IAMKP-B-A040 Copyright © Yokogawa Electric Corporation July 2006 The Clear Path to Asset Excellence - Vision & Concept - July 2006 Yokogawa Electric Corporation

IAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006

The Clear Path to Asset Excellence - Vision & Concept -

July 2006Yokogawa Electric Corporation

Page 2Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006

VigilantPlant Operational Excellence model

Excellence in production, asset, and safety sustained over the life cycle of your plant

Asset Excellence: for Asset availability and utilization

Production Excellence: for operational agility and 　　　 adaptability

Safety Excellence: for health, safety, and environmental (HSE) protection

Sustained over the life cycle of your plant


Maintenance management implications

A recent survey of maintenance management effectiveness in U.S. revealed that:– Maintenance costs can represent between 15

and 60% of the cost of goods produced– One-third of all maintenance costs is wasted as

the result of unnecessary or improperly carried out maintenance

– U.S. industry spends more than $200 billion each year on maintenance of plant equipment and facilities

– The result of ineffective maintenance management represents a loss of more than $60 billion each year

Source: An Introduction to Predictive Maintenance (2002) Keith Mobley


Operational effectiveness implications

-60 -40 -20 0 20 40

Unplanned Breakdowns

Spare Parts Inventory Costs

Production Downtime

Product Defects

Plant Availability

Workforce Efficiency

Asset Performance

% Improvement Beyond Maintenance

Source: ARC Advisory Group

P lant A sset Management (PAM) Offer Solutions Beyond Maintenance to Operations


• Reduce maintenance cost >50%*

• Reduce equipment failures 55 % avg*• Reduce expediting cost 60%*• Reduce insurance premium• Reduce energy cost

• Improve productivity 20-30%*

• Reduce spare part inventory >30%*• Increase equipment life >30%*

• Increase availability 30% avg*• Improve planning• Improve product quality

Value Creation Potential

Source:*Mobley, R. Keith, An Introduction to Predictive Maintenance (Survey based on 500 plants of various types)

Typical Payback: 10 times ROI or 6-12 months payback

Predictive maintenance benefits

IncreaseRevenue

Reduce Costs

Optimize Assets

ProductivityProductivity

GrowthGrowth


AE key components and customer benefit

Asset Excellence key success factors and core building blocks


Quality & Reliability

Reliable

Asset Reliability



Reliable

Asset Availability

+Maintainability

Available



Reliable

Asset Predictability

+Maintainability

Available

AdvancedDiagnostics+

Predictable



Reliable

Asset Performance

+Maintainability

Available


Predictable

Continuous improvement+

Sustainable

Asset Excellence



Reliable

+Maintainability

Available


Predictable

Continuous improvement+

Sustainable

The clear path to Asset Excellence

Asset Excellence


01

Asset ReliabilityReliability for non-stop production

The Operator PriorityDaily use of plant assets for safe and agile production

The Operator can focus on true process concerns, trusting in the reliability of the integrated production control system.


Reliability built in our Systems

Seven-9 (99.99999%) ultra high system reliability ensures fault avoidance and tolerance for plant operation

– Duplex key components: “Pair & Spare” CPU, power, network– Hot swappable I/O module– Advanced self diagnosis


Reliability built in our field devices

Dramatic reduction in instruments failure.- One-digit (10 times) difference in “mean time between failure”

Fundamental difference in performance metrics and maintenance costs.-0.1% of URL (Upper Range Limit) for 10 years, under all temperatures, static pressure, and overpressure.


Asset Reliability benefits

Minimize unplanned downtimeMission critical control with no system failure-induced shutdown

Minimize performance deteriorationUltra-stable process value measurement with near-zero

maintenanceBetter process stability, Less variabilityMore accurate control with better data quality


02

Asset AvailabilityMaintainability in the field

The Field Technician PriorityQuick engineering and efficient maintenance of field assets

The Field Technician can count on a versatile and integrated tool to perform life-cycle engineering and maintenance in the field.


World’s first portable field device engineering and maintenance tool supporting both DD & FDT/DTM

Innovative new tool for maintainability in the field

Viewer

Configuration

Setting & tuning

Log (Audit trail)

DD&FDT/DTM

Diagnostics


Faster commissioning and start-up

FieldMate as CAPEX saver

Field Devices

Yokogawa

Vendor A

Vendor B

EJX/EJA DYFAXF ROTAMASS

Multi devices

Multi vendors

Multi protocols

Multi presentationtechnologies

YTA Analyzers

・・・YVP

“One Tool for All”


Life cycle device

information management

FieldMate as OPEX saver

“One Tool over Device Life Cycle”

Shutdown Maintenance

Replacement

Configuration & Setting

Loop Check, Commissioning

Daily maintenance

One D/BOne D/B

Any timeAny time

EverywhereEverywhere

EveryoneEveryone

Maintenance Engineer

Instrument Engineer

Field Operator


Asset Availability benefits

Shorten commissioning & start-up- One tool for All field devices

Improve maintainability- Easy and faster tuning, calibration, and checking - Safety remote maintenance work with less people in the field

Shorten turnaround time- Quick replacement, Trouble-shooting

Maintenance knowledge management- One tool over device life cycle- Information sharing among operation & maintenance crews in

one common device database


03

Asset PredictabilityOnline monitoring and predictive diagnosis

The Maintenance Personnel PriorityMaintenance optimization for maximum plant uptime

Maintenance Personnel can easily diagnose asset conditions, ensuring asset availability while optimizing maintenance.


The positioning of PRM

Operation Maintenance

Plant Floor


The positioning of PRM

Board OperatorBoard Operator

quantum

Plant Floor

Maintenance EngineerMaintenance Engineer

Control System

Process DataServer Device

Master

Dashboard Solution

Cxx

Operation Maintenance

Control Diagnostics


Device status viewing

Audit Trail

Tuning, Adjustment & Calibration

Maintenance Information Management

Maintenance Alarm

Advanced Diagnostics

Integrated platform for maintenance & diagnosis

Core Integrated Maintenance Platform

Online Maintenance Core

Predictive Diagnostics Core


PRM as open asset management core

Integrated Device Management DB

On-line, remote maintenance from workshop

Full access to overall plant asset

Web enabled

Instruments & valves

Equipment & Process

•Rotating•Machiner

y

quantum

ERP

CMMS

Engineering

Web

MaintenanceEnterprise

Production

Safety

Device management

tool

Open interfaceOpen interface


PRM integrates predictive asset intelligence all over the plant

PerformanceDiagnostics

Loop & Equipment Diagnostics

DeviceDiagnostics

Process interface Diagnostics

PRM as predictive diagnosis core

•Sensor•CPU, Memory•Amplifier•A/D converter•Ambient temp

•Impulse line blocking•Steam tracing•Electrode adhesion•pH electrode•Valve signature

•Heat exchanger•Pump•Compressor•Control valve

•Control area monitoring•Valve total works•Device & process abnormality

PRM Advanced DiagnosticApplication Tool (PAA)


Classification

Interpretation

Notification

Predictive intelligence collection

Maintenance work prioritization

Alarm & guidance for actions

Alerting the right people with the right information

Board OperatorBoard Operator Field OperatorField OperatorMaintenance EngineerMaintenance Engineer

Predictive Diagnostics InformationOnline Maintenance Information

Collaboration between Operation and Maintenance

Central Diagnosis Engine


Asset Predictability benefits

Shorten commissioning & start-up- Quick online diagnosis- Efficient design and configuration by standardization

Eliminate unnecessary site trips- Quick online diagnosis

Minimize planned downtime- Optimize maintenance w/ predictive diagnostics

Shorten turnaround timeGenerate collaboration between Operation

and Maintenance- Maintenance function as a Reliability Team, not a Repair Team- Shift maintenance paradigm as a Process, not an Event


04

Plant Management can tap the wealth of diagnosis know-how and performance improvement solutions to ensure asset excellence over plant life cycle.

Asset PerformanceContinuous performance improvement

The Plant Management PriorityContinuous improvement of asset utilization and performance


InsightSuiteAE maximizes Asset Performance

The Yokogawa InsightSuite™AE Asset Excellence Services is a suite of consultancy, diagnosis, and optimization services that maximizes asset performance.

Sustainability

Reliability

Quality

Predictability

Availability

Maintainability

Yokogawa GLOBAL Response Center


Maximize asset life time- Installation environment diagnosis

Prevent performance deterioration- Monitor and diagnose asset performance

Maximize ROI- Maximum productivity (ROA)- Minimum operation, maintenance, and safety costs- Reduced manning

Quick and right decision making- Fact-based- Proactive

Asset Performance benefits


The Vigilant Integration Partner (VIP ) Initiative and other collaborative efforts

Open and Best-in-Class Collaboration


Open & best-in-class collaborations

CENTUM CS 3000 & PRM Plant Resource Manager

CENTUM CS 3000 & PRM Plant Resource Manager

Control Valves FieldInstruments

Condition Monitoring

Open Standards(FDT&EDDL)

Operators and Maintenance Personnel

Operators and Maintenance Personnel

VIP InitiativeVIP Initiative an open non-exclusive standard-based interoperability-driven partnership

(OPC)

Collaboration with:Collaboration with:


Yokogawa value propositions with Asset Excellence

Conclusion


Asset Reliability- Daily use of plant assets for safe and agile production

Asset Availability- Quick engineering and efficient maintenance of field assets

Asset Predictability- Maintenance optimization for maximum plant uptime

Asset Performance- Continuous improvement of asset utilization and

performance

Asset Excellence key success factors summary


With openness & interoperability...

Open & Interoperable solutions enable plant-wide collaboration for Asset Excellence

Condition Monitoring

For Maintenance Engineers

For Plant Managemen

t

• Process• Unit

And Operators as well

For Field Technicians

Instruments & valvesInstruments & valves


Yokogawa helps you achieve Asset Excellence

Minimum plant downtime, maximum asset utilization

Reduce blind spotsMonitor plant-wide asset conditions

Preempt bottlenecksOptimize operation and maintenance

Avoid surprisesPredict asset conditions and avoid downtime


Asset Excellence Solutions that maximize performance of assets and productivity of

production.

Documents

IAMKP-B-A040 Copyright © Yokogawa Electric Corporation July 2006 The Clear Path to Asset Excellence - Vision & Concept - July 2006 Yokogawa Electric Corporation