agricultural imports have remained important to the New Zealand economy, contributing about two-thirds of exported goods.
Image 1: Aerial of Canterbury Plains, South Island, New Zealand.
The Canterbury Plains region of New Zealand’s South Island is an area of braided rivers and pastoral perfection between the Southern Alps and the Pacific Ocean. Almost as flat as a billiard table, the plains are a patchwork of agricultural activity and produces more than 80% of New Zealand’s grains, crops and seeds.
With a growing population and increasing international demand for produce, New Zealand’s Public Works Department initiated a project in 1937 to divert water from the Rangitata River on to the Rakaia River crossing the Canterbury Plains. This was a dream come true for the regions pioneering farmers who had struggled with water management and drought for decades.
When officially opened in 1945, the 67km long Race (Race meaning an occurrence where a fast-moving tide moves through a constriction) provided water to over 600 farms via a canal network and would improve their production five or six-fold. Taking water from three rivers (Rangitata, Rakaia and Ashburton), the system is gravity fed with an average fall of around 200mm per km across the entire distance of the Race. Although the land from the Rangitata river is fairly flat, there is a mountainous section from the Rakaia river which requires water to be pumped uphill to link into the Race. This is the only non-gravity fed section, with around 28 MW of power provided for pumping and other use in the region by two hydropower stations which are part of the overall scheme.
Taking 20 years to reach full capacity it has since transformed farming in the district and is now considered their most important piece of infrastructure. Since its initial implementation it has continued to grow, now covering more than 110,000 square hectares (around 1,100 square kilometres).
Image 2: Water offtake point, Rangitata river, New Zealand.
RDR Management Ltd are a user-owned limited company consisting of five core shareholders. It is responsible for the effective operations and maintenance of the Race including environmental management, forecasting and future planning and development activities.
RDR Management Ltd are a lean and highly effective organisation managing all the operational and maintenance requirements of the Race with a team of only five employees. This is quite an achievement considering the wide geographical dispersion of the Race. It also places greater significance on the operational effectiveness and reliability of the control and visualisation tools they employ.
As a consequence, when reviewing their future requirements for control and visualisation in the late 2000’s, after an extensive and detailed evaluation process they selected Yokogawa’s FAST/TOOLS SCADA and Stardom RTU’s implemented by their partner Industrial Controls South Canterbury Ltd.
“The Race was going through a period of evolution as we prepared for growth, adapting to the changing requirements of farmers while also remaining environmentally sensitive” according to RDR Management’s Chief Executive Ben Curry.
“We needed a platform which not only provided us with accurate and reliable real-time operational information, but one which was simple to use and highly intuitive. Although our operations and maintenance team are highly skilled, running lean requires tools to support their activities in the most efficient way”.
RDR Management Ltd were also conscious of the remoteness of their application and the need to ensure continuous operation. Their choice of FAST/TOOLS and Stardom was not solely based on technological advantage for wide area operations, but also considered their vision for future and local support requirements. Yokogawa are one of a limited number of control and automation vendors to maintain an ongoing presence on the South Island, celebrating their 20th anniversary in the region during 2019. Location also being a prime consideration in the selection of Industrial Controls to integrate the Yokogawa solution, whose locality and reputation for engineering excellence made them an ideal partner.
Image 3: Stardom RTU panel at the river offtake station.
The Race comprises over six-hundred farm and twenty-five main gates and take-off’s, connected via a radio network back to the FAST/TOOLS central monitoring station at Ashburton. Covering an area of over 110,000 square hectares, this is an undertaking of enormous proportions and an area which is prone to extremes of weather (with temperatures dropping as low as -10 in winter).
With the scheme in operation all year round (more for power generation in winter) it is imperative that any equipment deployed must maintain the highest levels of reliability at all times and in all conditions. This is something the Stardom RTU’s are renowned for, providing not only high levels of availability, but also advanced functionality allowing local web services for in-field activities as well as connectivity back to the FAST/TOOLS operations centre for overall performance monitoring.
Image 4: Rangitata River South Island, New Zealand.
Industrial Controls specialises in industrial electrical automation systems, providing control solutions for industry. Founded in 1996 it is one of the South Islands foremost providers of industrial electrical and automation solutions. Having worked with Yokogawa for around twenty years, they have developed a strong and mutually beneficial partnership. When it came to selecting a FAST/TOOLS and Stardom solution for RDR, both parties knew the eventual outcome would be a highly effective and reliable control and visualisation solution.
According to Jeph Burns, Principal Automation Engineer at Industrial Controls, “When RDR’s upgrade requirements for wide area SCADA and RTU’s were issued, it was a clear choice which platform was most suited. We saw that RDR was looking for quality local support and FAST/TOOLS plus Stardom were the perfect fit for all parties, but more specifically RDR. The support process is much more straight-forward when you have reliable SCADA and RTU platforms designed to operate in-line with industry standards. This allows you to focus on optimising and improving the performance of the overall system rather than trouble-shooting a solution which was not designed for this type of application. With FAST/TOOLS both flexible and straight forward to configure, with well documented software, creating an operations environment which is intuitive and easy to use has long-term benefits to the client.”
When developing and implementing such a geographically dispersed project, Industrial Controls used their experience in manufacturing industries to advantage.
“We didn’t have the same mindset as other integrators working in telemetry” says Jeph. “Instead we combined our familiarity with real-time operations with our multi-disciplined team and a desire to provide the best technologies to our clients. This provided RDR with a real-time operations system that continues to meet their needs. Our approach led us to a wireless ethernet networking solution, made possible by the proximity of RDRs system to the mid-Canterbury foothills. We also engineered mobile based software solutions to account for the SCADA system not being manned 24/7 with the RDR lean approach, something FAST/TOOLS enabled through its integration API’s.”
Stardom RTU’s proved to be particularly well suited to the application, not only due to their ruggedness, but also their low power consumption and tight integration with FAST/TOOLS for ‘store and forward’ of data. This complimented the wireless networking approach, providing data security for when the network was unavailable.
The web HMI client provided by FAST/TOOLS reduced the administrative overhead of maintaining client software within RDR’s operations team, with its graphics system allowing the finishing touch of a modern interface that was eye catching and intuitive.
RDR Management Ltd also understand that they play an increasingly important and proactive role in managing the environment within which they operate. Managing fish and sediment related issues in the Race are part of their day to day operational challenges, as is carefully monitoring the amount of water they draw from the river.
Ben Curry comments; “The eco-system in this part of the South Island is particularly sensitive. Draw off too much water from the rivers to feed the farms via the Race and this can lead to unacceptable consequences down river. We have strict upper and lower thresholds of water that we are allowed to draw from the river network and we ensure we strictly abide by these. In times of drought this can be particularly challenging when river flow drops. Although the farmers are less than pleased when offtakes and supply to their farms fall, they understand the same way we do that environmental management is the responsibility of us all”.
As part of their long-term goals for improving their already high standards of environmental management, RDR are working on a number of initiatives to bolster the system to the benefit of all. The Race is currently just a ‘Run of River’ system and lacks storage. This presents issues during summer when river flows fall leading to challenges for the farmers.
As such, RDR have plans to build storage reservoirs at select locations along the Race which when completed will hold up to 53 million cubic metres of water. This will provide a higher degree of resilience and reduce dependency on the river during low flow periods. They are also working with farmers to reduce leakage levels, with pipe systems become far more prevalent and reducing leakage by around 40%.
Managing growth expectations, operational effectiveness and environmental requirements can be a daunting balancing act, especially in one of the most naturally beautiful regions on the planet. Doing so with a highly skilled but small team on an application which covers 110,000 square hectares is even more so.
Yet this challenge is accepted and delivered on by the dedicated team at RDR Management Ltd, supported by a highly reliable Yokogawa solution and engineering excellence from Industrial Controls. This three-way partnership has helped deliver water to the farmers of the Canterbury Plains for over ten years and continues to adapt with the recently installed R10.4 version of FAST/TOOLS. This further increases web client support providing additional functions for operational and maintenance activities. With a system which continues to grow and evolve to meet evolutionary needs of the Rangitata Diversion Race, FAST/TOOLS and Stardom continues to be one constant upon which firm foundations for operations and maintenance can be built upon.
Image 5: Large centre pivot irrigation system running on a farm in Canterbury, New Zealand.
Alewijnse provides Yokogawa's FAST/TOOLS package for a variety of marine applications, including the world's largest yachts (megayachts) built by Oceanco of The Netherlands. Alewijnse has selected FAST/TOOLS because of its quality and support, and this software has allowed them to both streamline the engineering process and reuse data.
INPEX Corporation (INPEX) is Japan's biggest oil and gas development company and is involved in all aspects of this business, from research to exploration, production, and sales. INPEX is engaged in projects all over the world, in a total of 29 countries, including Japan, where it operates a gas production plant near Oyazawa, a town in Niigata prefecture.
As the demand for food is increasing worldwide, fertilizers are playing an essential role in improving agricultural productivity. OCI Nitrogen (hereinafter OCI) is a leading producer of mineral fertilizers and the world's largest producer of melamine, which is used to make adhesives and resins for a wide range of applications, such as furniture panels, laminate flooring, coatings, paints, and plastics.
Granite Power is a geothermal company that has developed GRANEX®, a patented direct supercritical fluid heat transfer technology for the efficient, eco- nomic, and zero carbon emission generation of electricity from low grade geothermal sources using the Organic Rankine Cycle (ORC).
SENAI-AL selected Yokogawa to provide the training solutions to learn the latest technologies as well as measurement and feedback control.
Yokogawa's STARDOM and transmitters are used for the micro ethanol distillation plant to develop future engineers.
Water Supply Treatment
FAST/TOOLS, STARDOM, Flowmeters, Liquid Analyzers
The Malampaya Deep Water Gas to Power project delivers gas from an off-shore gas field to three power plants near the city of Batangas (100 kilometers south of Manila) in the Philippines. The project consists of an off-shore production platform, a 504 km subsea pipeline, and an on-shore gas treatment plant.
Many different types of gases are consumed in industries as varied as chemicals, food & beverages, and medical. These gases are normally delivered in liquid form by trucks and dispensed at the customer site. Although the flow volume of cryogenic liquefied gas is used for billing purposes, it is not easy to accurately measure this because the gas is always at saturation temperatures.
Yokogawa is one of a few companies worldwide that is able to successfully execute large SCADA host migration projects, i.e. data item counts in excess of 500,000 points. This advantage plus our robust technology coupled with the knowledge of previous Systems installed within various customers and our overall integration and knowledge of third party systems should give Yokogawa a clear technical advantage.
STARDOM FCJ/FCN can be used as an electronic flow measurement system described in API MPMS Chapter 21.1. The flow computer calculations are performed in order to provide a high performance flow metering for Natural Gas. FCJ/FCN can perform both normal control and flow computer function at the same time. Utilizing STARDOM and Yokogawa Multivariable Transmitter EJX (HART or Foundation Fieldbus field transmitter), the advanced flow measurement can be realized.
Many catalysts are used in the production of Alkyl-amines. Since some of these catalysts are recycled and reused, it is important that the plant measures and controls them to improve profitability and efficiency. Implementation of a Pilot Plant for the evaluation and selection of catalysts aimed to the improvement of the production of Alkyl-amines.
Due to current events of target virus attacks such as Stuxnet and Flame, the demand for cyber security has become high priority within Industrial Automation (IA). Since the beginning of IA, the global approach for security technologies has been reserved. There was a valid reason for the industry wide reticence, given that there were no direct vulnerabilities.
Recently, several ARC Advisory Group analysts and management team members had a chance to sit down with the new Yokogawa President and COO, Mr. Takashi Nishijima, and several other top Yokogawa executives to discuss the company's burgeoning presence in the worldwide upstream and midstream oil & gas industry.
Network and system security is now a necessity in process automation industry. YOKOGAWA provides a service lifecycle solution for cyber security to ensure that the security measures and deployments are continuously enhanced, monitored and inspected.
This white paper explains the details of the security design, implementation, operation and validation solutions from the technical perspective.
Only 5% of data is transferred into meaningful information so, asks Frank Horden, Business Development Manager, Yokogawa Global SCADA Center, USA, how to ensure pipeline management data is translated into valuable knowledge?
Distributors are offering a wide range of services in response to customers' changing needs.
Many global industrial companies and utilities rely on Yokogawa's FAST/TOOLS system to deliver high levels of data integration and guaranteed data integrity demanded by these companies. Yokogawa says that the secret to FAST/ TOOLS success in these critical applications is the highly reliable design, combined with exceptional performance and the online configuration capability.
Eduard van Loenen and Frank Horden, Yokogawa, describe utilising a modern SCADA system as a collaboration centre platform for bringing 'real-time' operations, maintenance and business information sources together in one integrated visualisation environment.
Industrial Automation Asia, August 2012
SCADA brings "real-time" operations, maintenance and business information sources together in one integrated Visualization environment. Data from different sources needs to be interrelated and translated into KPIs of the most elementary operational and business functions.
Supervisory control and data acquisition (SCADA) systems have been part of the process industries for many decades and cyber security measures need to grow as technology advances. SCADA systems are used in oil and gas pipeline and other remote control and monitoring applications, such as electrical transmission and distribution, and water/wastewater.
Modern historians do much more than just store process data. They also provide analysis, reports, and valuable operational and business information.
For large scale geographically dispersed projects, there may be a hierarchy of individual Process Automation systems, which in turn are each responsible for a specific region, and are managed by a higher level system. Engineering of systems on this scale is a huge challenge, because each individual system has its own database and its own configuration.
We have developed the FCN (field control node) and FCJ (field control junction) autonomous controllers as the core of STARDOM, a solution that actualizes a network-based control system (NCS) Yokogawa proposes for increased production efficiency.
Due to the rising energy demand in emerging countries in recent years, the amount of oil and gas production has been increasing, thus investment in the development of new oil and gas fields and replacement of old facilities has been booming.
To improve the efficiency of operations, production control systems are working together more closely with information systems. As a result, security measures have become indispensable for production control systems though they have not been emphasized to date. Because many production control systems are used for critical infrastructure, some malware tries to attack them.
To date, Yokogawa has focused on DCS (Distributed Control System) which control the entire power generation plant, including boilers, in the electric power industry. In contrast, turbomachinery control has been handled by turbine manufacturers, but as the electric power market has been active internationally, especially in China and India, in recent years, Yokogawa has been developing turbomachinery control systems to to further develop the electric power industry.
Yokogawa is pleased to present a quick walk through of a demo application that is hosted through FAST/TOOLS SCADA (Supervisory Control and Data Acquisition) mobile web server. The mobile operator interface is a pure HTML 5 implementation which is suitable for any web browser that supports this standard. No accessory applications or plug-ins are required beyond a web browser. Mobile browsers such as Chrome, Dolphin, Safari on platforms such as Android, iOS, and Windows should work equally well. The mobile clients offer a reduced set of functionality compared to the regular FAST/TOOLS rich client and are primarily intended for mobile process and alarm updates.
Yokogawa presents a demonstration of FAST/Tools Supervisory Control and Data Acquisition (SCADA) Operator Interface. A sample application covers the basics of navigation, trending, alarming, diagnostics, reporting, and operator interaction playback.
Yokogawa presents a quick review of FAST/Tools SCADA Visualization Editor. This video covers some of the most commonly used features within the visualization editor including layers, trending, and properties.
Yokogawa presents a tutorial on the trending and historical data logging capabilities of the FAST/TOOLS Supervisory Control and Data Acquisition (SCADA) software. The tutorial covers the key features of the trend application as well as setting up historical data collection.
Yokogawa presents a quick review of the FAST/TOOLS SCADA Collaboration Decision Support Solution (CDSS) option. The CDSS option allows FAST/TOOLS traditional operator interface screens to be combined with outside Internet based information for incorporation of Multimedia like camera feeds, video, news feeds, weather-feeds, stock prices, reports, and other sources of information that are critical to planning and operations.
Yokogawa presents a quick tour of a demo application for a Gas Pipeline SCADA Host. The tour shows Scheduling, EFM/EGM Metering Management, Storage, Compression, and Line Pack functionality.
Yokogawa presents a quick walk through of a liquids handling pipeline SCADA Host implemented in FAST/TOOLS 10.01. It features the fictitious AlbertaSouth Pipeline that includes tank farms, pump stations, block valves, metering stations, provers, pig launchers and receivers. It features applications like leak detection, batch scheduling, and strapping tables for storage tanks. Although it is a demonstration pipeline it does feature functionality that Yokogawa has deployed across the world on real pipeline SCADA Host projects.
Yokogawa presents a demonstration of how the combination of Stardom FCN-RTU and FAST/TOOLS SCADA can be combined to provide a powerful control and data collection system where in the event of a network disconnection or computer outage - Stardom internally buffers data that would otherwise be lost and on reconnection or restoration of the SCADA Server FAST/TOOLS is able to back-fill missing data in its trend.
- An OpreX Control and Safety System solution with enhanced capabilities for seamless system integration -
- Expanding our control business in the midstream oil and gas market-
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