CONTROL TECHNOLOGY UPDATE : “A ROAD TO PLANT...

CONTROL TECHNOLOGY UPDATE : “A ROAD TO PLANT PERFORMANCE IMPROVEMENT”

“A ROAD TO PLANT PERFORMANCE IMPROVEMENT”

Presented By:Presented By:

KUNTOROKUNTORO

Service Service & Solutions & Solutions BusinessBusiness Dept.Dept.Technical DivisionTechnical Division

PT. YOKOGAWA INDONESIAPT. YOKOGAWA INDONESIA

Presented in the event of “National Seminar & Workshop in Brawijaya University”Malang, 17 October 2012

Presentation Outline

Common Practices of Control Technology in Industrial ApplicationMost of industrial practices used basic regulatory control as the way to control and operate the plants

Industrial Challenge for Performance ImprovementIn recent industrial era, most of industrial practices was challenged to operate their plant in effective way for all of aspects

Control Technology and Improvement StrategyCurrent control technology and its implementation

SummarySummary of the related topic to highlight the point of presentation / discussion

Common Practices of Control Technology in Industrial Application

Current Industrial Practices Sector in Indonesia

Sensing and Actuation Equipment

• Flow, Pressure, Level, Temperature• Valve Positioner & Camera

Differential Pressure Transmitter

DPharp EJXAll weather CCD Color CameraTemperature Transmitter

YTAAdvanced Valve Positioner

FOUNDATION is a registered trademark of Fieldbus

Foundation

Magnetic Flowmeter

ADMAGVortex Flowmeter

digitalYEWFLO

Differential Pressure Transmitter

DPharp EJX

Ultrasonic Flowmeter

All weather CCD Color Camera

Variable Area Flowmeter

ROTAMETER

Temperature Transmitter

Coriolis Mass Flowmeter

ROTAMASS

Advanced Valve Positioner

Analysis and Quality Control Equipment

Dissolved Oxygen Analyzer

Stack Gas Analyzer

• Gas Analyzers (oxygen, IR gas, density, chromatograph)

• Liquid Analyzers (pH/ORP, conductivity, turbidity, residual

chlorine, alkalinity, MLSS, DO, density,

water quality)

Foundation

pH / ORP, Conductivity Analyzers

EXA seriesProcess Gas Chromatograph

GC1000 MarkⅡ

Dissolved Oxygen Analyzer

DO402Zirconia Oxygen Analyzer

ZR402GStack Gas Analyzer

pH / ORP, Conductivity Analyzers

EXAxt seriespH / ORP, Conductivity Meters

PH72/SC72

Test & Measurement Business

Waveform, Power, Optical, Frequency/Time Interval, Voltage/Current, Pressure, Communications/Network, Wireless Communications

� Digital Power Meters

Digital Oscilloscopes

DL1740ELPrecision Power Analyzer

WT3000

� Digital Oscilloscopes

Digital Oscilloscopes

DL9000Scope & Chart Recorder

Two-in-One

DL1740EL WT3000

Digital multimeter, clamp-on testers, calibrators etc

� Time Interval

Analyzer

� Portable Test

Instruments

DL9000 Two-in-One

DL750P

Time Interval Analyzers

TA720Mobile Phone Tester

� Wireless

Communicatio

� Optical

Spectrum

Analyzer

Optical spectrum

AQ6370

Production Control and Safety Management System

Foundation

Most of Control System Configuration PracticesMost of Control System Configuration Practices

V netV net

EthernetEthernet

GSGWGSGW

EthernetEthernet

SubsystemGateway

PROFIBUSPROFIBUS--DPV1DPV1

Discrete I/O Drive

DeviceNetDeviceNet

Photoelectricdevice

PLCPLC

FCJ/FCNFCJ/FCN

OPC OPC ServerServer

EthernetEthernet

Safety Safety SystemSystem

Other Other SystemSystem

Industrial Challenge for Performance Improvement

- 10 -

Current Industrial Practices Challenging

Quality

• High value of product

• Product competitiveness

Efficiency

• Cost efficient

• Green concept implementation

PROCESS PROCESS &&

OPERATIONOPERATION

POLICYPOLICY

Efficiency • Green concept implementation

Safety

• Plant operation safely

• Environmental safe and friendly

EQUIPMENTEQUIPMENT(CONTROL (CONTROL SYSTEM)SYSTEM)

�� How does the industry produce high quality How does the industry produce high quality products to be offered to market ?products to be offered to market ?

�� How does the industry to ensure the products How does the industry to ensure the products

Challenge in QUALITY

�� How does the industry to ensure the products How does the industry to ensure the products competitiveness in the market ?competitiveness in the market ?

�� How does the industry operate the plant How does the industry operate the plant operation with high efficiency level ?operation with high efficiency level ?

Challenge in EFFICIENCY

operation with high efficiency level ?operation with high efficiency level ?�� Does the industry comply to the “green Does the industry comply to the “green

industry” policy for their operation ?industry” policy for their operation ?

�� How does the industry operate the plant with How does the industry operate the plant with high safety level ?high safety level ?

Challange in SAFETY

high safety level ?high safety level ?�� How does the industry to comply to the How does the industry to comply to the

environment standard & policy ?environment standard & policy ?

Control Technology and ImprovementStrategy

- 15 -

Clear Path of Improvement Strategy

The new world standard controller for field-digital Era

Release 5

Processing performance : 4 times faster

Application storage capacity: 2 times larger

Control network throughput: 5 times greater

Signal Types Yokogawa’sCurrentController

A Company’sLatestController

B Company’sLatestController

Yokogawa’sNewController

Recent Control Equipment Update …

4-20 mA

1200 devices

400 devices

250 devices

350 devices

300 devices

400 devices

1700 devices

1200 devices

YFGW710FIELD Wireless Integrated Gateway

EJX118BDifferential Pressure Transmitter with Diaphragm Seal

YTA510Temperature Transmitter

EJX110B/EJX430B/EJX310BDifferential Pressure Transmitter

EJX210B Flange mounted Differential Pressure Transmitter

YTMX580Wireless Temperature Multiplexer

EJX510BAbsolute and Gauge Pressure Transmitter

The Fiber is the sensor

T1 T2 T3 T4 ……….

Safe – No electronics – explosion proof & non-inductive

Distributed Measurement: 1m spatial resolution

Measurement of 5km fiber = 5,000 sensors!

DTS Instrument

(interrogator)

Distributed Temperature Sensor (DTS)

Latest Technology for Monitoring Asset

Anti-Stokes Stokes

Rayleigh

Wavelength

Standard multi-mode optical fiber

1m pulse of light

Backscattered light provides

temperature at every 1m.

T4,999

T4,998T4,997

T4,996

T4,995

Fiber Sensor Cable (3P)

Yokogawa Modern Control Hierarchy/Technology

Plant Information Management SystemRobust Quality Estimator

Multi-Variable Model Predictive Control

Operational Efficiency Asset Management

Advanced ControlPlant Information Management

ProductionManagement

Asset Management andOperational Efficiency

Production Control and Safety Management

Event Analysis PackageOperation Efficiency Improvement Package

Integrated Production Control System Safety Shutdown Management SystemNetwork Based Control System

Plant Resource Manager

Production Control and Safety Management

Safety Management

Data Acquisition andLogic Control

Analysis andQuality Control

Sensing and Actuation

Control System Strategy for QUALITY Improvement

QUALITY aspects for improvement objects :�� Raw MaterialsRaw Materials

� The raw material quality will impact to the entirely product output, both of quality in spec and market

acceptable/competitiveness

�� Operation MethodOperation Method

�� Operation MethodOperation Method� Operation method may significantly impact to the quality performance. The strategy to optimize an operation method could enhance the maximum benefits within cost effective

�� ProductsProducts� As an output of series of process, its was definitely depend on the result. Final products handling was still need to be

addressed to maximize its quality

Sample – Maximizing operation method with PID Tools

Zone temperature controls are fluctuating due to line speed changes.

Average zone temperature is set 6% higher than preferable condition to keep required heat capacity.

Dryer and control equipmentControl Loops Dryers - Problem

keep required heat capacity.

Target

temperature

Zone temperature

Actual

temperature

Temperature sensors Control valves

Dryer temperature pattern

Control Loops Analysis

Solutions

– InsightSuiteAE’s “Control loop diagnostician” and “Control valve diagnostician”

– “TuneVP” tuning simulator

– For fine tuning of control loops

Effect Target

Actual

temperature

(1) Minimize

fluctuation

TuneVP (Tuning simulator)

Expected tuning result

Control Loops Dryers - Solution

Effect

– Drying steam saving by lowering zone temperature pattern

– Air compressor power saving

(Indirect effect: Less product quality variance)

Target

temperature (2) Lowering set point

(3) Expand to all zones

Control Loop Performance

Control loops tuning (Before) Control loop tuning (After)

Disturbance: Line speed change

(+ interference from up stream zones to

down stream zones.)

Temperature/

Line speed

Temperature/

Line speed

Control Loops Dryers - Results

Dryer temperatures

Zone 1, Zone 2

Zone 3, Zone 4

Zone 5, Zone 6

Time Time

Improvement Strategy on EFFICIENCY Aspect

EFFICIENCY aspects for improvement objects :

�� Production Cost ManagementProduction Cost Management� Effective production cost management will improve the

economical benefit for entirely plant operation. Maintenance cost as one of the component can be a focus

point of efficiency factor

�� Resource (Energy) SavingResource (Energy) Saving� International standard required the industrial practices to manage the energy usage which may impact to the global warming. Energy saving program with emission controlling

is now an issue for most of industrial practices

Sample – Maximizing Energy Usage with STA/WP

Core solution package of Yokogawa’s Onshore Gas Wellhead Portfolio.

Page.25

Architecture

Page.26

Wellhead Configuration for Wireless Instrument

Tubing pressure

Solar panel

Antenna

1km or more

Casing pressure

100Base-T

Solar voltage13 - 14VDC

Antenna cable

Access point

Battery

Standard Enclosure Hardware Pack

FCN-RTU

SA0 model

20A 12V

Solar Charger

Arrestor

(for serial)

FCN-RTU

FTA Board

Grounding bar

Control System Strategy for SAFETY Improvement

SAFETY aspects for improvement objects :

�� Plant safety levelPlant safety level� Plant safety is designed to secure and safe the production process during operation stage. Any of safety risk factor

has to be analyzed for protection system

�� Environmental friendlyEnvironmental friendly� Any of safety risk and its impact has to be analyzed for plant operation protection only. It was required to ensure

the protection system for environment surround on operated plant

Hazard

DemandDemand

HazardRate

Risk Reduction

Reduction

Consequence

SensorSensor

Process

PASPAS

(Centum(Centum

SCADASCADA

(Fast Tools)(Fast Tools)

Control System

OperatorOperator

InterfaceInterface

SensorSensor

3 X3 X LogicLogicSolverSolver(ProSafe (ProSafe

Sample – Maximizing safety operation with SIS

ValveValve

(Centum(Centum

CS 3000)CS 3000)

AnnunciationAnnunciation

InterfaceInterface

= Safety related

ValveValve

(ProSafe (ProSafe RS)RS)

ESD panelESD panel

The Prosafe-RS Safety System

Vnet/IP ProSafe-RS

EJX YTAProSafe-SLS

Summary

- 33 -

Summary session

Recent control system technology has widely developed and involved several aspects of industrial application concerning to the process knowledge, safety, IT and others

Recent industrial practices has had a challenging to improve their performance in order to get a widely benefits in both aspects, economical and plant reliability

aspects, economical and plant reliability

Control system latest technology is one of the aspect to do an improvement in industrial practices in term of quality, efficiency and safety

Thank You For Your Attention

- 35 -

CONTROL TECHNOLOGY UPDATE : “A ROAD TO PLANT...

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