Mitsubishi Chemical Builds Safer and More Reliable Emergency Shutdown System Using DCS Integration

Загрузить (184 KB)

Project Background

To process a greater variety of materials and improve global competitiveness, Mitsubishi Chemical Corporation's Kashima Plant (Tobu Zone) and Mitsubishi Chemical Engineering Corporation contracted with Chiyoda Corporation in May 2004 to construct an additional fractioner for an ethylene plant. Yokogawa's CENTUM CS 3000 R3 was selected as the new control system. After carrying out an extensive study, the customers decided to employ ProSafe-RS as the emergency shutdown system instead of conventional relay-based systems in order to:

  • Meet the IEC 61508/JIS C 0508 functional safety standards
  • Proactively introduce leading edge technologies
  • Accommodate the plant licensors' safety, reliability, and maintainability requirements
  • Improve the monitoring and operation functions of the emergency shutdown system


The Challenges and the Solutions

By introducing the ProSafe-RS, the Kashima Plant improved safety, reliability, monitoring, and operation as follows:

  • Dramatic improvement in plant safety through compliance with IEC 61508/JIS C 0508 SIL3
    ProSafe-RS is certified to comply with the IEC 61508/JIS C 0508 (up to SIL3) international functional safety standards. This affirms that a plant will be securely shut down whenever a critical condition occurs, greatly improving plant safety.
  • Achievement of high-level safety while minimizing erroneous trips
    ProSafe-RS maintains plant safety at a high level while keeping to a minimum unnecessary trips triggered by a system's own abnormalities. Mitsubishi Chemical's system incorporates redundant CPU and I/O modules that can avoid almost all erroneous trips, contributing to increased reliability and plant availability.
  • Improved centralized management of plant information through CENTUM CS 3000 R3 integration
    Plant information can be centrally managed thanks to ProSafe-RS's capability to achieve true integration with the CENTUM CS 3000 R3, enabling ProSafe-RS inputs and outputs as well as system operation statuses to be monitored on CENTUM's human interface stations. Emergency operations can also be initiated on the CENTUM stations for better emergency preparedness.

Customer Satisfaction

Takayuki Aoyama, Team Leader of the Instrumentation Group at the Maintenance Technology Center, commented:

"Usually introducing a new thing takes time: you must collect various kinds of information about it, then study actual records, reliability, and technological factors. This is even more so when you consider introducing a product that is used to guarantee safety.

This is where ProSafe-RS comes in. Safety instrumented systems can be evaluated according to international standards and certified by a registered certification body. This spares users the trouble of conducting a feasibility study. The safety standards cover a wide range of items and are thorough about maintaining safety during the detailed design phases. As the system design utilized probability theory, engineers are better able to give a logical explanation of it to third parties.

Introduction of the new safety system was a big decision for us as the existing interlock used hardware relays. As we understood the standards as well as the configured actual hardware and software, however, we were convinced that the new system took safety into much greater consideration than conventional systems and that we had made the right decision.

Interlock-related equipment is growing more complex as it is required to ensure safety against all types of failures, and the same was true when panel instruments were replaced by distributed control systems (DCS). For this reason we employed the ProSafe-RS safety instrumented system. We also believe that the time is approaching when all hardware relays will be replaced by CPU-based systems."

•Safety instrumented system   •Main products Kashima Plant, Mitsubishi Chemical:1.69 million m2


  • Bulk & Petrochemical

    Whether you produce petrochemicals, inorganics or intermediates, chemical companies are under cost and margin pressures to deliver products in a timely and efficient manner while maintaining safe and compliant operations. Additionally, chemical companies need to adjust to fluctuating feedstock and energy prices and to provide the most profitable product mix to the market.

    Yokogawa has been serving the automation needs of the bulk chemical market globally and is the recognized leader in this market. With products, solutions, and industry expertise, Yokogawa understands your market and production needs and will work with you to provide a reliable, and cost effective solution through the lifecycle of your plant.

    Узнать больше
  • Petrochemical

    Petrochemical companies’ needs are extremely diverse. To come out ahead in today’s highly competitive marketplace, producers are striving to improve quality and productivity. Yokogawa provides tailor-made solutions for these needs based on its long and wide-ranging experience in this field.

    Узнать больше
  • Нефтехимия

    Потребности нефтехимических компаний весьма разносторонни. Для того, чтобы выйти на первые места на сегодняшнем высоко конкурентном рынке, производителя постоянно стремятся улучшить качество и производительность. Компания Yokogawa обеспечивает индивидуальные решения для таких потребностей в отрасли на основе своего долго и разнообразного опыта в ней.

    Узнать больше
  • Нефтехимия и базовые химические продукты большого объёма

    Что бы вы не производили, нефтехимические, неорганические или промежуточные продукты, любая химическая компания находятся под постоянным давлением величин затрат и получаемой маржи в процессе обеспечения своевременной и эффективной поставки своей продукции заказчикам, сохраняя требуемый уровень безопасности и соблюдая необходимые нормативы. В дополнение к этому, производителям требуется постоянно подстраиваться к колебанию цен на энергоносители и сырьевой материал, чтобы обеспечить поставку самых маржинальных комбинаций продуктов на рынок.

    Компания Yokogawa обеспечивает потребности производств базовой химической продукции по всему миру и является признанным лидером в отрасли. С набором профильной продукции, решений и экспертных знаний, наша компания понимает ваши производственные потребности и сможет помочь Вам, работая вместе с вами и обеспечивая надёжные и выгодные решения на протяжении всего жизненного цикла Ваших производственных активов.

    Узнать больше
  • Химическая промышленность

    Химические производства применяют периодические и непрерывные технологические процессы производства, каждый из которых имеет свои особые требования для систем управления. Непрерывному технологическому процессу требуется надёжная и стабильно работающая система управления, защищающая от внеплановых остановов, в то время как для периодических процессов более важна гибкость организации партий, возможности внесения корректировок в рецепты и формулы. Для обоих типов процессов одинаково важно вести управление с поддержанием требуемого качества и способность управлять не рутинными операциями. Имея в наличии обширный послужной список и богатое портфолио проектов, а также опытных системных инженеров и обширную сеть поддержки по всему миру, у компании Yokogawa имеются решения для всех видов таких систем.

    Узнать больше

Related Products & Solutions