Since its foundation in 1915, Yokogawa Electric Corporation has developed many innovative and high-quality industrial automation (IA) systems and products as an instrumentation and measurement supplier, using technologies in the areas of measurement, control, and information, and has been supplying them to the global market. Yokogawa has accumulated a wealth of service experience and expertise through the selection, implementation, expansion, modification, and maintenance of IA systems and products, which are invaluable for customers' operational improvements. Recently, Yokogawa has launched a new comprehensive suite of services, VigilantPlant Services, to be a customers' lifetime partner for operational improvements, providing IA systems and products combined with in-depth know-how. This paper introduces the features and specific services of VigilantPlant Services.
|Figure 1 Growth rate in IA services|
Due to emerging competitors from the rapidly growing countries such as India and China and the global economic downturn triggered by the Lehman shock, many companies in the process industries are struggling to survive the severe global competition. Aiming to achieve ideal plant operation, continuous operational improvements have been carried out day after day in production sites around the world.
Since its foundation in 1915, Yokogawa Electric Corporation has been supplying the process industries with many innovative and high-quality industrial automation (IA) systems and products, focusing on technologies in the areas of measurement, control, and information. These are key infrastructure components for achieving customers' ideal plant operation that can secure safety, optimize production, maximize the use of plant assets, and optimize the total cost of ownership (TCO). Therefore, these systems and products must be properly selected, introduced, operated, and maintained.
Such tasks were usually performed by customers themselves with sufficient human resources and extensive experience. These days, however, customers are facing difficulties carrying out these tasks by themselves due to the shortage of human resources and expertise caused by the retirement of skilled engineers, rapid advancement and multi- functionalization of IA systems and products, and the trend toward a quick return on investment. As a result, they expect Yokogawa to complete such tasks relying on its wide variety of experience of project accomplishments and after-services. In response to this expectation, Yokogawa has launched a comprehensive suite of services "VigilantPlant Services" with its strong commitment to serve customers as a lifetime partner for continuous operational improvements.
This paper introduces the IA business environment, changes in customer needs, and features of the new VigilantPlant Services and its service product portfolio responding to those needs. It also outlines Yokogawa's existing IA systems and products that are used as a platform for VigilantPlant Services.
Figure 2 Operational Excellence Model
In response to current trends in the process industries and customers' latest needs for outsourcing operational improvement activities, Yokogawa has planned and developed VigilantPlant Services.
Shortage of Human Resources and Expertise for Operational Improvements
The anticipated demographic challenges as skilled engineers and operators retire at production sites are surfacing in developed countries such as Japan and the U.S. At the same time, increasing demands for such expertise in emerging countries such as China and India are intensifying the challenge. The process industries today focus more on the R&D and marketing of competitive products and sales activities, resulting in the lack of sufficient personnel to improve plant operation. In addition, the shrinking young workforce and less interest in engineering as a career today make the situation more difficult for customers to carry out their plant operational improvements by themselves.
Rapid advancement and multi-functionalization of IA systems and products
The advancement and diversification of customers' needs to cope with the increasing global competition and rapid progress in electric and information technology supported by the standardization of operating systems (OS) and communication interfaces have led to the rapid advancement and multi-functionalization of IA systems and products since the late 1990s. To make the best use of such complex IA systems and products, detailed knowledge and expertise of them are required.
Quick Return on Investment
As shown in Figure 1, there is growing interest in operating and consulting services for existing IA systems and products in plants as an area to achieve a quick return on investment1.
Transforming to a Lifetime Partner for Operational Improvements
In these circumstances, Yokogawa has developed VigilantPlant Services with a strong commitment to becoming a lifetime partner of customers for operational improvements by offering them a wealth of expertise in improving operations by fully utilizing IA systems and products which Yokogawa has acquired through the accomplishment of projects around the world. It is the supplier's responsibility to offer customers such expertise to help them use Yokogawa's IA systems and products throughout the plant lifecycle.
In 2005, Yokogawa announced the 'VigilantPlant' vision as the ideal plant, the concept of which is shared between the customer and Yokogawa2,3. VigilantPlant Services according to this vision is a comprehensive brand of a suite of services to assist customers to achieve a VigilantPlant.
VigilantPlant is an ideal plant operational concept shared between the customer and Yokogawa. More specifically, VigilantPlant is a plant in which:
As a result, fully optimized operation which can quickly adapt to future changes is achieved.
Customers' Competitive Edge by Achieving VigilantPlant
Figure 2 shows the Operational Excellence Model for plant operation. The model represents the four competitive edges (excellences) i.e. customers' benefits, which they can obtain by achieving VigilantPlant.
Table 1 Independent Protection Layers covered by VigilantPlant
|1st layer||Process Design||Process design for achieving an inherently safer plant. This includes investigation of lowering the operating temperature and pressure or minimizing the amount of hazardous materials to achieve the same process.|
|2nd layer||Basic Process Control System (BPCS)||The systems, including distributed control systems (DCS), mainly intended for monitoring normal plant operation. These systems activate alarms when process values exceed set thresholds and operator intervention is required.|
|3rd layer||Critical alarms differentiated from those activated by BPCS||Applied when there is enough time for the operator to intervene.|
|4th layer||Automatic Safety Instrumented System / Emergency Shutdown System||Shutting down plants automatically and safely with a safety interlock system or emergency shutdown system, etc.|
|5th layer||Physical Protection (Relief Devices)||Pressure relief systems such as safety valves and rupture disks.|
|6th layer||Physical Protection (Dikes)||Dikes for localizing spilled fluid.|
|7th layer||Plant Emergency Response||Emergency plans for plant safety.|
|8th layer||Community Emergency Response||Emergency response plans for communities or public facilities.|
Figure 3 The area of the ISA-95 (IEC 62264) functional hierarchy covered by VigilantPlant
|Figure 4 VigilantPlant Services concept|
Figure 4 shows the concept of VigilantPlant Services. To help customers achieve ideal plant operation (VigilantPlant) and obtain a competitive edge in plant operation (Operational Excellence), Yokogawa provides various IA systems and products (VigilantPlant Platforms) and a suite of services (VigilantPlant Services).
Product Lineup of VigilantPlant Services
As shown in Figure 5, VigilantPlant Services consist of three types of Services corresponding to customers' progress in operational improvement activities. Customers can introduce any Services depending on their progress. In line with the release of VigilantPlant Services, many services have been newly developed, especially for the Opportunity Identification Services and Solution Implementation Services.
Figure 6 shows the portfolio of VigilantPlant Services. The three types of Services are circularly linked to each other to help customers achieve continuous operational improvements. For example, a customer introduced the PID Loop Controllability Improvement, one of the services of the Solution Implementation Services, and achieved improved controllability. After a while, if the Regular Effectiveness Analysis, one of the services of the Lifecycle Effectiveness Services, reveals some deterioration in control performance caused by a change of raw material, Yokogawa would propose re-introducing the PID Loop Controllability Improvement to restore the control performance.
Figure 5 Three Types of VigilantPlant Services
To offer customers around the world high-quality services, Yokogawa has an in-house qualification system for service engineers who offer services. Those who have received a wide range of training and passed the examination can provide services.
Figure 6 VigilantPlant Services Product Portfolio
Opportunity Identification Services
Opportunity Identification Services support the provisional step for operational improvement such as identifying new improvement opportunities, selecting an effective solution, creating an improvement plan, and training the persons in charge of improvement. Phased approaches are provided considering the customer's progress in opportunity identification activities. The typical services are as follows.
Solution Implementation Services
Solution Implementation Services supports customers in solving problems by offering the best practice for their identified opportunities. As shown in Table 2, all services in Solution Implementation Services are standardized in accordance with the Six Sigma DMAIC steps, which are a famous product quality control and management control method, to carry the improvement activities within a specified period without missing steps.
Table 2 Procedure of Solution Implementation Services
|Define||Set the improvement goal|
|Measure||Gather relevant information for improvement|
|Analyze||Analyze the information and derive the solution|
|Improve||Implement the solution|
|Control||Evaluate the improvement result|
The main services to achieve each excellence of operations are described below.
Table 3 Solution Implementation Services based on RASIS indexes for optimizing TCO
|Reliability||Washing and coating
Replacement of deteriorated parts
Card device lending
As an example of the Six Sigma DMAIC procedure of the Solution Implementation Services, Table 4 shows the major steps taken for the Best Practice Pilot utilizing the Exapilot operation efficiency improvement package, which is procedural automation software.
Table 4 Procedure of Best Practice Pilot
|Define||• Determine the target operation (Start-up, feed change, etc.)
• Determine the target of procedural standardization and automation (Energy saving, reduction of transient time, labor saving, etc.)
• Set a quantitative target for improvement
|Measure||• Obtain the SOP (Standard Operation Procedure)
• Learn operation know-how from skilled operators
|Analyze||• Define the best practice
• Investigate automation of field devices
• Allocate tasks between Exapilot and DCS
|Improve||• Implement the best practice in Exapilot and test it
• Modify the field devices and update DCS
|Control||• Evaluate the improvement result|
Lifecycle Effectiveness Services
The Lifecycle Effectiveness Services support maintaining the effects of improvements achieved by Solution Implementation Services. As shown below, the benefits of solutions such as improving safety, improving productivity, improving availability of assets, and reducing TCO are periodically verified throughout the plant lifecycle.
Table 5 shows the major systems and products included in VigilantPlant Platforms that cover almost all of Yokogawa's IA systems and products. Among them, this section introduces those which are most likely to be used for VigilantPlant Services.
Table 5 IA systems and products for VigilantPlant Platforms
|Perspective||Category / description||Examples of systems or products|
|Independent Protection Layers||4th layer||Automatic Safety Instrumented System / Emergency Shutdown System||ProSafe-RS safety instrumented system|
|3rd layer||Critical alarms differentiated from those activated by BPCS||AAASuite alarm rationalization assistance package software|
|2nd layer||Basic Process Control System (BPCS)||CENTUM integrated production control system
Consolidated Alarm Management Software (CAMS)
|Optimal Production (Production Excellence)||Functional enterprise-control level||Level 3||Manufacturing Operations Management||ETSVision-Refinery total solution package for refineries|
|Level 2||Batch Control, Continuous Control, Discrete Control||CENTUM integrated production control system
Exasmoc multivariable model predictive control package
Exapilot operation efficiency improvement package
|Level 1||Physical Production Process||DPharp pressure and differential pressure transmitters|
|Maximum use of plant assets
|-||-||PRM plant resource manager|
Yokogawa's new service brand "VigilantPlant Services" represents Yokogawa's strong commitment to serve customers as a lifetime partner for operational improvements by providing Yokogawa's extensive expertise developed in the selection, installation, expansion, modification, and maintenance of IA systems and products. We sincerely hope that this paper helps you clearly understand Yokogawa's new approach in which Yokogawa has stepped ahead from being a reliable product supplier toward the goal of becoming a reliable partner.
This special issue of Yokogawa Technical Report introduces some of the detailed service products included in the VigilantPlant Services as well as some solutions combined with Yokogawa's systems and products for certain industries.
Yokogawa will expand its service products according to customers' feedback and requests. We hope to serve as your total solution provider throughout for the life of your plant.
Since it was released in 1993, CENTUM CS is widely applied in the plants of oil refinery, petrochemical, chemistry, iron and steel, non-ferrous metal, metal, cement, paper pulp, food and pharmaceutical industries, and power, gas and water supply as well as many other public utilities.
Advanced Alarm Administrator allows alarm review, alarm optimizing, and enhancement of alarm response by simplifying the process of alarm reduction and minimizing alarm flooding.
Plant Resource Manager (PRM) is a key platform for the Yokogawa VigilantPlant Asset Excellence initiative which aims to improve operations and maintenance and maximize the reliability and availability of plant assets by achieving greater predictability.
Procedural Automation (Exapilot) provides a flexible methodology to capture, optimize and retain procedural knowledge in a process plant while meeting requirements in reliability, flexibility, and lifecycle costs.
The ProSafe-RS is a Safety Instrumented System that is certified by the German certification organization (TÜV) to meet Safety Integrity Level (SIL) 3 specified in IEC 61508. It has been used in over 2,100 projects, ranging from large scale integrated process automation projects to stand-alone solutions. Yokogawa's ProSafe-RS safety systems are built with competence, life cycle support and long term sustainability.
VigilantPlant is Yokogawa's automation concept for safe, reliable, and profitable plant operations.
Yokogawa delivers critical operational infrastructure for process automation. Our distributed control system (DCS) enables automation and control of industrial processes and enhanced business performance. Over 10,000 plants entrust Yokogawa DCS to deliver their production goals.