挑戰
客戶面臨的挑戰
化學工業具有相當高的專業性質,工廠從原料生產的中間產品,會被其他工廠用來生產更先進的產品。在競爭激烈的市場中,每家化工企業都需要審慎思考企業定位。
我們的解決方案
基礎化工通常是連續生產的製程,需要高度可靠和穩定的控制系統。CENTUM VP綜合生產控制系統是非常符合要求的解決方案,可根據工業要求建立舒適的操作環境,並在穩定的製程控制下提供舒適的驅動環境。Exapilot線上導航工具提供操作員強大的支援,能可靠執行許多非常規操作,例如停俥和試俥等。
賦能技術
生產控制系統:CENTUM VP
統一的整合控制和安全系統(ICSS)資料庫簡化了工程設計、graphic、警報視窗和系統狀態螢幕,使它們都具有相同的外觀和使用感,操作也更加簡便。
安全儀表系統:Prosafe-RS
橫河提供從固態、硬線到DCS-SIS完全整合類型一系列完整安全儀表系統的產品線,涵蓋化工行業的所有安全完整性等級(SIL 1至4)。
提升操作效率:Exapilot
Exapilot線上導航工具可指引操作員逐步完成工廠操作程序。
透過使用Exapilot按照規範格式建立標準操作程序(SOP),減少甚至泯除人為錯誤,達到提高效率並降低總體擁有成本的目的。
分析
高速應答分析系統有助於精確測量產品/中間產品特性,幫助石化公司滿足日趨嚴格的品質控制和環境法規。
現場儀表
數位現場儀表提供穩定、精確的製程測量,安裝成本低、零維護,並有智慧自我診斷功能。橫河電機推出世界上第一款支援 FOUNDATION fieldbus™ 的儀表,此後除了符合 ISA100.11a 標準的無線通訊產品外,也開發了全系列的 FOUNDATION fieldbus™、HART 和 Profibus 協議儀表。
參考
ENEOS Materials successfully achieved the world's first long-term autonomous operation of a plant using Yokogawa's AI. FDKPP saves energy and reduces operator workload while maintaining manufacturing quality.
Caustic soda and hydrochloric acid, produced in electrolyzer plants, are fundamental materials used in varieties of industries; chemicals, pharmaceuticals, petrol-chemicals, pulp and papers, etc. Profit is the result of the effective production with minimized running / maintenance cost. Proper control of the process brings you stabilized quality of products with the vast operational profit.
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.
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.
Storage tanks are used in a variety of industries ranging from holding crude oil to holding feedstock for vinyl chloride monomer (VCM).
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.
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.
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.
Migration of a refinery's DCS provided an opportunity to reconfigure and consolidate the control rooms and operational management system.
July 2011
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.
September 2008
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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