Chemical

• 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.

Success Story

Increased Reliability and Security Through the Use of a Data Acquisition System

Syngenta aimed to promote sustainable agriculture as a social responsibility through digital transformation. Syngenta selected Yokogawa to start the smart manufacturing transformation journey.

Nitrogen Fertilizer Manufacturer Cyber Security Implementation Success Story

Kuraray Engineering provides IoT big data analysis solution in collaboration with Yokogawa.
Collaborative process data analysis achieved a high level of quality stabilization at a customer site.

Osaka Gas Chemicals selected Yokogawa to solve long-standing problem at carbon fiber manufacturing process.

Osaka Gas Chemicals established unique problem-solving method using Yokogawa's process data analytics solution.

Nippon Sanso Vietnam JSC (NSVN) equipped a digitalized supply-chain management system to optimize efficiency of industrial gases delivery.
The ODMS (Order delivery management system) was rapidly developed using the DevOps agile approach in collaboration with NSVN and Yokogawa.

Yokogawa & Nouryon Co-Innovation Leads to New pH-Analyzer
 
 

• Sumitomo Seika achieved the quality stabilization by cross-department project.
• The fusion of process knowledge and data analysis technology was a key to the success.

Ube Corporation Europe and Yokogawa co-created the Field Assistant mobile solution.
Field Assistant innovates inspection patrol, supervisory management, and O&M efficiency in the plant.

• 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.

Operator Training Simulator helps improve human reliability in a young plant of PetroVietnam Ca Mau Fertilizer.

PVCFC and Yokogawa implemented OTS for third-party control and safety system as a team.

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

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

• 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.

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.

• 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.

• 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.

• Main instrument vendor (MIV) concept was applied in this project to reduce the total project engineering cost.
• This consisted DCS, SIS, all instruments, control valves and tank gauging system under working with project management consultant (PMC) and EPC.

• 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.

• 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.

• 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.

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

• Migration from Micro-XL and CENTUM CS 1000 to CENTUM CS 3000 Improves Reliability.
• Operations at this plant, which runs more than 330 days per year, are carefully managed by the CENTUM CS 3000 DCS and the CS Batch package.

• A certified emergency shutdown system
• Substantial reduction in maintenance work
• System configuration with reduced footprint
• System scalability

• 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.

• 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

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.

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

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

• 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

• 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.

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

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

• 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.

• Yokogawa provides STARDOM and FAST/TOOLS for biomass pilot plant.
• FAST/TOOLS is an "all in one" SCADA solution that functionsa a data historian.

• 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

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

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

• 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.

• 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.

• 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.

• CENTUM CS 3000 and Exaquantum PIMS improve production efficiency at Chinese synthetic rubber plant.
• Exaquantum provides data on long-term trends needed to make improvements to plant processes.

• Single 'look and feel' operator interface for the DCS and NCS
• Fast and controllable integration cycle
• High speed hybrid compressor control solution
• Reduced OPEX for the compressor operation by replacing old and obsolete PLCs with a modern hybrid control platform

• 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.

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

• Reinstrumentation project at HDPE plant replaced legacy pneumatic instruments and PLCs with integrated CENTUM DCS 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.

• 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.

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

• The work was based on a preceisely formulated roadmap with detailed checklists for every control cabinet, process station, and network component.
• The seamless use of the same HMI for both PCS and SIS, and improved safety and integrity.

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

• Exapilot was built up as e-SOP system based on the standard operating procedures and the know-how of experienced operators.
• e-SOP system improved the quality and productivity in the performance chemical plant in China.

As the demand for food is increasing worldwide, fertilizers are playing an essential role in improving agricultural productivity. OCI Nitrogen (hereinafter OCI) is a leading producer of mineral fertilizers and the world's largest producer of melamine, which is used to make adhesives and resins for a wide range of applications, such as furniture panels, laminate flooring, coatings, paints, and plastics.

Tsurumi Soda Corporation,Yokohama,Kanagawa Prefecture, Japan

• IFCo chose Omegaland operator training system to make ready for a flawless and safe plant start-up.
• Omegaland is contributing to operator training prior to completion of the greenfield fertilizer plant.

Yokogawa CENTUM VP and SIS were selected for the Evonik Oxeno's BTX facility expansion project.
CENTUM provides the operational transparency, and more efficient diagnosis of compressors which are the heart of the facility.

Yokogawa's network healthiness check service helped the customer identify what they need to protect against cyber-attacks.
By “visualizing” network traffic in control system, the customer was able to detect unauthorized communication in their system.

• 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).

• Yokogawa assisted in the project implementation by providing design review, calculation modifications, pre-commissioning, training of operators and engineers, commissioning and post implementation review.
• Shell Global Solutions and Shell Deer Park Management were completely satisfied with the way the project was implemented and with the results achieved.

• The Advanced Process Control application implemented on the Scotford MEG unit helped control the plant with less variation, resulting in maximized TEG production and reductions in overall steam consumption.
• TEG production increases were greater than originally estimated and the prices for steam and TEG used in the post-implementation study were reduced significantly.

• TOK decided to start local production of high-quality photoresist for semiconductor manufacturing near its customers in Taiwan.
• The MES with traceability comparable with pharmaceutical manufacturing is one of the factors to win the trust of its customers.

• Yokogawa's operational performance program bench mark service enhanced the automation performance at the chemical plant.
• Operator stress was dramatically reduced by identifying the causes of excessive manual interventions.

• 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.

• FDT compliant FieldMate manages a wide variety of digital process instruments of multi-vendors.
• The SNF engineers can manage the complete lifecycle of assets and configure devices by using FieldMate.

• 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.

The TC series of temperature controllers is perfect for controlling the heating temperature of sealing parts and the temperature of sealing rolls (pre-heating) in a variety of different wrapping machinery.

Prevent costly downtime and process equipment failures with real-time pressure monitoring. Yokogawa’s Sushi Sensor is the optimal choice for industries depending on bottled gas in essential procedures.

Avoid flashing issues while loading cryogenic liquids with safe, reliable, and accurate density fluid measurements utilizing Yokogawa’s industry-leading Coriolis flowmeter to eliminate measurement issues and increase the accuracy of inventory. 

Accurate reactor level measurement enables flow optimization to enhance yield.

Yokogawa’s Tunable Diode Laser Spectroscopy (TDLS) is the ideal solution for both oxygen and carbon monoxide measurements in process furnaces that have aggressive and corrosive components.

Yokogawa's Paperless Recorder series offers a multi-point touch panel to improve intuitive operator control with predictive monitoring for early detection during sake production and managing brewery wastewater. 

Yokogawa’s distributed temperature sensors ensure comprehensive monitoring of thermal events in real-time, limiting facility damage by decreasing the risk of fire/duct explosions in exhaust air/fume ducts, allowing for early detection and quick response.

Reducing waste in the separator and electrode drying furnaces with Yokogawa’s distributed temperature sensors ensure comprehensive monitoring of thermal events in real-time.

Advanced solutions improve plant safety and product quality while reducing power consumption, emissions, and operator workload.

In the plants of food and beverage manufacturers, there are times when monitoring and recording of production equipment is necessary inside clean rooms. This is an introduction to monitoring and recording in clean rooms using paperless recorders.

Accurate and reliable measurement of wash oil in a high temperature process to avoid solidification of the chemical, it is essential to adjoin heat and insulation to the piping and equipment. Therefore, thermal management of the pipe runs is required, to avoid any heat loss in the fluid to maintain the fluid properties. 

Conductivity measurement can be used as a reliable indicator of the real-time brine concentration. Using an online process analyzer removes the need for timely grab sample analysis. 

Yokogawa’s Sushi temperature sensor is a cost-effective, reliable, long-range wireless communication for monitoring and recording to boost reliability, and also able to configure the network with redundant gateways for chemical manufacturers.

Hot Spot Monitoring for Safety with a Fiber Optical Temperature Sensor

The EJX910A with Micro-Orifice can measure ultralow flowrates for samples and carrier gases, and allows the technicians to access shelter readings remotely without performing time-consuming manual rounds.

This introduces a system that uses Ethernet communications to acquire measured values, target values, and control output values from a controller installed on site into a PLC at high speed (ten units' worth within one second).

Operators must receive diagnostic information before a line block leads to a malfunction. Yokogawa provides predictive diagnostics based on trend analysis of the blocking factor, which improves maintenance efficiency and reduces maintenance costs.

To meet state requirements for calibration checks, use Meter Verification (part of the Total Insight concept of the ADMAG TI - AXG) to verify the calibration and functionality of each meter. The reliable accuracy of the AXG magmeter results from Yokogawa’s proprietary, dual-frequency excitation method. It combines traditional high/low-frequency excitation methods to ensure greater stability and quicker response even if noise or other problems are present in the line. With EtherNet/IP, an operator can initiate a verification from the HMI to ensure the gallery is running optimally.

SMART digital sensors and advanced data management software enhance reliability and process safety.

One of the most common applications for differential pressure transmitters is flow measurement. DPharp differential pressure transmitters have some unique signal conditioning features to eliminate instability at low flow rates.

Corrosion, permeation, or drift can cause a degradation of pressure measurement readings, which, in turn, can put the electrolysis cell out of balance and risk damage to the cell membranes.

In order to reduce emissions of air pollutants such as sulfur oxides (SOx) and nitrogen oxides (NOx), power plants have installed flue gas desulfurization systems known as scrubbers.

Flow performance extends cell membrane life with accurate, reliable, and stable performance - saving millions of dollars in membrane repair costs, reducing instrument maintenance costs and production downtime, and production loss.

The GX20 and GX90UT offer an average value computation function making it ideal for controlling temperature and other fluctuating phenomena. The operating status can be controlled in real time, providing operating cost reductions.

Accurate and durable magnetic flow meters (magmeters) were difficult to maintain in the process as the corrosive and abrasive nature of the process degraded their operation. That led to leaks that not only reduced the flow but also contaminated the product and the magmeters. Since Sigura maintained strong vigilance, the company needed to replace some magmeters monthly...

In flue gas desulfurization systems that use magnesium hydroxide (Mg(OH)₂) slurry, the consumption of the desulfurization agent (Mg(OH)₂) is controlled by using online pH analyzers. A great concern in the pH measurement is heavy staining of the pH electrodes by the Mg(OH)₂ slurry. To ensure accurate measurement, frequent cleaning of the electrodes with an acid is required, adding to both maintenance workload and cost.

Industry:Chemical, Power

The ADMAG AXR employs the patented “Dual Frequency Excitation Method.” This unique technology combines the best properties of low-frequency excitation to enable a stable measurement and high-frequency excitation to deliver excellent noise immunity. As a result, the AXR can suppress process-generated noise to secure zero stability without sacrificing fast response time. In addition, the AXR achieves the same level of noise immunity as a 4-wire circuit under varying fluid conditions and delivers the performance necessary to meet the requirements for control loop applications.

Ideal for various tank and vessel level measurements, diaphragm seal systems with compensating capillaries set a new standard for high performance, safety, and reliability.

Control of sodium chloride (NaCl) concentration at a salt dissolver where solid salt is dissolved in water, is highly important because of the electrolysis efficiency. A conventional way of measuring the concentration of supersaturated NaCl solution had been performed by using non-contact type sensors (e.g., γ-ray density meter) since NaCl, impurities, and precipitates are in the solution.

The use of recycled oil as an energy source presents a significant processing problem. Because composition of the fluid is not consistent and it also may contain impurities, the use of conventional flowmeter technologies is not practical. ADMAG CA Series, however, has been shown to provide reliable and stable flow measurement of recycled oil containing water.

There are various methods for continuous fabric dyeing as well as dye fixing. When dye is directly applied, steaming (heat treatment) is required. At present the pad-steam method is widely used for continuous dyeing. To ensure stable product quality, the humidity in the steamer is kept at a constant level. 

Caustic soda is an important basic material in the chemical industry and is mainly produced by the electrolysis of soda. In the electrolysis process to make concentrated caustic soda, the DM8 Liquid Density Meter ensures high product quality through accurate measurement of liquid density.

Process liquid analyzers such as pH meters, conductivity meters, ORP meters, and density meters play an important role at electrolysis plants in the control of concentrations of various process solutions. This requires both precision and stability under harsh conditions that include highly corrosive substances, high temperatures, and many impurities.

For safe and efficient operation, the quality of feedwater, steam, and condensate in boiler plants must be controlled and maintained in the most favorable conditions.

Electrolysis plants create hydrogen and chlorine from a brine solution. Chlorine gas generated from the anolyte of the electrolysis tank generally contains between 0.5 to 2.0 vol% H₂O. The sample is then cooled and filtered to remove brine, subsequently coming out as wet chlorine gas. The wet gas is sent to a drying tower where it is treated with sulfuric acid to get moisture down to the ppm level. 

• Effeciently controls the inlet valve and blow-off valve when the compressor starts and stops.
• During steady operation, controls the inlet valve so that the amount of discharged compressed air becomes constant (flow control)
• Surging: Load decreases, the amount of discharge flow and pressure drop, and a limit is exceeded, possibly destroying the compressor.

• Emergency interlock circuits for petrochemical plants and other facilities must be independent of the main control system.
• The YS80 Rack Instrument interfaces not only with field devices and upstream control systems, but also with emergency interlock circuits guarding against process abnormalities.

Clean-in-place (CIP) is the system designed for automatic cleaning and disinfecting in the food & beverage, pharmaceutical, and chemical industries. Tanks and piping are cleaned and sterilized with various cleaning solutions, fresh or hot water, or steam after manufacturing products is completed.

With industrial and economic development comes increasingly large and advanced power plants and factories. Nevertheless, we find many cases where the original cables, cable tunnels, and other components of the power infrastructure have languished under continuous operation.

In limestone-gypsum flue gas desulfurization systems, the consumption of a desulfurization agent (lime) is controlled using online pH analyzers.

Fired heaters are used for various processes in oil refining and petrochemical plants.

Reverse osmosis (RO) is a separation process that uses pressure to force a solution through a membrane that retains the solute on one side and allows the pure solvent to pass to the other side. More formally, it is the process of forcing a solvent from a region of high solute concentration through a membrane to a region of low solute concentration by applying a pressure in excess of the osmotic pressure.

Both bulk and finished inventories are stored in distributed tank farm remote from the site operations. These are difficult to instrument due to the infrastructure cost involved. These are then monitored daily by patrol rounds. While effective, this method does require a large skilled labor force to monitor all of tanks. This can impose an additional risk when the stored medium is of a hazardous nature.

• Daily manual reading of pressure and temperature gauges with report by phone.
• The customer wants to change measurement from off-line to on-line.
• Cabling for wired transmitters in huge plants (up to 300 meters long) is expensive.

• Manual temperature reading requires walking about 130 m and climbing up and down elevated sections of the dryer stages.
• Multiple temperature measurement points along the various stages of the dryer require many cables to the control room.
• Very high humidity.

Install a YTMX580 on the side of the rotating furnace that can wirelessly transmit measured values from multiple temperature sensors.

DPharp performance in boiler drum level measurement applications is superior to metallic capacitance type pressure transmitters. Improved performance can be attributed to the unique resonant silicon sensor design with dual resonators.

• Temperature is monitored to maintain consistency of the viscous fiber entering the drum.
• Existing system requires manual temperature readings.
• Wired temperature measurement is not available because the tank is rotating.

• Wireless temperature measurement
  Gateway x1, transmitter (YTA) x1, repeater x2 (The 2 repeaters are for redundancy)
• Extended antenna to circumvent obstacles and improve the radio path for stable measurement (communication was unstable when the height of the antenna was low).

The ammonia (NH₃) gas is injected to remove the NOx and thus reduce the NOx concentration in the stack flue gas. With conventional NH₃ analyzers that perform measurements indirectly, NH₃ concentrations are obtained through a sampling system. Therefore, there are problems with the maintenance and running costs of the sampling system, and time delays in measurement. The TDLS8000 Laser Analyzer is the solution to all these problems.

ISA100 wireless temperature and pressure transmitters with orifice plates allow:

• No cabling installations or maintenance.
• Small amount of hardware and simple equipment implementation means minimizing potential vandalism.

ISA100 Wireless Monitoring  

• Gateway x1, Temperature Transmitter (YTA) x3, Pressure Transmitter (EJX) x1, Repeater x1

Gateway is installed at control room and 3m height extended antenna is set.

Controls temperature in, and acquires data from, various internal components of plastic film manufacturing equipment. An easy to use, high cost-performance data acquisition and monitoring system can be assembled by using Ethernet compatible instruments and GA10.

Heat exchangers are devices that provide the flow of thermal energy between two or more fluids at different temperatures. Heat exchangers are used in a wide variety of applications. These include power production; process, chemical and food industries; electronics; environmental engineering; waste heat recovery; manufacturing industry; and air-conditioning, refrigeration, and space applications.
 

In maintaining and managing industrial plants, monitoring waste water pH/ORP is both a legal obligation and an unavoidable necessity for protecting the environment. Monitoring without an attentive eye can lead to severe consequences.

Yokogawa’s Process Liquid Analyzers series help pigment producers achieve a more reliable and accurate analysis of pH during industrial bioprocesses, improving product quality with less total operation costs.

Pressure measurement of tubeless tyres to monitor the air loss is one of the key performance tests in the tyre manufacturing units. Relocation of tyres from one testing rack to the other for various tests and frequent movement of the testing setup for conditional tests to various locations calls for cable free implementation for ease of handling.

Ion Exchange is a method for the exchange of ions between two electrolytes or between an electrolyte solution and a complex molecule. In most cases the term is used to denote the processes of purification, separation, and decontamination of aqueous and other ion-containing solutions with solid polymeric or mineralic ion exchangers.

Hydrogen is the simplest and smallest atomic element. Water, acids, bases, and the immense family of organic compounds all contain hydrogen. Even though hydrogen is not corrosive, it can cause problems for pressure transmitters through Hydrogen Permeation.

To defray energy costs, many industrial plants have their own boilers to generate steam to produce a portion of their energy needs. In addition to generating power, the steam may also be used directly in plant processes or indirectly via heat exchangers or steam jacketed vessels. 

After extraction from sugar cane or sugar beets, the juice must be purified to remove the many other organics and minerals that accompany it. The processing to accomplish this is heavily dependent on reliable pH measurement and control as illustrated. 

In this eBook we explain how to improve fired heaters safety & efficiency by controlling combustion using TDLS technology. Download it now and learn:

• The 4 top industry challenges related to fired heaters
• How to efficiently and safely manage combustion
• How TDLS technology can improve operational excellence in fired heaters

Plants increasingly are turning to machine learning (ML) and artificial intelligence (AI) to recognize precise patterns in sensor data. The technologies ease differentiating between normal and abnormal equipment behavior and also detecting specific patterns that lead up to failures — and, so, enhance capabilities for predictive maintenance.

Read this report to learn how more insightful data and better analyses can boost uptime.

Download this eBook and learn:

• The top challenges that drive reinstrumentation
• How to plan for and achieve a successful project
• Best practices in identifying your project scope
• 5 ways to improve operator effectiveness
• Different scenarios and best practices for updating, migrating or replacing process controls, safety systems, and instrumentation in plants

This eBook explains why implementing IIoT based digital operator monitoring solutions for autonomous anomaly detection enhances operations.

In this Yokogawa RAP Best Practices eBook, you’ll discover how our wealth of knowledge about Integrated Safe Systems and Control of Work is available to help you and your teams design and implement a system that best suits your needs.

Visual MESA© is a steam system optimization and management computer program that was originally developed at Chevron and now marketed by Nelson & Roseme, Inc. Visual MESA is currently used at refinery and chemical manufacturing sites to optimize the overall site steam system and the parts of the electrical system that economically trade off with the steam system.

This paper will explore significant optimization variables and constraints commonly encountered in refinery steam system optimization, the strategies Visual MESA uses to deal with them.

Chemical Processing Special Report:  Understand  the Process of Open Process Automation

Sponsored by YOKOGAWA.

On-site digital champions can drive your operation towards data integration and a more aligned way of working.

The whitepaper discusses the importance of safety culture in achieving a smarter and safer working environment. It highlights statistics on work-related accidents and diseases, the cost of poor safety culture, and the need for a true safety culture achieved through company leadership.

Get Connected: Advancing Workers and Capabilities
In this whitepaper by Shahzad Khan, you will learn how to use collaborative, integrated, optimized, and autonomous operations to integrate your systems and emerging performance metrics.

By downloading this whitepaper you will learn how to:

• Connect operations, systems, processes, maintenance, and goals
• Empower employees digitally, to improve their decision-making skills
• Gain access to immediate improvements to production efficiency

The agnostic approach to cybersecurity and solution integration, built around the concept of modularity, offers a scalable and flexible way to reduce the risk of cyberattacks on OT networks.

Digital twins are dynamic digital representations that enable companies to understand, predict and radically reorient their business processes.

In general, refineries exhibit a very good potential for real time monitoring and optimization using Visual MESA Energy Management System.

Based on our extensive experience, overall benefit in the range of 2% to 5% of the total energy cost can be achieved. Expected project payback is always less than one year.

Outline

• Introduction

• What is Energy Optimization
• How does a Real Time Online Energy Management System based on Visual MESA work
• Calculation Foundation for Key Performance Indicators
• Visual MESA implementation at Saudi Kayan (A SABIC Affiliate) (SK)
  • Optimization Actionable Items
  • Economic Benefits
  • Relevance of Visual MESA RTEMS for SK's Sustainability Initiative
  • Conclusions

The REPSOL company had in mind the improvement of the control on one of their chemical reactors. A feasibility study for the implementation of an Advanced Control technique (Predictive Control for temperature control for chemical Reactors - PCR) for a batch reactor for Polyols production has been performed. The proposed technique PCR is based on a dynamic model of the unit which makes the prediction of the process variables behaviour.

Industrial facilities where power and steam is produced (i.e., Cogeneration) exhibit a very good potential for real time monitoring and optimization using Visual MESA Energy Management System.

Based on our extensive experience, overall benefit in the range of 2% to 5% of the total energy cost can be achieved. Expected project payback is always less than one year.

Visual MESA was successfully applied to many industrial facilities worldwide, several of them operating steam and power generation networks of different complexity and capacity but all with energy cost savings. 

Utilities and energy systems are often the major source of SOx, NOx and CO2 emissions, therefore, emissions control and the management of credits and quotas are tightly interrelated with energy management.

In the case of refineries, chemical and petrochemical plants, energy represents the main cost (second to feedstock) and therefore its reduction has become a bottom line business decision. The energy systems at these sites are inherently complex, with the emissions cost analysis and limits compliance introducing an additional factor to the complexity of the energy costs reduction challenge.

Process plants use different type of fuels, they often operate cogeneration units, their steam networks consist of several pressure levels, there are different types of energy consumers and there are emission limits to be observed. Import or export of electricity in deregulated markets, which could also be traded off with more or less CO2 and other contaminant gaseous emissions, increase the optimization problem complexity.

After a feasibility study, Repsol YPF decided to apply a model-based predictive controller to a batch reactor producing polyols. The predictive controller for reactors (PCR) is a set of control modules that are designed to face most of the reactor configurations. The important increase of production is a consequence of the better handling of the reactor temperature. Here's a description of the unit and control objectives, methodology, project steps, results and the corresponding benefits.

Smart devices, like Yokogawa’s line of Total Insight transmitters and flowmeters contribute to Digital Transformation during operations and throughout the lifecycle of the instrument.

This paper addresses some of the root causes for issues and discusses the best practices that will help to avoid project failures. Main project steps are explained and critical details to be taken into account to assure successful use and proper technology transfer are discussed. It also presents real industrial examples in which the whole utilities system cost of a production Site (i.e., steam, fuels, boiler feed water and electricity) is optimized with a real time, online, industrially well established software.

Utilities and energy systems are often the major source of SOx, NOx and CO2 emissions, therefore, emissions control and the management of credits and quotas are tightly interrelated with energy management.
In the case of refineries, chemical and petrochemical plants, energy represents the main cost (second to feedstock) and therefore its reduction has become a bottom line business decision. The energy systems at these sites are inherently complex, with the emissions cost analysis and limits compliance introducing an additional factor to the complexity of the energy costs reduction challenge.

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.

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.

Alarm management is not just a project that has a start and end date; it's a continuous cycle. Once the alarm system has been reviewed and improvements have been identified, we must check that controls are in place to ensure the alarm system remains functional. The key is to ensure that the system is continuously monitored and any changes are fully documented. There are seven key steps for alarm management. Rationalization is one of those critical steps.

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.

The world of process automation is governed by procedures. While we like to refer to the process industries as being largely "continuous", this could not be further from the truth. Process manufacturing is constantly in flux.

From engineering to installation, commissioning, operations, and maintenance, FOUNDATION fieldbus offer significant cost reductions of 30 percent or more versus conventional analog systems. Many of these cost reductions come from the advanced functions that fieldbus offers versus analog technology.

The automation suppliers that will be successful in the long term will be those that effectively address application or industry specific problems for end users with a value proposition that cannot be ignored. These problems exist throughout the process industries today, and they won't be solved by simply offering a product, but through a combination of hardware, software, services, application expertise, and knowledge.

In ARC's view, customers need a compelling business value proposition to justify investment in any kind of automation. Vigilance and VigilantPlant were created with this in mind. Yokogawa's vision with VigilantPlant is to create an environment where plant personnel and operators are well informed, alert, and ready to take action. 

Yokogawa has come a long way in making its message clear to the world of process automation. Last year, the company embarked on a full-scale global marketing campaign to make customers aware of the company's focus on system reliability, security, dependability, and robustness. Dubbed "Vigilance", the campaign created a unified message for the company and greatly helped expand awareness of the Yokogawa brand and corporate philosophy.

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.

Migration of a refinery's DCS provided an opportunity to reconfigure and consolidate the control rooms and operational management system.

This article will not get into evaluating potential safety hazards or designing safety systems, which are extensively covered elsewhere. Instead, we will discuss ways of interpreting and implementing the findings of these evaluations.

When other methods fail, AI provides critical tools to help plant personnel find and solve process problems

Overcome Temperature Challenges. Correct common conditions for better level measurement.

Optimizing automated equipment condition monitoring calls for a different wireless protocol than that used with process instruments.

Podcast: The benefits of a tried-and-true pressure-based level measurement technology.

With fired heaters, users hope to get greater efficiency and reduced emissions but often are disappointed. Given the number of fired heaters operating every day and their importance in the process industries, any improvements realized across the board will have huge impacts. More units can reach their potential with some simple changes in work practices and technology upgrades.

A Perspective on New Technology Impacts on the Chemical Processing Industry by Sergio Fernandes, Chemical Market Leader, Yokogawa Corporation of America

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. 

Protect Plants from Process Perils, Up Your Fired Heater Safety with TDLS Technology - Chemical Processing - eHandbook April 2022

September 2008

Yokogawa is helping a large chemicals site in China manage product transfer by road, ship and pipeline.

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.

In times of abnormal operations, systems are configured to produce lots of data – humans are not configured to handle or interpret them. However, when presented with the right information, in the right context, during an abnormal condition, humans are able to do things machines cannot.

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

ISA S88.01 provides great benefit to users and vendors by solidifying batch operating models and standardizing batch control terminology. On the other hand, as befits an industry-wide standard, ISA S88.01 leaves great flexibility for individual users to apply their own project practices and implementation methodology. Even when utilizing ISA S88.01 models and terminology, many pitfalls remain for those who implement batch controls and recipe management without thinking ahead. Real-world project experience has demonstrated a number of design and implementation "lessons" which might be overlooked to the eventual grief of the batch engineer.

The S88.02 draft standard defines a means for depicting procedural control in master and control recipes. This depiction method is called a Procedural Function Chart (PFC). This standard depiction is based on the requirements of S88.01, technical report ISA-TR88.0.03-1996, user requirements, previous standards and commonly used procedure depiction methods in use today. PFCs can provide a common basis for the exchange of recipes, reduce the learning curve between control systems, and establish a common ground for improved human communication. This paper provides a brief overview of the development of PFCs, the rules for their use and some of the benefits expected by their adoption in the industry.

The case study in this paper illustrates the value of integrating front-end scheduling with a batch control system. Recipe changes, and addition of recipes, occur frequently in the target process. However, since both scheduler and batch packages were designed with the ISA-S88.01 model in mind, these packages could be tightly coupled (well integrated) – and, as a result, it is easy to add or change recipes. The front- end scheduler is not limited to performing scheduling; it also provides an easy-to-grasp real-time production status display which can help enhance efficiency and productivity.

As batch processes are automated, it is common to leave certain less essential field devices without automatic actuators. Thus, the initial control design must accommodate both automated and manual activities. Later, the manual field devices may be automated, either one-at-a-time or in related groups as equipment modules. These field changes, often occurring over a period of years, each require rework of the batch control logic, which can easily exceed the cost of the actuator. In response to this undesirable situation, a technique has been developed which permits the batch design to automatically modify itself, or evolve, to accommodate changes in field automation.

Vibrating element (VBE) type gas measurement devices measure refinery reformer stream compositions, power generator hydrogen purity, centripetal compressor gas inputs, process heater fuel gas quality, and others in multiple process control environments.

Six Sigma is a quality improvement methodology applied to improving any type of process. It is a methodology endorsed by and heavily integrated into several major chemical companies.

Key Performance Indicators (KPIs) are used in batch processing industries as measurements of production performance. Their use is one element in the current trend of real-time performance management. A single KPI used as the primary measurement of production can cause other dimensions of production performance lose importance. When multiple KPIs are used to measure a batch's production performance it can be difficult to reconcile differences between them for individual batches or for groups of batches. KPIs based upon meeting a target, or specification, measure absolute performance yet do not provide relative information regarding how a batch performed against its peers. The peer comparisons are important for monitoring variability of production performance, which is a critical factor in documenting ROI.

The application of DCS-based "advanced controls" is a common method of achieving enhanced performance from continuous processes such as refinery units. However, it is less widely recognized, but nonetheless true, that modern DCS systems can include other software tools for the significant improvement of batch plant productivity, product quality, and economic performance. Due to the fundamental processing differences between the two types of plants, unique batch "advanced control" features are required which are different from those used for continuous plants.

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.

Wiring temperature sensors installed in a chimney back to a control room can be challenging and expensive, so many plants and facilities are instead implementing wireless solutions, such as this Yokogawa YTMX580 8-input temperature transmitter.

Process automation in oil refineries is undergoing major changes, driven by customers frustrated by what they consider to be slow and incremental advances from the main automation original equipment manufacturers (OEMs) in the industry. ExxonMobil has become a de facto industry representative and is driving vendors like Yokogawa and others to reevaluate how large-scale automation projects are implemented.

Supervisory control and data acquisition (SCADA) systems have been part of the process industries for many decades and cyber security measures need to grow as technology advances. SCADA systems are used in oil and gas pipeline and other remote control and monitoring applications, such as electrical transmission and distribution, and water/wastewater.

Many lubricant blending businesses find themselves in a challenging situation: there are opportunities to increase their overall business volume and profits by improving production flexibility, expanding their product slate and optimizing high-margin blends. At the same time, they find themselves constrained by current manufacturing limitations. However, launching a capital project for a significant manufacturing expansion may not be possible, and it may not be necessary.

Spectrometric technology can assess many critical characteristics about products, but it has limits. It can be challenging to determine when the line has been crossed

Machines can support humans when facing a stressful situation. Using a standards-based approach can reduce the likelihood of a problem escalating.

SABIC Turns to Yokogawa TDLS Analyzers to Enhance Safety Functions and Production

Honeywell and Yokogawa have both been producing Distributed Control System (DCS) platforms for decades, and both are very active in this area. In 1975, Honeywell introduced its TDC2000 platform and Yokogawa brought out CENTUM. These two competing systems emerged from a similar place, oil refining and petrochemical industries, so they started out with similar basic concepts and use cases in mind. 

The accuracy of pH measurements depends upon maintenance; maintenance frequency largely depends upon the application. Understanding and addressing the causes of pH measurement difficulties comprise key to ensuring stable and accurate readings.

Immunize Plant Instrumentation Against Uncertainty

Get the most from what exists currently and take advantage of new methods. Appeared in the March 2021 issue of an ISA.org publication.

Kind of. Calibration itself will not extend the life of a sensor, however, a sensor that is not calibrated properly can cause unreliable measurements - that are often misdiagnosed leading to unnecessary replacements.

Optimizing the maintenance cycle is not always straightforward. In some cases, cleaning once a week is sufficient and other processes may require every 8 hours.

Learning these four lessons will help you improve your engineering skills and most importantly extend the life of your pH sensors.

Select the correct pH glass and reference type to improve your pH sensor lifetime and you can limit or even eliminate the effects of temperature and pressure on especially the reference sensor.

The lifetime of a pH sensor has a significant impact on the overall annual costs of a pH measuring loop. Optimizing four key factors will decrease these costs and optimize process control and overall plant efficiency.

ROTAMASS is the integral and remote type Coriolis Mass Flow Meter. Both types have highly refined digital signal processing electronics, so that accurate and stable mass flow measurement is achieved.

It is the most technologically advanced mass flow meter yet. By combining the superior design of the application specific flow sensor and transmitters with the Total Insight philosophy and functionality, the flexibility of the ROTAMASS to adapt to changing  requirements guarantees performance throughout the lifecycle of the process measurement.

TDLS8100 & TDLS8200 Features and Benefits Video

The GC8000 is a process analyzer that uses gas chromatography to measure the composition of multiple components in a stream. Engineered with reliable electronics and intelligently designed columns and valves, the GC8000 improves ease of maintenance while reducing operating costs. Its intuitive touchscreen HMI with system diagnostics reduces operation and maintenance headaches, maximizing measurement accuracy, reliability, and uptime. More Information

Open up control. Open Process Automation (OPA) opens the door to expanded choices, leverage, and customization.

Create a scalable, sustainable architecture. Remove the restraints of proprietary systems. OPA enables you to leverage all available technologies to open up solutions. Explore the possibilities today.

Chet Mroz, President & CEO Yokogawa North America, discusses the benefits of IoT at the 2015 ARC Industry Forum in Orlando.

How much do you know about pressure transmitters? Are you accurately, quickly and reliably measuring pressure? Ultimately, the drive of any good pressure transmitter is to get an accurate, reliable pressure measurement to the data user quickly. This video gives you the answers to your basic questions about pressure and pressure transmitters.

Podcast: The benefits of a tried-and-true pressure-based level measurement technology.

Join this webinar to better understand which manifolds you should use for specific applications and conditions. You will learn:

• A brief history of manifolds
• An overview of the different types of manifolds that are available
• The advantages, disadvantages, and application considerations you should consider when selecting a manifold

Fired heaters are the largest energy consumer in the manufacturing sector and represent a tremendous opportunity for energy savings. However, energy efficiency is not the only concern for fired heaters. Compliance and safety are continuous challenges.

In this one-hour presentation, we will discuss:

• How to improve fired heater safety and efficiency by controlling combustion using Tunable Diode Laser Spectrometers (TDLS) technology
• The 4 top industry challenges related to fired heaters
• How to efficiently and safely manage combustion
• How TDLS technology can improve operational excellence in fired heaters

This workshop provided by industry partners Yokogawa and ThreatConnect will show you a way to strategically manage cyber risk within an industrial environment. Learn how to transition from the “break/fix” model of industrial cybersecurity to a business risk management strategy through cyber risk quantification, return on investment (ROI) for industrial cybersecurity solutions calculations, and cyber risk identification.

Addresses productivity challenges in the chemical industry and how digital field instruments can improve productivity.

Sample systems are a crucial component of and have a significant impact on the performance of a process gas chromatograph analyzer. When working on sample systems, you must have a constant awareness of time delays. This fundamentals webinar will take the mystery out of lag times.

Discover how to achieve industrial autonomy step by step through one of the 75+ inspiring presentations.

In this webinar, we will:

• Share best practices for monitoring, recording, and transferring data 
• Challenges in data acquisition and how Yokogawa can help
• Demonstrate GA10 Data Logging Software capabilities

In this webinar, industry-leading experts will describe how OPAF is selecting standards that will achieve the vision of truly open systems, the status of its efforts, and what this exciting change to the process automation world means to you.

In this webinar, we will:

• Introduce Yokogawa AI, including Sushi Sensors
• Demonstrate GA10 AI Dashboard and simple setup
• Discuss applications and real-world examples

DX value delivery at scale requires high-quality data to be accessible to the users and systems that rely on it.