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CONTROL TECHNOLOGY UPDATE : “A ROAD TO PLANT PERFORMANCE IMPROVEMENT”
Copyright © Yokogawa Engineering Asia Pte Ltd - 1 -
“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
Copyright © Yokogawa Engineering Asia Pte Ltd - 2 -
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
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Current Industrial Practices Sector in Indonesia
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Sensing and Actuation Equipment
• Flow, Pressure, Level, Temperature• Valve Positioner & Camera
Differential Pressure Transmitter
DPharp EJXAll weather CCD Color CameraTemperature Transmitter
YTAAdvanced Valve Positioner
YVP
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FOUNDATION is a registered trademark of Fieldbus
Foundation
Magnetic Flowmeter
ADMAGVortex Flowmeter
digitalYEWFLO
Differential Pressure Transmitter
DPharp EJX
Ultrasonic Flowmeter
US300
All weather CCD Color Camera
Variable Area Flowmeter
ROTAMETER
Temperature Transmitter
YTA
Coriolis Mass Flowmeter
ROTAMASS
Advanced Valve Positioner
YVP
Analysis and Quality Control Equipment
Dissolved Oxygen Analyzer
TMI
Stack Gas Analyzer
• Gas Analyzers (oxygen, IR gas, density, chromatograph)
• Liquid Analyzers (pH/ORP, conductivity, turbidity, residual
chlorine, alkalinity, MLSS, DO, density,
water quality)
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FOUNDATION is a registered trademark of Fieldbus
Foundation
pH / ORP, Conductivity Analyzers
EXA seriesProcess Gas Chromatograph
GC1000 MarkⅡ
Dissolved Oxygen Analyzer
DO402Zirconia Oxygen Analyzer
ZR402GStack Gas Analyzer
SG800
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
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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
VC200
� Wireless
Communicatio
ns
� Optical
Spectrum
Analyzer
Optical spectrum
AQ6370
Production Control and Safety Management System
Copyright © Yokogawa Engineering Asia Pte Ltd - 8 -
FOUNDATION is a registered trademark of Fieldbus
Foundation
:
:
:
Most of Control System Configuration PracticesMost of Control System Configuration Practices
V netV net
EthernetEthernet
GSGWGSGW
EthernetEthernet
SubsystemGateway
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ooo
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
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Current Industrial Practices Challenging
Quality
• High value of product
• Product competitiveness
Efficiency
• Cost efficient
• Green concept implementation
PROCESS PROCESS &&
OPERATIONOPERATION
POLICYPOLICY
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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
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�� 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
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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
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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
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Clear Path of Improvement Strategy
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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 …
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4-20 mA
FF
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
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Inte
nsi
ty
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
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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
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�� 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
Copyright © Yokogawa Engineering Asia Pte Ltd - 21 -
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keep required heat capacity.
Target
temperature
Zone temperature
Actual
temperature
Time
Temp
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
Temp
Control Loops Dryers - Solution
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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
Time
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
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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
Copyright © Yokogawa Engineering Asia Pte Ltd - 24 -
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.
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Page.25
Architecture
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Page.26
Wellhead Configuration for Wireless Instrument
Tubing pressure
Solar panel
Antenna
100m
1km or more
Copyright © Yokogawa Engineering Asia Pte Ltd - 27 -
Casing pressure
Temp.
12VDC
100Base-T
Solar voltage13 - 14VDC
Antenna cable
Access point
Battery
Wifi
RTU
Standard Enclosure Hardware Pack
FCN-RTU
SA0 model
20A 12V
Solar Charger
Arrestor
(for serial)
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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
Copyright © Yokogawa Engineering Asia Pte Ltd - 29 -
�� 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
Rate
DemandDemand
HazardRate
Risk Reduction
Copyright © Yokogawa Engineering Asia Pte Ltd - 30 -
Reduction
Consequence
DCS
Low
Consequence
SensorSensor
Process
PASPAS
(Centum(Centum
SCADASCADA
(Fast Tools)(Fast Tools)
Control System
OperatorOperator
InterfaceInterface
SensorSensor
3 X3 X LogicLogicSolverSolver(ProSafe (ProSafe
Vnet
Sample – Maximizing safety operation with SIS
Copyright © Yokogawa Engineering Asia Pte Ltd - 31 -
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
Copyright © Yokogawa Engineering Asia Pte Ltd - 32 -
EJX YTAProSafe-SLS
Summary
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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
Copyright © Yokogawa Engineering Asia Pte Ltd - 34 -
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
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