Química

Chemical plants rely on continuous and batch production processes, each posing different requirements for a control system. A continuous process calls for a robust and stable control system that will not fail and cause the shutdown of a production line, whereas the emphasis with a batch process is on having a control system that allows great flexibility in making adjustments to formulas, procedures, and the like. Both kinds of systems need to be managed in available quality history of product, and to be able to execute non-routine operations. With its extensive product portfolio, experienced systems engineers, and global sales and service network, Yokogawa has a solution for every plant process.

Chemical Industry Value Chain

Yokogawa Electric Corporation released the world’s first DCS in 1975, which rapidly became popular among many customers in the chemical industry worldwide. Yokogawa has thus been contributing to the safe and stable operation of users’ plants as a leading supplier of process control solutions in this industry.
As the processes, products and value chain of the chemical industry are becoming more complex and sophisticated, so too are customer requirements. Yokogawa continues to provide industrial solutions and services to meet those needs by leveraging its wealth of experience and expertise in this field. We have also released various new solutions such as energy management in order to optimize plant operation.
Yokogawa will continue to meet the expectations of customers in the chemical industry by providing state-of-the-art automation solutions as a comprehensive supplier.

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Production Excellence

Production Management

MES integration
A variety of individual systems that perform scheduling and other functions are included in the manufacturing execution systems (MES) domain. The connectivity among systems is a fundamental key enabler for agile production management.
Workflow standardization
Production workflows should be defined and monitored for reliable production management. The standardization of workflows is especially effective at companies with multiple production sites.
Real-time production management
Overall real-time production management is required to speed up the production plan-do-check-action (PDCA) cycle.

Production Control

Loop tuning
Process identification (PID) control plays a fundamental role in process control. Proper tuning is required for stable process control and is a prerequisite for advanced-level control.
Advanced automation
Advanced process control and knowledge-based navigation systems are key contributors to a well-automated operation.
Real-time optimization
Plant-wide optimization can be achieved with a real-time optimizer using rigorous model calculations.

Production Monitoring

Alarm rationalization
An approach to alarm management based on the well-known engineering equipment & materials users’ association (EEMUA) No.191 guideline is recommended. Alarm root cause analysis is also an effective approach to successful alarm rationalization.
KPI monitoring
A wide variety of key performance indicators (KPI) should be monitored by each person. KPI monitoring requires comparison with targets and drilling down for detailed information.
Production navigation
Production tasks need to be managed correctly by the system. Task progress monitoring is a valuable bridge between planning and manufacturing that facilitates cooperation in production management.

Production Environment

Operator training
Operator training systems allow operators to gain experience in handling various situations such as equipment malfunctions and in performing start-ups and other routine operations. It helps operators upgrade their skills.
Control room design
Control room design needs to take into consideration all aspects of the work environment including ergonomics, safety, ease of communication, functionality, automation of systems, and business policy.
Resource optimization
A central control room is desirable for an effective production environment. All production-related units should be stationed nearby to ensure good communication. In addition to centralizing the control room, the optimization of human resources and other activities can be considered to achieve production excellence.

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