Plant Asset Effectiveness Optimization Service

Transcription

1 Plant Asset Effectiveness Optimization Service Bulletin 43D02A03-02EN

2 Improve the productivity of your plant assets With the increasing demand for energy that has accompanied the economic growth of newly industrialized nations, companies need to find every possible way to add value and max out the efficiency of their production processes. And they must find a way to do this without doing harm to the environment and while complying with stringent HSE regulations. Optimized Operations and Maintenance Yokogawa has solutions for a sustainable future that solve the issues you face with your plant assets. We can detect problems at an early stage and put forth proposals that show you the way forward to achieving concrete improvements. We make it possible for you to slash your plant asset operating and maintenance costs while reducing both energy consumption and carbon emissions Asset Performance Diagnostics Control Valve and Control Loop Diagnostics Field Digital Device Diagnostics Yokogawa helps you The three s have proven effective in optimizing the efficiency of plant assets. Choose any one of these s, depending on the condition of your plant assets, as your entry point for using our state-of-the-art diagnostics and services. In this, Yokogawa will work with you in a collaborative effort to get the maximum possible productivity out of your plant assets. ACT WITH AGILITY SEE clearly, with a birds-eye view, the condition of your plant assets by providing diagnostic solutions SEE CLEARLY ACT with agility to implement proposals that resolve specific issues and achieve improvements The challenges for management and field operators - Increasing availability - Improving efficiency - Reducing maintenance and operating costs - Saving energy KNOW IN ADVANCE KNOW in advance what must be done to optimize these plant assets by providing information-intensive service solutions that precisely detect and analyze their conditions 1 2

3 SEE Field Digital Device Diagnostics for accurate measurement and control ACT WITH AGILITY KNOW IN ADVANCE CLEARLY Case Study Mitsubishi Chemical Corporation Japan 01 Isn t it time for a more efficient maintenance approach using field digital technology? Yokogawa s InsightSuiteAE enabled us to easily grasp the device health and early detect problems that Mitsubishi maintenance engineers hadn t recognized. By using both PRM and KPI Report, Mitsubishi was actually able to spot a failure in a critical temperature transmitter that was connected to the safety system and could take corrective action before this could cause a plant shutdown. The Challenges The Solutions Take your plant into the digital era to make more efficient use of your devices - Our field digital device diagnostics show how to eliminate the root causes of inaccuracy in measurement and control. - The monitoring of the conditions of all your field devices enables a condition-based maintenance (CBM) approach. Knowing exactly what is happening with your field devices Usually there are so many devices from a variety of vendors and it is difficult for any one operator to monitor their health. An easy to implement and time saving solution must be found. Making sure that essential know-how is not lost With the retirement of your most experienced operators, you stand the risk of losing the knowledge and expertise needed to properly maintain field devices. Visualize field device and process interface conditions Automatically generated key performance indicator (KPI) reports provide numeric data that make it possible to spot at a glance which devices are generating alarms and in need of maintenance. Maximize use of field digital information Combined with field digital baseline tuning, our consulting services show you how to maximize the availability of your field devices. Field Asset KPI Report - Critical maintenance targets highlighted The Benefits Our Services Field Asset KPI Report Based on the information gathered from field devices, KPI reports are generated that help to visualize which device or interface process is likely to experience an abnormality. Consulting services Using our know-how and expertise, we offer field digital baseline tuning and consulting services to correct the problems identified in the KPI reports. Maintenance optimization Consulting reports present proposals on how to make use of device information, which may include the use of PRM to optimize the daily maintenance workflow. Reducing maintenance time and costs It is a waste of time and money to check devices that are functioning normally, which is what often happens with time-based maintenance (TBM). A more effective approach is needed that allows you to know exactly when maintenance should be performed. Identify targets and establish an efficient maintenance workflow Our KPI and consulting reports show you how to prioritize your maintenance activities. A conditionand risk-based maintenance workflow reduces maintenance time and costs. A condition- and risk-based maintenance and operation approach - Easier to prioritize maintenance work. - Make the best use of your maintenance expenditures. - Optimize Process operation. Get maximum benefits from field digital technology over the entire plant lifecycle - Have an exact, quantitative grasp of your field device conditions. - Improve asset reliability by being able to analyze and solve bad actors. Maintenance workflow with PRM 3 4

4 Control Valve and Control Loop Diagnostics for stable operation Case Study Thai Acrylic Fibre Co., Ltd. Thailand 02 Have you been looking for a more effective approach to control valve and control loop maintenance? InsightSuiteAE has been continuously monitoring the entire dryer section of the plant. The average temperature set point was found to be maintained at 6% higher and the maximum control valve movement was observed to be 12%. With the help of Tune VP, tuning simulator tool, it was possible to eliminate the higher set point and control the temperature without any quality issues. After control valve recalibration / servicing, the average amplitude was reduced to less than 5% which resulted into lesser requirement of instrument air.in two production lines out of five, it is estimated that annual steam saving is approx. 3,100 tons. The Challenges The Solutions Detecting and resolving issues to stabilize operations at your plant - Our control loop and control valve diagnostics help address problems that destabilize measurement and control. - An effective alarm management system ensures that the right information is delivered to the right person at the right time so that proactive maintenance s can be taken. Being able to monitor control valves from multiple vendors Checking control valves can be time consuming, and it can be very difficult to uniformly monitor the condition of devices from multiple vendors. Easily identifying unstable control loops Monitoring control loops spread out over a wide area can be difficult, and it can take a considerable amount of time to pinpoint the bad actors. Promptly solving problems There is a need to devise and implement a maintenance approach that makes it possible to quickly resolve problems. Using diagnostics to identify problematic control valves at a glance Even with multiple vendors control valves, it is possible to monitor how effectively they are being controlled and to promptly identify any problems. Combining diagnostics of control valves and control loops with the monitoring of sensors The combination of diagnostics and extensive monitoring make it easy to identify problems occurring over a wide area. Improved efficiency of maintenance workflow Diagnostics and consulting reports facilitate the planning of an optimized maintenance approach. Controllability trend data (daily/weekly/monthly) The Benefits Spot hidden problems - Never again overlook the signs of an unstable control loop. Improved asset reliability - Minimize failures by carrying out tuning and preventive maintenance. - Reduce energy consumption and maintenance costs. Our Services Control valve and control loop monitoring Control valve and control loop conditions are clearly displayed so that operators can quickly spot abnormalities. Trend monitoring and prediction Daily/weekly/monthly controllability trend data can be monitored online, allowing operators to quickly make predictions and take remedial actions. Root cause analysis Control valve and control loop diagnostics help identify the root causes of instability in control loops. ( Upper ) Controllability deviation trend ( Lower ) Accurate and effective maintenance planning Average valve movement 5 - Sophisticated diagnostics give you a quick and accurate grasp of device conditions. - It is easy to determine what remedial s must be taken. 6

5 Recommended Cleaning Threshold Recovered Cleaning Index after Cleaning Energy saving in hot fuild = 44.6 E06 kwh Energy saving in pumping = 1.7 E06 kwh SEE Asset Performance Diagnostics for increased efficiency ACT WITH AGILITY KNOW IN ADVANCE CLEARLY Case Study Rayong Olefins Co., Ltd. Thailand 03 Why not consider a new maintenance approach that saves energy and reduces your lifecycle costs? InsightSuiteAE, heat exchanger diagnostics identified that badly fouled heat exchangers were impacting performance. With its failure prediction diagnostics, the maintenance team was able to prioritize a maintenance list based on estimations of criticality and expected time to failure. In the furnace section, the formation of coke on the coils can be precisely monitored using fault monitoring diagnostics that check for normal operating conditions and report on any deviations in real time. The information on the severity of coke formation is also utilized to optimize the decoking procedure during the decoking cycle. The Challenges Protecting the environment There is a need to lessen our impact on the environment and achieve a sustainable society through measures that include the reduction of CO2 emissions. The Solutions A maintenance approach that focuses on reducing energy consumption Our comprehensive solutions improve energy efficiency while ensuring a stable and environmentally friendly O&M. Mapping out a path that will improve asset performance and save energy - We use sophisticated diagnostics to analyze your assets and propose an optimal maintenance approach that will help reduce your energy consumption. - We identify how efficiently your plant is using energy and show you a maintenance approach that will improve productivity. Our Services Real-time monitoring of asset health Online monitoring gives you immediate access to asset health information. Prediction of future performance Time-series data makes it possible to predict future performance. Reducing energy costs Plant operators need to know how to optimize plant operations and maintenance (O&M) to improve energy efficiency and reduce energy costs. Measurement of energy efficiency We can visualize present and future energy consumption to prepare a precise and effective maintenance plan. Maintenance planning support Our diagnostic and consulting services help you map out an optimum maintenance approach. Heat exchanger diagnostics Effectively reducing energy consumption Predicting when maintenance needs to be performed Performance monitoring The Benefits Optimizing maintenance for each asset - Based on asset conditions and the need to minimize energy costs, you can know exactly when maintenance should be performed. It is difficult and time consuming to effectively An online system efficiently monitors the status of E241A/B Fouling Prediction Diagnostics monitor all of a plant s assets and map out an many different field assets. It enables a 1 Raw Data Fitted Data 0.9 effective maintenance approach that will save condition-based maintenance approach that energy. extends the service life of individual devices by Online, real-time monitoring ensuring that they receive the most appropriate Easily track asset conditions and performance. 0.3 maintenance. - Reduce maintenance costs even as the number of 0.2 assets increases Jun08 Oct08 Mar09 Aug09 Jan10 Jun10 Nov10 Apr11 Sep11 Feb12 Jul12 Dec12 May13 Oct13 Periodic Periodic - Detect abnormalities and be able to promptly respond in Data maintenance maintenance the event of sudden failure. 7 1st 2nd Performance 8 prediction Cleanliness Index Planned Shutdown for Cleaning Predided cleaning data if cleaning was carried

6 VigilantPlant ServicesTM is a suite of comprehensive services that enable Yokogawa s VigilantPlant concept, helping manufactures achieve safe, reliable, environmentally friendly and profitable plant operations. From design through project execution, operations and maintenance, VigilantPlant Services support manufactures to achieve ongoing Operational Excellence over the plant lifecycle. - Field Digital Device Diagnostics - Control Valve and Control Loop Diagnostics - Asset Performance Diagnostics Yokogawa helps you improve plant asset efficiency for optimized maintenance and operation. We contribute to your plant asset management, realizing energy and cost savings Opportunity Identification ServicesTM s t e p Solution Implementation ServicesTM InsightSuiteAE is a part of Solution Implementation Services under VigilantPlant Services. We provide InsightSuiteAE service solutions for monitoring, diagnosing, and optimizing your plant assets. Three Introductory Steps Lifecycle Effectiveness ServicesTM Field Digital Analog 9 10

7 The Clear Path to Asset Effectiveness Optimization Based on a wealth of industry experience and leading-edge technology, Yokogawa provides a range of value-added service solutions for monitoring, diagnosing, and optimizing your plant assets. As your partner throughout the plant lifecycle, we make sure that your plant assets operate at peak efficiency while working to minimize your maintenance costs. YOKOGAWA ELECTRIC CORPORATION World Headquarters 9-32, Nakacho 2-chome, Musashino-shi, Tokyo , Japan Represented by: YOKOGAWA CORPORATION OF AMERICA 2 Dart Road, Newnan, Georgia 30265, USA YOKOGAWA EUROPE B.V. Euroweg 2, 3825 HD Amersfoort, The Netherlands YOKOGAWA ENGINEERING ASIA PTE. LTD. 5 Bedok South Road, Singapore , Singapore YOKOGAWA CHINA CO., LTD. 3F Tower D Cartelo Crocodile Building No. 568 West Tianshan Road, Shanghai , China YOKOGAWA MIDDLE EAST B.S.C.(c) P.O. Box 10070, Manama Building 577, Road 2516, Busaiteen 225, Muharraq, Bahrain Trademarks All brand or product names of Yokogawa Electric Corporation in this bulletin are trademarks or registered trademarks of Yokogawa Electric Corporation. All other company brand or product names in this bulletin are trademarks or registered trademarks of their respective holders. Subject to change without notice All Rights Reserved. Copyright 2010, Yokogawa Electric Corporation [Ed:01/b] Printed in Japan, 007(KP)