Total Productive Maintenance, TPM, is highly regarded as an effective productivity improvement methodology in the manufacturing industries. Yokogawa's asset management solution deploys TPM through proactive and preventive techniques for improving reliability and production efficiency in the following key areas:
- Equipment failure: Prevention of equipment downtime or loss of functionality
- Process failure: Prevention of plant shutdown due to changes in chemical or physical properties of process materials, operational errors or other disturbances
- Transition losses: Prevention of problems during start-up, shut-down, and switchovers in plant processes
- Idle time: Prevention of abnormalities or failures that result in process slow-downs or under-performance
FieldMate 3.0 is a PC based tool that enables you to see intelligent field devices clearly, know their condition in advance, and act with agility throughout maintenance work flow.
Have the facility managed properly for high-reliable and stable plant operation? PRM contributes to improving the quality of maintenance plans and optimizing maintenance costs throughout the plant life cycle.
By detecting cavitation, quantifying information on this, and displaying this data in real time, this system provides an early indication of conditions that can result in a degradation in pump performance.
Analyzer Management and Data Systems (AMADAS) are meant to monitor, maintain, determine and improve the performance of on-line process analyzers. Yokogawa's Advanced Analytical Instrument Management System (AAIMS) is one step ahead, in that it provides real-time asset maintenance management for a wide range of on-line/in-line process analyzers from simple analytical devices such as pH, conductivity and O2 as well as for complex analytical devices such as gas chromatographs (GC) and Near Infrared (NIR).
With the increasing demand for energy that has accompanied the economic growth of newly industrialized nations, companies need to find every possible way to add value and max out the efficiency of their production processes. And they must find a way to do this without doing harm to the environment and while complying with stringent HSE regulations.
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.
- Base Chemical
- Biomass Power
- Bulk & Petrochemical
- Geothermal Power
- Iron & Steel
- Mining & Metal
- Offshore (FPSO FLNG & FSRU)
- Oil & Gas Downstream
- Pulp & Paper
- Renewable Energy
- Specialty & Fine Chemical
- Waste to Energy
- Water & Wastewater
- Water Treatment
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.
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.
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.
Combining smart instruments, analyzers and valves with a modern asset management system can provide faster response to incidents, enable proactive maintenance, and reduce downtime.
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.
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.
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.
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.
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 Control Valve Diagnostics leads to the revolving of the valve 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.
"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 InsightSuiteAE leads to the revolving of the plant assets issues throughout the plant life cycle.
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