Whether you produce Petrochemicals, Inorganics or Intermediates, you are under constant cost and margin pressure to deliver products to your customer in a timely and efficient manner while maintaining safe and compliant operations. Additionally, you need to adjust to constant feedstock and energy prices and be able to provide the most profitable product mix to the market.
Yokogawa has been serving 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.
The chemical industry is highly specialized, with plants producing intermediate products, out from raw materials, that, in turn, are used by other plants as inputs in their production of more advanced products. Each chemical company needs to carefully consider its positioning in a highly competitive marketplace.
Basic chemicals are usually produced in a continuous process that requires a highly reliable and robust control system. Here also, the CENTUM VP integrated production control system is the ideal solution which realizes a comfortable operation environment in response to process requirements, and provides a comfortable driving environment with a stable process control. The Exapilot online navigation tool provides operators with a strong support for reliable execution of non-routine operations such as shutdown and startup.
Production Control System: CENTUM VP
The single Integrated Control and Safety System (ICSS) database simplifies engineering.With graphics, alarm windows, and system status screens all having the same look and feel, operation is also easier.
Safety Instrumented System: Prosafe-RS
Yokogawa offers a full-lineup of safety instrumented systems from solid-state and hard-wired types to fully integrated DCS-SIS integrated types, covering all safety integrity levels (SIL 1 to 4) for the chemical industry.
Operation Efficiency Improvement: Exapilot
Exapilot is an online navigation tool that guides operators step by step through plant operating procedures.
Using Exapilot, Standard Operating Procedures (or SOPs) are created in a standardized form. SOPs improve efficiency and reduce the total cost of ownership by reducing or eliminating human errors.
Highly responsive analytical systems contribute to accurate measurement of product/intermediate property, helping chemical companies meet tighter quality control and environmental regulations.
“Install and forget” digital field instruments deliver stable and accurate process measurements with low installation cost, near-zero maintenance and self-diagnostic intelligence. As a true leader in the process automation industry and its related technologies, Yokogawa brought the world’s first FOUNDATION fieldbus™ enabled device to market and has since developed a complete range of FOUNDATION fieldbus™, HART, and Profibus protocol instrumentation, in addition to ISA100.11a compliant wireless communication products.
- Legacy System Replaced with Yokogawa CENTUM VP and ProSafe-RS at PTA plant in Indonesia.
- PID parameters imported to CENTUM VP without complex calculations.
Yokogawa provided CENTUM DCS, APC, Exapilot, and Exaquantum for migration project at Juhua Group's methane chloride plant.
The entire management and optimization solution contributes to improving economic benefits, plant safety, quality, etc.
- Main instrument vendor (MIV) concept was applied in this project to reduce the total project engineering cost.
- This consisted DCS, SIS, all instruments, control valves and tank gauging system under working with project management consultant (PMC) and EPC.
- CENTUM CS 3000 production control system contributes to smooth HDPE production.
- The challenge for this replacement project was in completing the work and starting up the new CS 3000 system as soon as possible, keeping downtime to a minimum.
- CS 3000 efficiently controls and monitors coal gasification process.
- Once an operator selects "Start", the necessary instructions are sent to all plant equipment via the sequence control.
- Rapid Implementation of Integrated CENTUM CS 3000 and ProSafe-RS.
- The highly reliable CENTUM CS 3000 system has also helped TOL maintain high productivity at this plant.
- Introduction of CENTUM CS 3000 maximizes productivity and improves product quality at special polymer plant.
- A major improvement as a result of this project is that butadiene monomer recovery efficiency jumped huge.
- CENTUM VP Batch replaces the legacy system and improves production efficiency in the acrylic plant.
- CENTUM VP Batch capability can handle the recipe management to Batch report handling and unit management.
- Exapilot is Effectively Applied to Polypropylene Plant and Optimizes Operation, Cost Savings.
- By using Yokogawa's Exapilot, Safripol were able to eliminate product variations and kept the operations consistent.
- PetroChina Dushanzi Petrochemicals Polyethylene Plant system migration.
- The revamp included the challenging creation of function design specifications (FDS) as well as FAT and SAT.
- Kaneka Corporation has urgently needed to implement countermeasures that would reduce this facility's energy costs.
- Optimization of control strategy helps BTG plant save energy and operate more efficiently.
- Single 'look and feel' operator interface for the DCS and NCS
- Fast and controllable integration cycle
- High speed hybrid compressor control solution
- Reduced OPEX for the compressor operation by replacing old and obsolete PLCs with a modern hybrid control platform
- Provided a better way to transfer its manufacturing know-how to the next generation
- Reduced energy consumption and operator workload by implementing Advanced Process Control (APC) and Advanced Operator Assistance (AOA)
- Implementation of AOA package for improved grade-change operation
- Dramatically reduced operators' workload and transient products, as well as sharable operation know-how
- The work was based on a preceisely formulated roadmap with detailed checklists for every control cabinet, process station, and network component.
- The seamless use of the same HMI for both PCS and SIS, and improved safety and integrity.
- IFCo chose Omegaland operator training system to make ready for a flawless and safe plant start-up.
- Omegaland is contributing to operator training prior to completion of the greenfield fertilizer plant.
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.
Tsurumi Soda Corporation,Yokohama,Kanagawa Prefecture, Japan
- Yokogawa's operational performance program bench mark service enhanced the automation performance at the chemical plant.
- Operator stress was dramatically reduced by identifying the causes of excessive manual interventions.
Yokogawa CENTUM VP and SIS were selected for the Evonik Oxeno's BTX facility expansion project.
CENTUM provides the operational transparency, and more efficient diagnosis of compressors which are the heart of the facility.
- Yokogawa joined forces with Air Liquide to co-innovate the step-by-step revamping plan based on Air Liquide's specific requirements.
- Customer was satisfied that Yokogawa was able to deliver its solutions on time and on budget.
This introduces a system that uses Ethernet communications to acquire measured values, target values, and control output values from a controller installed on site into a PLC at high speed (ten units' worth within one second).
In the plants of food and beverage manufacturers, there are times when monitoring and recording of production equipment is necessary inside clean rooms. This is an introduction to monitoring and recording in clean rooms using paperless recorders.
Operators must receive diagnostic information before a line block leads to a malfunction. Yokogawa provides predictive diagnostics based on trend analysis of the blocking factor, which improves maintenance efficiency and reduces maintenance costs.
Steam is still one of the most popular methods of providing an energy source to a process and its associated operations. The more accurate and reliable measurements that are made, the more informed decisions can be taken that affect costs and product quality.
The GX20 and GX90UT offer an average value computation function making it ideal for controlling temperature and other fluctuating phenomena. The operating status can be controlled in real time, providing operating cost reductions.
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.
With industrial and economic development comes increasingly large and advanced power plants and factories. Nevertheless, we find many cases where the original cables, cable tunnels, and other components of the power infrastructure have languished under continuous operation.
If a sensor is not operating, the manufacturer cannot detect moisture in the chlorine and must stop the process. Unfortunately, sensors can deteriorate and deliver inaccurate measurements due to contact with the process.
In limestone-gypsum flue gas desulfurization systems, the consumption of a desulfurization agent (lime) is controlled using online pH analyzers.
- Temperature monitoring is required to prevent wind-fueled fire hazards.
- The measuring points are up to 600 meters away from the control room.
Both bulk and finished inventories are stored in distributed tank farm remote from the site operations. These are difficult to instrument due to the infrastructure cost involved. These are then monitored daily by patrol rounds. While effective, this method does require a large skilled labor force to monitor all of tanks. This can impose an additional risk when the stored medium is of a hazardous nature.
Industrial Combustion sources such as thermal cracking furnaces and, process heaters play a critical role in the process industry.
- Daily manual reading of pressure and temperature gauges with report by phone.
- The customer wants to change measurement from off-line to on-line.
- Cabling for wired transmitters in huge plants (up to 300 meters long) is expensive.
Storage tanks are used in a variety of industries ranging from holding crude oil to holding feedstock for vinyl chloride monomer (VCM).
Install a YTMX580 on the side of the rotating furnace that can wirelessly transmit measured values from multiple temperature sensors.
Risk management is crucial when expanding your business.
- Temperature is monitored to maintain consistency of the viscous fiber entering the drum.
- Existing system requires manual temperature readings.
- Wired temperature measurement is not available because the tank is rotating.
- Manual temperature reading requires walking about 130 m and climbing up and down elevated sections of the dryer stages.
- Multiple temperature measurement points along the various stages of the dryer require many cables to the control room.
- Very high humidity.
- Wireless temperature measurement
Gateway x1, transmitter (YTA) x1, repeater x2 (The 2 repeaters are for redundancy)
- Extended antenna to circumvent obstacles and improve the radio path for stable measurement (communication was unstable when the height of the antenna was low).
ISA100 wireless temperature and pressure transmitters with orifice plates allow:
- No cabling installations or maintenance.
- Small amount of hardware and simple equipment implementation means minimizing potential vandalism.
ISA100 Wireless Monitoring
- Gateway x1, Temperature Transmitter (YTA) x3, Pressure Transmitter (EJX) x1, Repeater x1
Gateway is installed at control room and 3m height extended antenna is set.
- Temperature Transmitter (YTA) and Pressure Transmitter (EJX) are installed at each monitoring point.
- Repeater is installed on high position.
- Wireless pressure and temperature monitoring.
- Repeater was set under the gateway.
- The maximum distance between the repeater and transmitters is approximately 500m.
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- The top challenges that drive reinstrumentation
- How to plan for and achieve a successful project
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- Different scenarios and best practices for updating, migrating or replacing process controls, safety systems, and instrumentation in plants
Visual MESA© is a steam system optimization and management computer program that was originally developed at Chevron and now marketed by Nelson & Roseme, Inc. Visual MESA is currently used at refinery and chemical manufacturing sites to optimize the overall site steam system and the parts of the electrical system that economically trade off with the steam system.
This paper will explore significant optimization variables and constraints commonly encountered in refinery steam system optimization, the strategies Visual MESA uses to deal with them.
In general, refineries exhibit a very good potential for real time monitoring and optimization using Visual MESA Energy Management System.
Based on our extensive experience, overall benefit in the range of 2% to 5% of the total energy cost can be achieved. Expected project payback is always less than one year.
This paper will not describe just all the features of the software or fully explain on-line optimization technology. The objective of this work is to present some interesting facts and lessons from the experience of implementing a cost based optimization program at thirty oil refineries and petrochemical complexes, around the world, since 1997. This paper will focus on the key optimization variables and constraints in steam system optimization, how they should be handled and how the human and organizational aspects can be addressed.
Industrial facilities where power and steam is produced (i.e., Cogeneration) exhibit a very good potential for real time monitoring and optimization using Visual MESA Energy Management System.
Based on our extensive experience, overall benefit in the range of 2% to 5% of the total energy cost can be achieved. Expected project payback is always less than one year.
Visual MESA was successfully applied to many industrial facilities worldwide, several of them operating steam and power generation networks of different complexity and capacity but all with energy cost savings.
This paper discusses real industrial examples in which the sitewide utilities system of refinery and petrochemical Sites are optimized with a real time, on line, industrially proven software. Experiences gained during more than 20 years of industrial projects deployed worldwide are commented (Refs. 1 to 10 are related to some recent projects). Main project steps are explained and critical details to be taken into account to assure successful use and proper technology transfer are presented. Specific case studies will be discussed in the paper.
Utilities and energy systems are often the major source of SOx, NOx and CO2 emissions, therefore, emissions control and the management of credits and quotas are tightly interrelated with energy management.
Big and complex industrial facilities like Refineries and Petrochemicals are becoming increasingly aware that power systems need to be optimally managed because any energy reduction that Operations accomplish in the producing Units could eventually be wasted if the overall power system cost is not properly managed. However, process engineers always attempted to develop some kind of tools, many times spreadsheet based, to improve the way utilities systems were operated. The main drawback of the earlier attempts was the lack of data: engineers spent the whole day at phone or visiting the control rooms to gather information from the Distributed Control System (DCS) data historian, process it at the spreadsheet and produce recommendations that, when ready to be applied, were outdated and not any more applicable.
Utilities and energy systems are often the major source of SOx, NOx and CO2 emissions, therefore, emissions control and the management of credits and quotas are tightly interrelated with energy management. In the case of refineries, chemical and petrochemical plants, energy represents the main cost (second to feedstock) and therefore its reduction has become a bottom line business decision. The energy systems at these sites are inherently complex, with the emissions cost analysis and limits compliance introducing an additional factor to the complexity of the energy costs reduction challenge.
The energy systems, the steps for the implementation of Visual MESA and several features of the model are described in this article, with a focus on the use of the software for the calculation of energy-related KPIs. The EMS implementation project is discussed and the main conclusions relative to the reduction in operating costs are also presented.
Experiences gained during more than 20 years of industrial projects deployed worldwide are commented. Main project steps are explained and critical details to be taken into account to assure successful use and proper technology transfer are presented. Specific case studies will be discussed in the paper. Open loop vs Closed loop implementation is also presented.
Rohm and Haas Company is one of the world's largest manufacturers of specialty materials, including adhesives, sealants, coatings, monomers, electronic materials, inorganic and specialty solutions, and ion exchange resins. Founded in 1909 by two German entrepreneurs, Rohm and Haas has grown to approximately $6 billion in annual revenues.
This paper shows how to improve distillation operations by focusing on procedure automation. It will review the importance of using procedures in distillation operations and highlights the collaboration work underway between Fractionation Research Inc. (FRI) and Yokogawa Corporation to improve procedural operations.
The worlds of process automation and production management have been converging for some time. What once used to be islands of automation and production management functionality connected through highly proprietary integration schemes that were costly to maintain have developed into integrated platforms that provide seamless data exchange between the world of automation and the plant floor, the functions of production and operations management, and integration with business level systems.
The world of process automation is governed by procedures. While we like to refer to the process industries as being largely "continuous", this could not be further from the truth. Process manufacturing is constantly in flux.
From engineering to installation, commissioning, operations, and maintenance, FOUNDATION fieldbus offer significant cost reductions of 30 percent or more versus conventional analog systems. Many of these cost reductions come from the advanced functions that fieldbus offers versus analog technology.
The automation suppliers that will be successful in the long term will be those that effectively address application or industry specific problems for end users with a value proposition that cannot be ignored. These problems exist throughout the process industries today, and they won't be solved by simply offering a product, but through a combination of hardware, software, services, application expertise, and knowledge.
Yokogawa has come a long way in making its message clear to the world of process automation. Last year, the company embarked on a full-scale global marketing campaign to make customers aware of the company's focus on system reliability, security, dependability, and robustness. Dubbed "Vigilance", the campaign created a unified message for the company and greatly helped expand awareness of the Yokogawa brand and corporate philosophy.
In ARC's view, customers need a compelling business value proposition to justify investment in any kind of automation. Vigilance and VigilantPlant were created with this in mind. Yokogawa's vision with VigilantPlant is to create an environment where plant personnel and operators are well informed, alert, and ready to take action.
Process automation end users are under more pressure than ever to do more with less. The current economic climate means that many automation capital projects are on hold. With capital budgets tighter than ever, users instead focus on operational budgets (where cost cutting is also a key concern), or on automation investments with a very rapid return on investment.
In today's dynamic industrial marketplace, the only constant is change. Raw material costs, energy costs, market demands, environmental and safety regulations, technology, and even the nature of the labor force itself are constantly changing, and not always in predictable directions.
Migration of a refinery's DCS provided an opportunity to reconfigure and consolidate the control rooms and operational management system.
Process plants are run according to operational procedures. These procedures consist of a set of tasks that are executed in a consistent manner to achieve a specific objective, such as starting up, shutting down or transitioning a unit as part of making a product.
Yokogawa is helping a large chemicals site in China manage product transfer by road, ship and pipeline.
The Wyoming Trona Ore Mine and Refinery upgrade from Yokogawa Centum CS3000 to CENTUM VP-R5 involved two domains, 21 RIO and FIO field control stations, 17 operator stations, 6 engineering stations and 8 different plant servers
CONTROL, January 2013
Standard Automation Methodology Improves Operations and Prevents Incidents by Enabling the Sharing of Best Practices Among Operators.
ARC believes that by implementing procedural automation, many process plants can minimize variability to help ensure smooth, efficient, and safe state transitions.
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