Plant Resource Manager (PRM)

• Highlyadvanced biopharmaceutical plant uses CENTUM, VP Batch, Exaquantum and PRM.
• Total system integration for large-scale biotech production facility.

• Operational Excellence by Asset Maximization, Utilizing Yokogawa's DCS, SIS, Analyzers, and Field Instruments.
• The CENTUM VP PCS and ProSafe-RS SIS were integrated using the same engineering environment.
• Nearly 60 gas chromatographs and a large number of other types of analyzers in several analyzer houses.

• Stable operation and proactive maintenance were realized at new coal-chemical plant in China.
• Yokogawa engineers ensured a successful and efficient commissioning and startup.

• As the main automation contractor (MAC) for this plant construction project, Yokogawa Brazil engineered, installed, and commissioned an integrated control and instrumentation solution
• Yokogawa Brazil completed the commissioning of these systems ahead of schedule and the production of green polymer was started just one week later

• Reinstrumentation project at HDPE plant replaced legacy pneumatic instruments and PLCs with integrated CENTUM CS 3000 PCS and ProSafe-RS SIS.
• HART field devices can be monitored from the central control room with the plant resource manager (PRM) package, enabling a more predictive and proactive maintenance approach that reduces total cost of ownership.

• Italian waste to energy plant turns to CENTUM, PRM and FOUNDATION fieldbus solution
• Nearly 1500 FOUNDATION fieldbus devices are monitored and managed using the PRM

• Replacement of legacy control system by CENTUM CS 3000
• Replacement of 4 – 20 mA protocol to FOUNDATION fieldbus™

• Steady boiler control by CENTUM CS 3000 with dual redundant CPUs and seven 9s availability
• Total plant information integrated into supervisory information system via OPC interface
• Reduced water, coal and other resource consumption

CENTUM VP was selected for the BOP in a concentrated solar power plant of the Xina Solar One Project.
Yokogawa provided a complete control system solution that integrates the subsystems in the plant as a system of systems.

• Yokogawa's integrated solutions control FGD processes at Romania's largest power plant
• SO₂ and dust emissions are controlled within the EU environmental standards

• CENTUM CS3000 seamlessly integrates with multivendor control systems through OPC interface. 
• Challenging predictive maintenance to monitor many transmitter data through PRM.

• DCS, SIS, PRM with FOUNDATION fieldbus and OTS Installed in Thailand First LNG Terminal.
• Alarms are issued before any device fails completely, enabling predictive maintenance that reduces maintenance costs throughout the facility lifecycle.

• Xstrata designed and supplied a plant wide process control system for the project based on a Yokogawa CENTUM CS 3000 system.
• Xstrata has used Yokogawa extensively in the past and trusted the reliability of the CS 3000 system.

• Computerized Maintenance Management System by PRM and SAP Schedules Field Instrumentation Maintenance.
• The frame applications and DTMs support the preventive maintenance strategy with self-diagnostic and condition monitoring.

• FDT technology gives users centralized access to all devices.
• FDT technology provides a common environment for configuring, operating, or maintaining any devices.

• Fieldbus technology introduced to realize predictive and preventive maintenance.
• ISAE to improve the reliability of diagnosis and parameter setting, utilizing data collected by PRM.

• 16,000 FOUNDATION Fieldbus devices
• Main Automation Contractor (MAC)
• DCS anywhere concept integration with site SAP system
• Long term maintenance contract
• Sustainable development

• CS Batch is used to automate a wide range of Reichhold's batch processes and multi-product/multi-path processes.
• Using PRM, process engineers can immediately find out the status of every field device without having to do an onsite inspection.

• HMEL selected an integrated solution from Yokogawa
• Yokogawa India oversaw and implemented the engineering, installation, and commissioning of the refinery

Eraring Power Station, located just north of Sydney, is one of the largest power stations in Australia, comprising four 660MW coal-fired units. The power station has operated reliably since 1981. To ensure continued reliability for the next few decades, Eraring Energy, the owner of the power plant, decided to replace the original hard-wired control equipment with a modern integrated control and monitoring system (ICMS).

• This is the first offshore platform in Thailand that is designed to make full use of FOUNDATION fieldbus technology.
• Thanks to Yokogawa's highly reliable systems and products, a safe working environment has been achieved.

• Integration of CENTUM CS 3000 with ProSafe-RS improves plant safety and reliability.
• Yokogawa's PRM package manages more than 500 HART field devices including control valves.

Thai Acrylic Fibre Co., Ltd. (TAF) was established in 1987 and is currently a leading acrylic fiber manufacturer in the ASEAN region with 450 employees. It produces a wide range of acrylic fiber productions with varied deniers and the annual production recorded 77,000 megatons in 2004 which is five times the production rate at the time of establishment.

• PRM allows a preventive maintenance approach where maintenance can be scheduled and performed before a field device fails.
• Exaquantum gathers plant data from the CENTUM VP to generate a variety of reports on the polymerization process.

• Smooth and safe switchover to the new system
• Easy-to-use, easy-to-engineer system, plus various post-installation enhancements
• Tuned controllers for smooth plant operation and better traceability of process upsets
• Various other improvements thanks to advanced process control and MVC implementation

Saudi Aramco's operations span the globe and the energy industry. The world leader in crude oil production, Saudi Aramco also owns and operates an extensive network of refining and distribution facilities, and is responsible for gas processing and transportation installations that fuel Saudi Arabia's industrial sector. An array of international subsidiaries and joint ventures deliver crude oil and refined products to customers worldwide.

• CENTUM VP Batch package improves productivity.
• Reduction of operator workload and safe operation.

• NAM needs to remotely monitor field devices and organize their maintenance schedule.
• True value in instrument diagnostics and preventative maintenance with powerful software tools like DTM.

• Extremely cost-effective, reliable fieldbus solution to revive control system
• Minimized total cost of ownership and maximized total value of ownership

• Yokogawa provides CENTUM CS 3000, Exaquantum and PRM solutions for China's largest refinery/petrochemical complex.
• Process data management by Exaquantum is a key issue in the petrochemical complex.

PetroChina Guangxi Petrochemical Company has completed construction of a combined refinery and petrochemical production complex in Qinzhou, a port city in China's Guangxi Autonomous Region. With a 10 million ton per year capacity, the refinery is one of China's largest, and is truly world class, using a highly advanced hydrogenation process, with the main process technologies coming from the USA and France.

• Using the CENTUM CS 3000 system, many kinds of plant key performance indexes are calculated and analyzed to produce further improvements.
• During plant start-up, PRM helps the customer's engineers perform all the loop checks.

• Yokogawa's CENTUM VP and PRM improve efficiency at new nylon plant in Thailand.
• At the plant startup stage, PRM was used together with FieldMate to thoroughly check all loops.

• Yokogawa's integrated solution contributed to reliable and efficient operation.
• All the instrument information is fully integrated with the instrument management system.

• The visualization of data using the Exaquantum PIMS plays an important role in efforts to improve operations at this power station. 
• To reduce operator workload and eliminate unplanned shutdowns, HERA decided on the use of field digital technology at this power station.

• A Japanese petrochemical plant leverages FDT/DTM-compliant intelligent field devices and Yokogawa's PRM asset management system for maintenance efficiency.
• The customer aims to improve maintenance efficiency further by introducing condition-based maintenance (CBM).

To enable central control of the entire plant, all of its subsystems are integrated with Yokogawa's CENTUM VP DCS.

• Kuraray EVAL and Yokogawa prepared carefully for the expansion and modernization of the CENTUM system.
• Management of 400+ fieldbus instruments by Yokogawa's PRM plant resource manage also helped the project to proceed smoothly.

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.

Yokogawa Electric Corporation promotes the standardization of FOUNDATION™ fieldbus as the communication foundation supporting Asset Excellence for VigilantPlant, which is an approach aimed at the advancement of plant instruments and equipment. With the recent dramatic advancement of fieldbus technologies, information processing technologies, and network speed, it has become possible to process various kinds of information inside the field sensors and transmit the results to the distributed control system (DCS) and host computer.

In 2005, Yokogawa announced "VigilantPlant" as a concept to ward the realization of a type of plant operation that is considered ideal by our customers.

Intelligent field instruments and process analyzers accumulate diverse field information including process values and diagnostic results. This data needs to be sent to upper systems such as distributed control systems (DCS) via digital communications such as FOUNDATION Fieldbus and analyzer buses, or hybrid communications such as HART and Brain, and visualized to enable the customer to utilize them for plant operations and maintenance.

More than ten years have passed since the first digitized field devices were introduced. These support either a hybrid communication protocol such as HART or a full digital communication protocol such as FOUNDATION Fieldbus.

As field instrumentation devices become increasingly digitized and computerized, interactive and remote access to a large quantity of field information becomes possible. This will increase the efficiency of plant equipment maintenance by reducing labor requirements in field patrol work for example. 

There has been increasing demand for cost reductions and lower-priced products in the manufacturing industry, and maintaining cost competitiveness and achieving optimum costs have become necessary for the survival of manufacturers. This calls for minimizing TCO (Total Cost of Ownership) over the whole life cycle of plants and maximizing TVO (Total Value of Ownership).

Process automation involves both operation and maintenance. Plant operation and monitoring are mainly conducted by a control system such as CENTUM, while equipment maintenance is handled by Plant Asset Management (PAM) such as Plant Resource Manager (PRM).

As compared to Distributed Control Systems (DCS) such as CENTUM VP that monitors the operations of the overall plant, PRM is a type of Plant Asset Management (PAM) software package that primarily focuses on the maintenance of devices and instruments.

Environment and safety are major topics on a global scale in recent times. As symbolized by the effectuation of the Kyoto Protocol, an interest in preserving the environment is growing worldwide, and there is also a tendency to criticize more severely, occurrences of industrial accidents that are accompanied by environmental contamination or which may cause damage, etc., to residents in the surrounding areas.

The FieldMate versatile device management wizard is PC software mainly used for configuring and adjusting field devices. Under the concept of "one tool for all," Yokogawa has been enhancing this software to support a wide range of field devices and field communication protocols.

Asset Excellence (AE) provides a set of solutions for maintaining a plant in good condition at reasonable cost to ensure that it works as a production infrastructure. To reduce maintenance costs without causing a risk to production, it is necessary to change from breakdown maintenance to predictive or preventive maintenance.

Latest field devices have not only various self-diagnosis functions but also process-interface-diagnosis functions such as valve diagnosis of valve positioners and impulse line blockage detection of differential pressure transmitters. The YVP valve positioner can easily perform initial tuning, parameter adjustment, trend monitoring, and valve diagnosis, by using the ValveNavi YVP management software.

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.

March 2006

The new CSPC (CNOOC and Shell Petrochemicals Company Limited) petrochemical complex at Daya Bay in southern China is one of the world's largest process industry projects (see box, Figure 1 and Table). It has a control system to match. Process Worldwide spoke to Johan Veerman, principal instrument and process control engineer at CSPC, about the challenges of managing such a huge job.

May 2006

Predictive maintenance allows to schedule plant maintenance before a failure occurs only when it is necessary, greatly reducing unnecessary inspection and improving productivity. Yokogawa's Asset Excellence initiative helps its customers make their plant asset condition predictable and performance sustainable.

2011

Decades of operation, modernization and expansion have left many chemical plants with a somewhat haphazard automation mix of different controls, process control systems, remote I/Os and field devices. The various components may use different communication protocols such as HART, PROFIBUS or FOUNDATION Fieldbus, and are often based on different device integration technologies. 

Combining smart instruments, analyzers and valves with a modern asset management system can provide faster response to incidents, enable proactive maintenance, and reduce downtime.

September 2007

Yokogawa's web-based DCS Anywhere has simplified commissioning at the Nanhai petrochemicals complex. With a total investment of 4.2 billion US dollars, the Nanhai petrochemicals complex at Daya Bay in Huizhou, China, has attracted a lot of attention because of its sheer scale.

Offshore, February 2013

Offshore and deep-water production has been a significant factor in the sustained growth of the oil and gas industries over the past decade and this trend is expected to continue beyond 2013. 

October 2008

Yokogawa's Raju Seshadri reveals the latest trends in predictive maintenance solutions. We all dream of being able to see into the future, of being able to predict what will happen before it has, and taking decisive action before something negative occurs later.

September 2006

Asset management systems need to be able to handle more data and present information in better formats if plant managers are to move towards proactive maintenance, says John van der Geer, industrial automation marketing manager at Yokogawa Europe.

July 2010

Martin te Lintelo, Yokogawa Europe B.V., The Netherlands, discusses high level control system design for LNG receiving terminals. As demand for LNG increases worldwide, players face seemingly conflicting challenges. On one hand, they must expand capacity in different regions, make the business and production as agile and adaptive as possible, and improve operational efficiency.

LNG Industry, Summer 2012

Martin te Lintelo, Yokogawa, The Netherlands, discusses the need for better automation, measurement and control instruments to cope with the rising popularity of LNG.

What's the proper plant asset management (PAM) to prevent sudden equipment failures? Have the facility managed properly for high-reliable and stable plant operation? Yokogawa's PRM leads to the revolving of PAM issues throughout the plant life cycle.

By prompt trouble shooting realizes to improves Plant Productivity. Yokogawa’s Plant Resource Manager, PRM enables you to check remotely the status of equipment without head on-site. PRM contributes to Increased Plant Productivity.

"Remote plant maintenance is absolutely impossible!" ...Don't you think so?
In order to minimize travel and contact with people, it's becoming commonplace to work remotely. That’s why we’d like to propose the Field Asset KPI Reports provided by Yokogawa PRM. 

Yokogawa's Control Valve Diagnostics leads to the revolving of the valve issues throughout the plant life cycle.

Yokogawa's parameter monitoring is effective in understanding the trend of device abnormalities in field devices, and can be used for preventive maintenance of devices.

Yokogawa's InsightSuiteAE leads to the revolving of the plant assets issues throughout the plant life cycle.

Plant Healthcare Service for field assets is a service that Yokogawa quantitatively grasps the status and risks of customer’s plant assets, and provides useful information for asset maintenance optimization.