When the automation assets in a plant near its end of life, it becomes more likely that they may cause an unplanned shutdown. Even if the aging systems are not showing any sign of deterioration, the shortage or lack of spare parts make it a risk to be mitigated. The most common direction decided upon is rip and replace of the asset, and taking the opportunity of a planned shutdown, a study is done which other assets require to be demolished and/or replaced.
Challenges for Customers
Recently more and more owners decide to also initiate a study to improve operational excellence by implementing an MES solution.
End-users have to look at the lifecycle of their system based on different tiers of longevity:
- Poor Performance of Existing System / Unplanned Shutdowns
- Quality of Existing Drawings/ Documents / Data (Accuracy, Fragmented, Missing)
- Online Verification of above Existing Data/ Documents
- Training of Plant Operators / Engineers on new Technologies
- Cutover Schedule / Disruption of Operations During Cutover
- Unavailability of some stakeholders like licensors, package vendors, Cooperation of existing system vendors.
- Revisit Existing Safety Provisions, SIL Requirements, Alarm Rationalization, Ergonomics etc.
- Accuracy of Conversion & Validation Process/ Tools
- Level of Migration / Upgrade to be performed
- Alignment of existing control philosophies, Graphics to meet current Industry standards
- Justifying Migration to Management, ROI
Yokogawa is transforming and changing its focus from product to customers, providing value in projects together with our customers.
For brownfield sites this means we can engage in a masterplan study covering all control and instrumentation assets and operational efficiencies.
Yokogawa’s approach is what new and long term customers have come to appreciate. Their expectation from a leading ICSS Supplier is that operation to be maintained on as-is basis while improving some of the parameters, to take Lumpsum responsibility for complete migration as a partner, requiring minimum inputs and Involvement from operations and maintenance teams. The latest technology is provided while minimizing the shutdown duration by optimizing hot and cold cut-over, deploying local resources during the execution and retraining the operation and maintenance teams. After the plant returns into stable operation, Yokogawa’s condition based maintenance during the total plant lifecycle is implemented for at least 30 years.
Brownfield / Migration Solutions implemented by Yokogawa enable customers to achieve a smooth transition from current level of automation to next generation of automation.
Engaging a Single Vendor from concept (Pre FEED) to commissioning to perform various activities with maintainability and operability as the goal while minimising risk and schedule. This is achieved over and over again by utilizing our proven MAC model of execution, proven cutover methodologies, commissioning tools and workforce having rich industry experience.
Yokogawa’s extensive Brownfield experience is reflected in its detailed work procedures and installation guidelines which are part of the Global Engineering Standard.
At the basis we are committed and have served the Automation Industry for the last 100 Years and having a presence in 85 Countries with more than 18000 Employees. Our reliable services match our manufacturing of Highly Reliable Certified Products & Solutions to meet all levels of Automation as per Industry Standards. We have integrated and installed systems based on local implementation expertise and automated more than 25000 plants across various Industries.
We have executed more than 1000 Brownfield Migration Projects on EPC / Lump Sum Basis and have experience of migrating more than 400 Competitor Systems.
We have engaged as a MAC Vendor with Major Energy Organizations, applying IEC 61508/61511 Compliant Functional Safety Management Systems by local execution locations near the plants and local engineers based on our proven Project Execution Methodologies, Tools, and Engineering / Cutover Procedures. Our training and development Centres near the Customer Facilities enable customers to train and maximize the utilization of their Local Workforce.
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