Yokogawa's Integrated Control and Safety Systems (ICSS ... · PDF fileYokogawa’s solution: Yokogawa will provide the ... Centum VP Integrated Production Control System 128 Mbps Operator

<ISD-MASP-S12010> Copyright © Yokogawa Electric Corporation <date/time>

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Yokogawa's Integrated Control and Safety Systems (ICSS) for Oil and Gas Industries

Joshua Kyaw Zwa

Product Manager – DCS & SIS

Systems Business Center

IA Platform & Marketing Division

Yokogawa Engineering Asia Pte Ltd

15-Oct-2014

<Document Number> Copyright © Yokogawa Electric Corporation <date/time>

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Self Introduction

Joshua Kyaw Zwa

Product Manager – DCS & SIS

Systems Business Center

IA Platform & Marketing Division

Yokogawa Engineering Asia Pte. Ltd.


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Agenda

Customer’s Challenges in Oil & Gas Industries

Yokogawa’s ICSS Solution for Oil & Gas Industries

Brief Introduction of Yokogawa


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Brief Introduction of Yokogawa


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100-Year History of Yokogawa

New

2014

ProSafe-RS Master Rev2.0 Copyright © Yokogawa Engineering Asia

14-Sep-2011 - 6 -

Yokogawa’s Coverage – Level 1 to Level 4 Integration


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Yokogawa is a reputable global company...

Ｃ

Global network supporting business growth

As of the end of March 2010

World Headquarters

Yokogawa Electric Corporation (Japan)

Yokogawa Corporation of

America （USA）

Yokogawa China （China）

Yokogawa Middle East （Bahrain）

Yokogawa Europe （The Netherlands）

Global & Regional IA Business HQ

Yokogawa Electric International (YEI)

Yokogawa Engineering Asia (YEA)

88 subsidiaries and affiliates

19,685

Worldwide

Singapore – 200

India - 100

R&D

Facilities

Copyright © Yokogawa Engineering Asia - 8 -

Yokogawa’s Global Network for Operation Support

A global network of 225 service offices and response centers delivering: Around-the-clock real time support (24/7, 365-day-per-year basis)

Remote diagnosis & performance analysis

Asset optimization consulting

Global Response Center

at Yokogawa Headquarters

India Response Center

at YIL Bangalore

South America Response Center

at YSA San Paulo

South Korea Response Center

at YKO Seoul Europe Response Center

at YEF Netherlands

North America Response Center

at YCA Houston

China Response Center

at YCS Shanghai

Asia Response Center

at YEA Singapore Middle East Response Center

at YME Bahrain


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DCS/SIS Global Manufacturing Centre is in Singapore.

• Global Manufacturing Centre for DCS and SIS

• First factory outside Japan to receive JIS certificate (1981).

• ISO 9001 Certified for the manufacture of DCS & Panels including the Assembly of Printed Circuit Boards for DCS (1993). Manufacturing of Meters and Measuring Instrument.

• YAS is ISO14001 Certified.

• Two Factories

– Bedok Factory, Singapore

– Batam Factory, Indonesia


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Customer’s Challenges in Oil & Gas Industries


2 Key Challenges for Customers in Oil & Gas Industries

1) Equipment failures that lead to costly (unplanned/unexpected) downtime

2) Tough competition and the need to improve earnings

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Challenge 1: Equipment failures that lead to costly

(unplanned/ unexpected) downtime.

1. Oil & Gas wells are being drilled to

greater depths.

2. They are distributed over wider areas.

3. Complex equipment with advanced technologies are used more and more.

4. Costs have risen proportionally.

5. To help keep costs under control, it is essential to prevent equipment failures that can lead to unexpected/unplanned downtime.

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What if? 1. Unplanned/Unexpected downtime

disrupts production plans and hurts the bottom line.

2. Unplanned/Unexpected downtime -> So many consequences -> Production Lo$t


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Challenge 1:

Equipment failures that lead to costly (unplanned/unexpected) downtime

What is Yokogawa’s solution for it?

Yokogawa’s solution:

Yokogawa will provide the most reliable Control Systems with Highest Availability for customer’s peace of mind.


Positioning of Control System

Small

Large

Scale

(I/O

Size)

PA (Process Automation) FA (Factory Automation)

Redundancy Function No Redundancy Function Compact Type Modular Type (Building Block)

PLC

HYBRID PLC

DCS


Positioning of Yokogawa’s Control Systems

Small

Large

Scale

(I/O

Size)

PA (Process Automation) FA (Factory Automation)

Redundancy Function No Redundancy Function Compact Type Modular Type (Building Block)


<SBDB-110031> Copyright © Yokogawa Electric Corporation <July 2011>

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“ As a result of Yokogawa’s high R&D investment and the consistent long term migration policy of the CENTUM DCS family our investment are secure ” Christian Vermum Manager of Electrical Engineering Department Degussa Oxpeno, Germany

CFFS

HF-Bus

CFCS

COPS F-Bus

250 KBPS Dual

Redundant

Token Pass

CENTUM

CFCD

1MBPS Dual

Redundant

Token Pass

CENTUM-XL

EOPS

CFCS EFCD

ENGS PFCS

KFCS LFCS COPS2

CENTUM V

CFCS2

COPSV

CFCD2

ABC

CENTUM CS

ICS

EWS PICS

V net

10 MBPS

Dual Redundant Token Pass

HIS

CENTUM CS 3000

AVR

FFCS

HIS

CENTUM CS 3000 R3

HIS

CENTUM VP

Vnet/IP

2008

1975

1983 1988

1998

2001 2005

1993

FFCS

1Gbps Dual

Redundant

•Unique Pair & Spare reliability technology

•Seven 9’s (99.9999959) availability

•~26,000 systems installed worldwide

2011

Long History of Yokogawa DCS - CENTUM New

2014


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Fully Redundant Control System

Page.19

SOE

Field Control

Station

Hardwired I/O

Local I/O Nodes

PLC

Remote I/O Nodes

Centum VP

Integrated Production

Control System

Operator

Station Engineering

Station Open Data

Server

(OPC)

Ethernet

Asset

Management

1Gbps

Redundancy at all levels – Power, CPUs, Network & I/O

Redundant

Control

Network

128 Mbps



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Yokogawa’s Proven Pair & Spare Technology

ACTIVE STANDBY ACTIVE STANDBY

(1993)

(1998)

(2001)

(2008)

Based on actual live plant data

(2011)

Most Reliable DCS in the Market. 99.99999% (Seven 9’s) availability

is proudly declared publicly.



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What does seven-9s mean?

Using Systems with High Availability

No Unexpected Down Time

No Production Lo$t


Yokogawa’s SIS – ProSafe-RS

Professional Safety

“RS” stands for;

Responsive

Solution with images of;

Reliable and

Robust System ProSafe-RS can be used for ESD, FGS and BMS.


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True Integration between Control System and Safety System

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CENTUM-XL

EOPS

CFCS EFCD

ENGS

CENTUM CS3000

HIS

PFCS

KFCS LFCS

COPS2

CENTUM V

CFFS CFCS2

COPSV

CFCD2

HF-Bus

1MBPS Dual Redundant

Token Pass

CENTUM

CFCD CFCS

COPS F-Bus

250 KBPS Dual Redundant

Token Pass

ABC

CENTUM CS

ICS

EWS PICS

Vnet

10 MBPS Dual Redundant

Token Pass

1975

1983 1988

1993 1998

ProSafe-PLC

Relay

DCS Evolution # High performance/Reliable technology - Control BUS / IO BUS - HMI # Pursuing new technology - Fieldbus integration

Panel/ Single Loop

SIS Evolution # Unified Architecture # Scalable System # Flexible System # Robust, reliable and integrated comm. # Integrated HMI # Sensor Validation # PST

2005

ModBus

ProSafe-RS, technical evolution of

SIS is core platform of Safety Excellence.

ProSafe-SLS (Solid State, SIL4)

1965


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One Integrated System for Production & Safety

Integrated graphics

Common faceplate

Integrated trending functions

Integrated alarm management with CAMS for HIS

Common system maintenance & diagnostic

Integrated asset management


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ProSafe-RS adopts proven “Pair-and-Spare” Technology

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ACTIVE STANDBY

• Base on DCS proven “Pair-and-Spare” technology (to increase availability)

• Common Architecture

• TÜV SIL-3 Certified by itself.


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Each module is SIL3 by itself….

• SIL3 will be achieved in single Input-CPU-Output module configuration for DTS or ETS configuration without add-on hardware

Single CPU module

Single Input module Single Output module

Input Circuit, MPU

Circuit, MPU

CPU MPU, memory

MPU, memory

Output Circuit, MPU

Circuit, MPU

• Over 99% Diagnostics by step by step comparison • With self-diagnostics in CPU & IOM, DC it reaches over 99.5%.

No Time Restriction


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Integrated Maintenance

• CENTUM VP and ProSafe-RS System Overview in same window

DCS Controller Safety Controller

Similar Troubleshooting skills required

- 28 - ISD-MASP-S13011 Copyright © Yokogawa Electric Corporation July, 2013

Data buffering – SIS with SCADA

SCS

FAST/TOOLS data_A

1 ID

IN

data buffering FB

data_B

2

data_C

3

Time ID Data

MAX 135,000 Events on RAM (Rotary buffer)

ID

IN

ID

IN

Communication Lost

Recovered


14-Sep-2011 - 29 -

29

TÜV Certification

had been certified as SIL3 by

TÜV Rheinland,

Who certified 73% of SIS Vendors

www.tuvasi.com (Yokogawa, Triconex,

Honeywell and many many more)

TÜV Sud – 25% (Siemens)

TÜV Nord – 2% (or 1 SIS Vendor

Emerson)

6 SIS vendors switched from Sud to

Rheinland (HIMA, Honeywell)

http://www.tuvasi.com/


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Portable, Handy and Heavy Duty RTU

• Especially suitable for remotely distributed and hazardous locations. • Low Power Consumption (<2W) : can be powered by Solar Power • Wide Temperature Range (-40 to +70 degC) • Designed with Error Check and Correct (ECC) memory • Embedded battery diagnosis function prevents tuning and logging data loss. • Big memory capacity to facilitate the long-term storage of gas volume data and other on-site information as well as to accommodate larger Java data Logging program.


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Data Buffering Function - RTU

Reliable

System

Highly

val, time

Lost data recovers

Read stored data from controller

Network recovers

No communication, No data

EXAMPLE

in case of gathering 20 I/O points with Scan Time of 10sec

Up to 4.5hrs of event buffering is possible

Continuous data gathering on FAST/TOOLS at temporary network trouble

- Storing data with timestamp inside STARDOM - FAST/TOOLS read stored data after network recovery

System


Yokogawa will provide the most reliable Control Systems with Highest Availability

for customer’s peace of mind.

Challenge 1:

Equipment failures that lead to costly (unplanned/unexpected) downtime

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Challenge 2: Tough competition and the need to

improve earnings.

1. Oil & Gas companies are trying to stay

competitive and struggling very hard to be profitable.

2. One way being done is through the application of Field Digital Technologies to enhance performance.

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What If? Using traditional/conventional technologies is no longer competitive in this fast changing Technology World.


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Challenge 2:

Tough competition and the need to improve earnings

What is Yokogawa’s solution for it?


Yokogawa’s highly accurate and stable Field Digital Technology

gives Oil & Gas companies a competitive edge by reducing

unplanned downtime and eliminating the need for travel

to field sites.


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Why Digital?


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Digital Technology has changed the way we communicate…

vs.


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Da

ta

2010 2000 1990 1980 1970 1960

Evolution of Field Technology

ANALOG DIGITAL


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Conventional Instrument will make you busy with many guessing

Is it due to device faulty?

Is it due to I/O card spoiled?

Is it due to the instrument cable damaged?

So many GUESSING??? 4-20mA Instrument Operator in

Control Room

Operator will NOT know what is the exact root cause of the error.


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With Field Digital Technology, no more guessing!!!

Fix Me!

Asset Management

Planning

Work Order

Fix It

Email Notification

Smart Device (HART, FF, Profibus, ISA100)


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Digital Technology Enable Device Based Diagnostics

• Self Diagnostics

– Sensor/Amplifier/Out of range/Parameter Check

– Electrode Adhesion/ Empty Pipe (Mag)

– Sensor Clogging Predictive (Vortex)

• Process Interface Diagnostics

– Predictive Impulse Line Blocking ：

– Steam Trace：

– Online Valve Diag.：

– Flow Profile Condition (Vortex)

• Diag. information of plant/process Management

160.545

m3/h ＦＲ

ＦＴＬm3

LEVEL３ ADH

160.545

m3/h ＦＲ

ＦＴＬm3

LEVEL３ ADH

Electrode

Common

Steam Trace Adhesion Mag ILBD

By calculation of capsule Temp.

Under Development

Under Research

Cycles Sick-Slip

Cycles Sick-Slip

Near Close TSO

Ans-back

Online valve

Standard

Increase asset utilization with predictive diagnostics

Standard

Standard

Standard

Standard

Standard

Standard

Standard


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Impulse Line Blockage Diagnostics

Blockage at both H/L side

Blockage at High side

Blockage at Low side

No Blockage

DP (Differential

Pressure)

PH (Static

Pressure H side)

PL (Static

Pressure L side)

Outcome DP, PH, PL

Low fluctuation

PH

Low fluctuation

PL

Low fluctuation

Independent

fluctuation

Reference Data

at no blockage condition

DP, PH, PL fluctuation

Data for Diagnostics Normal

?

PH

PL

DP = PH-PL

Patent

Pending

Multi-Sensing technology enable advanced diagnosis

– Enhanced Silicon Resonant Sensor can measure D/P & SP

– Only transmitter that measures STATIC PRESSURE


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No more guessing. The exact root cause will know.

On Operator Station, operator can see the field device diagnosis information by DeviceViewer, integration with Asset Management.

Increase maintenance efficiency by eliminating the need to travel to site/the remote well locations.

Appropriate action can be taken effectively & efficiently.


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Device Viewer (Sample)

Alarm: Device Needs Maintenance Now Cause: Capsule module damage Action: Replacement of parts

Result of Device Self-diagnostics

Field Digital Solutions Copyright © Yokogawa Electric Corporation Jan 2012

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48

Yokogawa takes active role in Field Digital Technology

Yokogawa is a founding member of Fieldbus Foundation

Also a founding member and sponsor of the FDT/DTM Group

Member of the Profibus users group

Member of the ISA-SP100 wireless standards committees

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Committed to technology benefiting customer


Yokogawa’s highly accurate and stable Field Digital Technology gives Oil & Gas

companies a competitive edge by reducing unplanned downtime and eliminating the

need for travel to field sites.

Challenge 2:

Tough competition and the need to improve earnings


Recent Project Reference (Oil & Gas, LNG Supply Chain)


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Conclusion


Key Challenges vs. Yokogawa’s Solution

1) Equipment failures that lead to costly (unplanned/unexpected) downtime

Yoko’s Solution: Providing Most Reliable Control Systems (99.99999%)

2) Tough competition and the need to improve earnings

Yoko’s Solution: Field Digital Technology to enhance performance.

vs.


Yokogawa has a wealth of Experience in Oil & Gas Industries

Yokogawa can cover from Offshore & Onshore facilities to pipelines, terminals, and deep-water operations.

Please visit to Yokogawa Booth (E08) for more information.

For more details, please visit to

www.yokogawa.com

http://www.yokogawa.com/


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Thank you

Documents

Yokogawa's Integrated Control and Safety Systems (ICSS ... · PDF fileYokogawa’s solution: Yokogawa will provide the ... Centum VP Integrated Production Control System 128 Mbps Operator