Distributed Control System (DCS)

The customer has successfully brought online a greenfield 800 MW supercritical power plant, using a Yokogawa full-replica plant simulator to ensure a fast and smooth plant commissioning process.

• Implementation of control system supported by global maintenance, service, engineering, and technical support capabilities
• Improved stability and safety of plant operation

• ABS plant migrates from CENTUM XL to integrated CENTUM CS 3000 solution.
• CENTUM CS 3000 Integrated Production Control System together with CCTV equipment, a plant information management system (PIMS), the Exaplog Event Analysis Package, and the CS Batch 3000 package.

• The AR1 refinery recently replaced its legacy DCS with Yokogawa's CENTUM CS 3000.
• Achieving an Intelligent Oil Management System.

• Pharmaceutical automation solution delivered through commitment to local expertise
• Enhanced process reliability and consistency leading to greater assurance of product quality

INPEX Corporation (INPEX) is Japan's biggest oil and gas development company and is involved in all aspects of this business, from research to exploration, production, and sales. INPEX is engaged in projects all over the world, in a total of 29 countries, including Japan, where it operates a gas production plant near Oyazawa, a town in Niigata prefecture.

The AFCO project is a showcase of the good coordination between Yokogawa Middle East, Yokogawa Thailand, Yokogawa Singapore, and Yokogawa Electric Corporation. Yokogawa Middle East and Yokogawa headquarters both were involved in the project execution.

• CACT Offshore platform reduces unplanned downtime by migrating from Legacy PLC System to reliable CENTUM CS 3000.
• It is possible for CACT engineers to modify the system configuration, download software updates, and hot-swap I/O cards while the process control system is online.

• CS 3000 efficiently controls and monitors coal gasification process.
• Once an operator selects "Start", the necessary instructions are sent to all plant equipment via the sequence control.

• All correct operation procedures are carefully configured in the CENTUM CS 3000 and smoothly in operation
• CENTUM CS 3000 ensures stable supply of electricity and steam to Bangkok's Suvarnabhumi airport

• The solution was a remote connection via Microsoft Terminal Services across the internet.
• It enables an Ausmelt technical expert in Melbourne to log on to the Yokogawa control system at Karabash in Russia.

• CENTUM CS 3000 production control system contributes to smooth HDPE production.
• The challenge for this replacement project was in completing the work and starting up the new CS 3000 system as soon as possible, keeping downtime to a minimum.

• Unified operator interface thanks to CENTUM CS 3000/UOI
• Automated plant startup and shutdown using new block sequences
• Advanced alarm management using consolidated alarm management software

• CENTUM VP Batch replaces the legacy system and improves production efficiency in the acrylic plant.
• CENTUM VP Batch capability can handle the recipe management to Batch report handling and unit management.

• Completion of First FPSO Project for Prosafe Production Services Pte Ltd
• Integrated Control & Safety System (ICSS) makes possible centralised plant supervision and management of all control and safety functions on this FPSO.

• Complete automation and control of glass plant
• Improved production cycle time and stabilized product quality with reduced energy consumption and costs

Since entering commercial operation in 2000, the environmental control facilities at the Tachibanawan Thermal Power Station have been managed effectively by the CENTUM control system, achieving a stable electricity supply with minimal impact on the environment.

• Smooth upgrade for fully redundant system and advanced information technology
• Stable and high-quality sulfonate production around the clock

Yokogawa Electric Corporation has completed a unique control system project in Arcadia, Florida, which is located in the heart of a beautiful citrus-growing region. Peace River Citrus Products has installed a Yokogawa CENTUM CS 1000 R3 control system to control a proprietary orange juice production process at its citrus processing plant.

• Operator intervention during the automated plant and turbine startup and shutdown processes is minimized
• Greatly reduces operator work load and errors, and mitigate thermal and physical stress on the turbine

• Online hot cut over from the legacy Honeywell TDC3000 to the Yokogawa CENTUM CS 3000.
• The work was successfully completed 48 days ahead of schedule and without disruption to operations.

• Exapilot automates comlex and non-routine decoking process of NCUs.
• Operator workload has been drastically reduced.

• Exapilot contributes to safety, reduces cost, and retains operational know-how.

• Exapilot improves operations and reduces energy use at PTT Khanom Gas Separation Plant #4.
• This is a real solution package and a good tool for the plan-do-check-act (PDCA) cycle to achieve operational excellence in the plant.

• Exapilot smoothly starts up and shuts down the world's biggest experimental distillation unit.
• Data visualization is the key, giving operators a complete understanding of what is is going on in the process, in real time.

• Based on a careful review of all operational procedures and operator roles and configured new SOPs in Exapilot.
• As a result, SFC has been able to reduce operator workload, improve product quality, and reduce production losses.

The Itoigawa Power Plant was constructed adjacent to a cement plant in Itoigawa City, Niigata Prefecture, and is operated by an IPP that supplies electricity to Tohoku Electric Power, one of Japan's major power companies. The use of a 149 MW coal-fired CFB boiler in this power plant is a first for an IPP in Japan, and this effectively reduces NOx emissions.

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

Nederlandse Aardolie Maatschappij (NAM) is the Netherlands' largest natural gas producer. In addition to onshore fields, NAM operates manned platforms and four unmanned monotowers in 19 offshore locations. These connect to a pipeline network that comes ashore at Den Helder. 

Successful project completion of control system, configuration engineering, customer training, and commissioning assistance for proprietary methanol production

Nishi Nippon Environment Energy Co., Inc. was founded in 1990 with the concept of a full, safe and comfortable urban life by harmonizing the global environment with energy-savings. Also, as a total energy industry corporation, which is promoting the efficient use of heat energy for the region, it is developing a broad business on the theme of civic improvement in the 21st century by preparing a stable city infrastructure.

• Successful, economical implementation of control system
• Increased process availability, reduced maintenance costs, and lowered cost of ownership

• 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

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

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).

• Highly reliable CENTUM CS 3000 replaces legacy system and automates batch plant operation.
• Working together, Hanwha Chemical and Yokogawa Korea project personnel completed this work on time and on schedule.

• 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.

• Implementation of AOA package for improved grade-change operation
• Dramatically reduced operators' workload and transient products, as well as sharable operation know-how

• Up to 90% of all manual tasks can now be carried out automatically.
• Increasing productivity by means of partially automated start-up and load change procedures.

PT. Tanjung Enim Lestari Pulp and Paper (PT. TEL) operates a pulp mill in Muara Enim, which is 130 km west of Palembang, the capital of Indonesia's South Sumatra province. This is the only pulp mill in the world to produce high-quality, bleached-hardwood kraft pulp solely from plantation grown Acacia mangium trees.

• Innovative GEOLIDE waste water treatment complex in Marseille uses CENTUM and Exaquantum. 
• The visualization of all data on items such as motor and pump operating time and chemical consumption amount allows operators to optimize key operation items.

• Integrated automation solutions for high reliability and availability system
• Reduced consumption of steam, bagasse, and bunker fuel oil with increased daily throughput of massecuite

• Integrated CENTUM VP and ProSafe-RS Systems Ensure Nonstop Operation of ADU/DKU Processes.
• "This is a real VigilantPlant! We will continue to improve our production efficiency."

• Introduction of CENTUM CS 3000 maximizes productivity and improves product quality at special polymer plant.
• A major improvement as a result of this project is that butadiene monomer recovery efficiency jumped huge.

Samsung Petrochemical Co. Ltd. (SPCL), a major Korean petrochemical company, produces 700,000 tons per year of purified terephthalic acid (PTA) at its Daesan plant. PTA, a white powder substance that is produced by oxidizing and refining para-xylene, is a precursor to polyethylene terephthalate (PET), a polyester material that has excellent thermal resistance and wear resistance and is widely used as a substitute for natural cotton fibers and in film packaging, beverage bottles, tire cords, paints, adhesives, and other applications.

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

• At the company's Ulsan resin plant, six Exaquantum servers were connected to CENTUM CS 3000 and other vendor's systems.
• KKPC needed to expand its SBC capabilities and improve production efficiency at its plants.

• Implementation of multivariable optimizing controllers and robust quality estimators within a record short period
• 3% rise expected in CCR feed amount

• Legacy System Replaced with Yokogawa CENTUM VP and ProSafe-RS at PTA plant in Indonesia.
• PID parameters imported to CENTUM VP without complex calculations.

• To decrease downtime and maintenance costs, the decision was made to introduce Yokogawa's CENTUM DCS.
• With well-experienced MAC approach, Yokogawa replaced successfully legacy DCS.

• Meet the IEC 61508/JIS C 0508 functional safety standards
• Proactively introduce leading edge technologies
• Accommodate the plant licensors' safety, reliability, and maintainability requirements
• Improve the monitoring and operation functions of the emergency shutdown system

An international corporation based in Duisburg, Germany that was able to secure a US$ 780 million contract to construct a project marketly known as "Musi Pulp Mill". Construction started Sept. 1997 after financial agreements between the plant's owner, PT TEL and 32 foreign banks has been sealed-off.

• Modern waste to energy facility in UK uses CENTUM CS 3000 and ProSafe-RS
• Lakeside exports at least 34MW per hour to the country's national grid

• Modernized controls, assured stable power supply to Ulaanbaatar by a highly reliable, expandable distributed control system
• Fully automated boiler, burner, balance-of-plant operations
• Power plant simulator for efficient DCS operator training

• World's largest control systems and PIMS for securing production over an extended period
• Fully-automated, alarm-free operation and reduced total cost of ownership

• One day switchover
• Productivity improvement and cost effectiveness achievement

• 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.

• Kaneka Corporation has urgently needed to implement countermeasures that would reduce this facility's energy costs.
• Optimization of control strategy helps BTG plant save energy and operate more efficiently.

• PetroChina Dushanzi Petrochemicals Polyethylene Plant system migration.
• The revamp included the challenging creation of function design specifications (FDS) as well as FAT and SAT.

• Accelerated plant commissioning through useful online maintenance
• Flexible load control-based on-demand change, and more reliable, efficient operation

• Rapid Implementation of Integrated CENTUM CS 3000 and ProSafe-RS.
• The highly reliable CENTUM CS 3000 system has also helped TOL maintain high productivity at this plant.

• 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.

Based in Japan's Nagano Prefecture, Miyota Co., Ltd. is a developer and manufacturer of precision-processed electronic components whose principal business lines are wristwatches, quartz crystal oscillators, and electronic video components such as LCD backlights and microdisplays.

• Smooth replacement of old control system by early involvement and close teamwork
• Improved security, flexibility and quality of production

• Power supply made dramatically reliable thanks to CENTUM CS 3000 with seven-nines availability
• Visualization of almost all plant data on the same HMI by linking up subsystems via Modbus
• Improved plant performance

• 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.

The construction of Tuas Power Station started in the mid 1990s. The plant has steadily grown to be a significant player in the competitive Singaporean electricity market. Stage One of Tuas Power Station is equipped with the country's largest steam generators which are capable of producing 600 MW each.

• 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.

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

• Smooth and safe migration to CENTUM VP enhances production efficiency at major Australian gold mine.
• The HMI stations instaled at the central control room, training system, primary crusher, workshop, and office are all connected via thesame communication bus.

Mobil Oil Indonesia (MOI) identified Yokogawa as its vendor of choice for all natural gas exploration installations in the north of Sumatra.

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

• Successful migration of in-line blending distributed control and oil movement systems.
• To minimize operator intervention and to keep the product properties on specification.

• Thai SPP uses CENTUM CS 3000 to improve efficiency of Biomass Power Plant
• The burning of the ground rice husks in the boiler's furnace chamber is a complex process that must be carefully controlled

• TOKUYAMA improves productivity by migrating from MicroXL to CENTUM CS 3000.
• TOKUYAMA appreciates the high reliability of this Yokogawa system.

• Monitoring and control of the entire cogeneration plant including the two once-through steam generators
• Reliable and cost-effective power supply
• Operator-friendly HMI

• Eight LNG trains integrated into a single control system
• Increased steam production and boiler response with improved production downtime

• State-of-the-art FOUNDATION fieldbus technology
• Plant Resource Manager (PRM) field device management system
• Remote data monitoring via WAN

• 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.

Unified operator interface solution enables remote operation

Universal Terminal (S) Pte Ltd, one of the largest independent petroleum products storage terminals in the Asia Pacific, has been built on Singapore's Jurong Island at a cost of S$750 million.

• Smooth project execution with no schedule and/minimal safety incidents.
• Easy to use, easy to reconfigure interface that has resulted in numerous post-installation enhancements.
• Minimizing day-to-day plant operation problems including reducing the alarming factor.

• 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

• World's first offshore regasification terminal relies on Yokogawa ICSS (CENTUM CS 3000, ProSafe-RS).
• LNG carrier scheduling, unloading, tank storage, and vaporizing are all procedure based operations.

• World's largest LNG terminal relies on CENTUM to maximize safety and reliability.
• It is very important for KOGAS to be able to adjust flexibly to shifts in demand in the gas that it supplies to power plants, industrial companies, and residences.

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

• 2009 PACE Zenith joint winner project
• Reduced operating and maintenance costs
• Increased power generation
• Improved plant operating flexibility
• Modernized, screen-based operations
• Reduced emissions

• Integration of previously independent water usage functions into automatic control system
• Reduced operators' workload and environmental impact

• Steady power supply and safe operation thanks to reliable Yokogawa CENTUM CS 3000 and transmitters
• Environmentally optimized operation by fine-tuned boiler combustion control and strict monitoring and control of CO, NOx and SOx in flue gas and pH of water from cooling towers
• Full replica plant simulator for effective plant operation and engineering staff training
• Annual maintenance contract

• CENTUM CS 3000 distributed control system to control the ethanol plant and it's utility boilers
• Batch processes that require careful automated control for maximum efficiency and product quality

• The plant was designed to be unmanned, except for some first-line maintenance personnel who are stationed at the plant.
• Through the use of the latest control system and FOUNDATION™ fieldbus technology supplied by Yokogawa, process control and the diagnostic monitoring of field instrumentation is done from remote locations.

• Smooth conversion of existing controls solely by customer
• Lowered cost of ownership

• Installation of Exaquantum PIMS package improves efficiency of process data management.
• Improve quality and yield through proactive maintenance of plant assets.

• Yokogawa installed a B/M9000CS quality control system with various cross direction profile control functions.
• The installation improves product quality and efficiency at pulp & paper mill.

• This has considerably improved the safety, quality, and efficiency of off-site operations.
• Yokogawa was the clear choice for installation of the OMS.

• All logistics of raw materials, intermediate products and final products are controlled and managed by MAS.
• MAS enables Operational Excellence with its seamless interface to enterprise resource planning system.

• The project goals emphasized schedule, quality, cost and safety.
• More than 40 sub-system interface cards are utilized for b14 partners company7s system integrated with CENTUM CS 3000.

• Yokogawa provides CENTUM CS 3000 and ProSafe-RS for the largest LNG terminal in Europe.
• Yokogawa's OmegaLand plant operator training simulator (OTS) helps to reduce costs, optimize LNG terminal processes.

The Mathura refinery is a strategically important facility that supplies diesel, gasoline, aviation turbine fuel, kerosene, liquefied petroleum gas, furnace oil, and bitumen to customers throughout northwestern India.

• 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.

• Yokogawa provides CENTUM VP with Batch Recipe Management Package for new fine chemical plant.
• Yokogawa's CENTUM VP complies with the requirement of Good Automation Manufacturing Practices(GAMP).

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 receives award for hot cutover of BP Sharjah plant DCS.
• Yokogawa was selected by BP as main automation contractor (MAC) for a project to replace the Sharjah plant's existing legacy DCS with Yokogawa CENTUM VP.

• Yokogawa revamp of control systems at NAM Den Helder plant ensures stable gas supply in the Netherlands.
• Site survey, creation of a function design specification (FDS) from the existing TDC system database, documentation verification.

• To replace the existing CENTUM XL control station with the latest Yokogawa CS 3000 hardware and upgrade the control network.
• The plan was to minimize plant downtime by doing a hot cutover from the old to the new control system.

• 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

• Yokogawa's CENTUM CS 3000 DCS Monitors and Controls Operations at Poultry Litter-to-energy Plant
• The boiler and turbine startup procedures reduces operator workload and helps to ensure a smooth and safe startup

• 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.

The Mars B Project added the following greenfield infrastructure to boost production at the Mars field and nearby exploration discoveries: the Olympus tension leg platform (TLP), which has 24 well slots and a self-contained drilling rig; the West Boreas/South Deimos subsea system; and an oil and gas export system, which includes the WD-143C shallow-water platform. The Olympus tension leg platform (TLP) started producing on February 4, 2014. The TLP is the second at the Mars field and the sixth of its type for Shell in the Gulf of Mexico.

Okinawa Prefecture is promoting clean energy with the aim of becoming a low-carbon society in the 21st century. Ocean thermal energy conversion (OTEC) technology is particularly well suited for this purpose, and is expected to both reduce the environmental impact that power generation has in the prefecture and lessen the prefecture's dependence on imported fossil fuels.

• Exapilot was introduced to maximize operational efficiency at an experimental refining facility.
• To prevent operator errors, it was essential to standardize operating procedures.

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

• OTS for familialization of liquefaction processes and operator training.
• Yokogawa's integrated solutions contribute to safe and steady production at gas liquefaction plant in Norway.

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

The municipal water system of Oviedo, Florida provides high quality water to more than 30,000 area residents from its West Mitchell Hammock and A.M. Jones water treatment facilities. The West Mitchell Hammock facility is designed to provide an average daily flow of 10 million gallons per day (MGD), with an ultimate design flow of 16 MGD. 

Shree Renuka Sugars Limited (SRSL) is a global agribusiness and bio-energy corporation. The company is one of the world’s largest sugar producers and refiners.

• Yokogawa joined forces with Air Liquide to co-innovate the step-by-step revamping plan based on Air Liquide's specific requirements.
• Customer was satisfied that Yokogawa was able to deliver its solutions on time and on budget.

• Yokogawa Taiwan successfully replaced 3rd party DCS, which had worked over 20 years, with CENTUM VP.
• CENTUM VP's high reliability and easy engineering function realized a silent control room for the customer.