Systems Maintenance

Maintain your Yokogawa DCS, SIS, SCADA, PLC systems, as well as systems from third party vendors, with:

  • Corrective and Emergency Maintenance
  • Disaster Recovery
  • On-Line Operating Inspection
  • Off-Line Shutdown Inspection
  • System Backup
  • Foundation Fieldbus Reliability and Performance Services
  • Foundation Fieldbus Segment commissioning
  • Documentation Updates
  • Long or Short Term Site Resident Support

Corrective and Emergency Maintenance

For all your process control service and support needs Yokogawa has implemented the ONE CALL program. By calling 800-524-7378 you can access technical support advisors that will guide you to the correct department, service or person that can provide support, answer your questions, provide quotations and dispatch. From minor questions to complete plant retrofits we are making it easier for you to get answers and support faster.

Disaster Recovery

Yokogawa will work with you to accurately identify the impact and risk potential of abnormal events on your systems. Together we will design the Disaster Recovery Plan best suited for your operations. Yokogawa can assist with recovering a failed system, recovering from customer or programmer error, ensuring data integrity and avoiding the additional costs from attempting to recover or reconstruct lost data. Regularly scheduled backups are recommended and can be incorporated into a preventative plan implemented by Yokogawa.

On-Line Operating Inspection

On-Line Operating Inspections are scheduled inspections on a running system that are performed to help maintain the Yokogawa system in a reliable state by recognizing problems or patterns with the system that if not addressed might lead to impaired system performance. A scheduled maintenance visit will identify potential problem areas and recommend corrective actions to prevent these failures from occurring. All Yokogawa recommended on-line services are included and are performed by trained and experienced Yokogawa service personnel. Detailed documentation of this service is provided upon completion.

Off-Line Shutdown Inspection

Off-Line Shutdown Inspections are scheduled inspections, similar to the on-line inspection, that are performed to help maintain the Yokogawa system in a reliable state by recognizing problems or patterns with the system that if not addressed might lead to failure of some components. A scheduled maintenance visit will identify potential problem areas and recommend corrective actions to prevent these failures from occurring. The Off-Line Inspection is more in-depth and involves component level checking and testing along with replacing consumable parts. All Yokogawa recommended on-line services are included and are performed by trained and experienced Yokogawa service personnel. Detailed documentation of this service is provided upon completion.

System Backup

Data needs to be backed up in case of unforeseen disasters and loss of data and configurations that can lead to problems. Yokogawa will perform an on-site backup of your system and provide you a copy for local retention. Increasing reliability can be achieved by Yokogawa maintaining a copy of your system in our permanent archives as part of the overall security and recovery strategy.

Foundation Fieldbus Reliability and Performance Services

There are many digital communication technologies being promoted however Foundation Fieldbus (FF) has been designed specifically for the process automation industry. Fieldbus is not any more difficult than the traditional technologies, but it is different, thereby affecting the design and implementation aspects of a project. From Front End Engineering Design (FEED) through start up and into the operational phases, Yokogawa is there to support your FF needs with consulting, engineering, and performance services. We can assist with training and knowledge transfer, conduct technical reviews and confirm your Fieldbus segments by providing our customers detailed segment performance reports, including the statistics and loading reports using diagnostic data from our advanced diagnostic applications. After start up Yokogawa will be there to assist with segment troubleshooting when a diagnostic failure or device failure occurs, review your hardware and insure your site is at the most current software revisions.

Foundation Fieldbus Segment commissioning

Foundation Fieldbus Segment commissioning assist customers with the addition of new segments and devices utilizing Yokogawa's FF Builder and Device Panel software. Yokogawa will also ensure the loading of appropriate CFF, DD, DTM files and device templates for use with any new device that may be added in the future. The associated area of Yokogawa's Plant Resource Manager (PRM) device asset management system will be updated accordingly when a new segment or device is added. Each segment will be commissioned and then tested and logged to be within design parameters.

Documentation Updates

As project and operational complexity increase and availability of resources decrease there is a temptation to finish the paperwork later. Postponing completion of the documentation may result in increased costs, lost productivity, or HSE concerns for operations and maintenance when redlined P&ID's, revised control narratives, and other plant documentation are not maintained and kept current. Out of date documentation may lead to non-conformance items on OHSA and ISO compliance audits. Yokogawa's team of document control experts can assist your facility with staying current, safe, and secure.

Long or Short Term Site Resident Support

Regardless of the term; weekly, monthly, year to year, Yokogawa can provide site support. Depending upon the tasks required, this site resource could include the skill levels from an instrument engineer to site service engineer on up to application or senior plant process engineer and/or consultant. Yokogawa site resident support will act as the first point of contact for the customer. Depending on the level of person required, assignment and duration of the service provided, some of the responsibilities that the site resident may have assigned will include expediting support as it is now being provided locally. This includes executing all service or engineering requirements as assigned in order to maximize the customer's use of technology for Yokogawa and 3rd party vendors, automation, instrumentation and information systems.

Details

Refresh your plant.

Keeping installed assets up to date and in good condition while avoiding bumpy capital expenditure. Sound too good to be true? Well, it can be done with the right long-term inventory management partnership.

Yokogawa takes care of spare parts management and hardware/software upgrade on your behalf, providing consistent coverage instead of unexpected capital investments and out-of-pocket expenses.

Our "technology refresh" option let's you take advantage of the latest components under the same no-hassle partnership arrangement.

Parts & spares management

Parts & Spares Management

Reduce your capital investment and expenses through parts & spares management. This program replaces older hardware and software before its performance falls below an acceptable standard.

Technology refresh

Technology Refresh

With the fast pace of technological change in today's marketplace, our customers face the continual challenge of achieving the right balance between utilizing existing assets and upgrading to benefit from the capabilities of the latest technologies. 

Yokogawa's comprehensive technology refresh program is an automated service that reduces your total cost of ownership. Under this program, off-the-shelf, open-system items such as DCS operator stations and the systems supplied as part of our software based solutions are periodically upgraded (generally every three years) to the latest specifications. This type of replacement means that only one operator station will be shut down at any given time, minimizing interruption to the work process. 

With Yokogawa technology refresh, our customers are assured that their hardware and software stay up-to-date in terms of hardware performance, software compatibility, and support facilities. 

Benefits:

  • Improve performance with the latest technology
  • Reduces maintenance costs
  • Flexible payment options
  • Predictable budget control

Cost efficiency

Get exceptional visibility and control of your assets without raising capital appropriations under Yokogawa's technology refresh program. Along with these outstanding benefits, you can expect: 
 

  • Lower operating costs 
  • Higher product quality
  • The ability to predict costs

Cost efficiency

Example: 

Item Year
1 2 3 4 5 6 7 8 9 10 11 12
HDD replacement                    
HIS replacement                
Software upgrade            

•:Replacement

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