IAMKP-B-A041-SE Copyright © Yokogawa Electric Corporation 2006/12 Safety Excellence December 2006 Yokogawa Electric Corporation

IAMKP-B-A041-SECopyright © Yokogawa Electric Corporation2006/12

Safety Excellence

December 2006Yokogawa Electric Corporation

Page 2IAMKP-B-A041-SECopyright © Yokogawa Electric Corporation2006/12

Safety Excellence

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

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

Sustained over the life cycle of your plant


Safety Excellence

Agenda

What is Safety Excellence?The Yokogawa solutionsYour benefitsRoadmap for the futureSafety consulting & services


Safety Excellence

　

What is Safety Excellence?

How to address the entire loop to maximize both safety and availability


Safety Excellence

Integrated solutions designed with the entire safety loop in mind maximize both safety and availability at the same time

Integrated solutions not only reduce engineering time and cost but also minimizes engineering mistakes that compromise safety and availability

Maximizing both safety and availability

Sensors Logic Solver

Asset ManagementScheduled partial stroke test (PST)Device status & diagnostics

OperationsProcess alarms

&device alarms

ProSafe-RSDPharp EJX SVI-Ⅱ ESD

Processdata

Output

signal

Sensors Logic Solver Final Elements


Safety Excellence

What is safety?

Bring processes to safe conditions when needed

In the old model, simple signals (e.g. on/off) were used to trigger the safety loop. While assuring a certain level of safety, this model lacked:

- Mechanisms to ensure availability (preventing false trips) - Intelligent information exchange (diagnosis information, etc.)

Sensor Logic Solver Final Elements+ +

Assurance of safety (=safety integrity) is achieved by the entire loop


Safety Excellence

How about availability?

Malfunction of a safety loop device can cause a false trip and shut 　 the process down By far the biggest source of malfunction is the final element (valve)

Typical valve malfunction:

- Solenoid malfunction. Cuts air supply and causes false trip

- Shut-off valve malfunction. Moving parts left motionless for a long period 　 of time develop problems such as stuck valves.

30%

10%

60%

Logic solvermalfunctionLogic solvermalfunction

SensormalfunctionSensormalfunction

ValvemalfunctionValvemalfunction

Primary cause of safety applications failure


Safety Excellence

The Yokogawa solutions

Addressing the entire loop for safety and availability


Safety Excellence

Why not have the best of both worlds?

The vigilant approach delivers both uptime and peach of mind

Operatorsnow have an all-in-one interface to effectively handle both controland safety loops.

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

Asset Manager

DPharp EJXDigital Transmitter

ProSafe-RSIntegrated Safety System

SVI-Ⅱ 　 ESDDigital Positioner

PRMPlant Resource Manager


Safety Excellence

Certified transmitters (pressure)

The world’s first and only fully digital pressure transmitter Standard models are certified for use in SIL2/3 applications

Key Features:

- Certified IEC 61508 compliant by TÜV and Exida

- Inherently fail-safe silicon resonant sensor and reverse calculation mechanism secure 　 a safe failure function (SFF) of 93.2%

- Industry-leading PFD avg = 1.49E-04/year

- Inherently fail-safe silicon resonant sensor

DPharp EJXPressure Transmitter


Safety Excellence

Certified transmitters (temperature)

■ 　 Not only high-end models YTA310/YTA320 but also middle-range model YTA110 is certified by TÜV

■ 　 SIL2/3 capability is not option - No additional cost - Yokogawa guarantees high reliability both for safety and general usage products

Key Features: - Certified IEC 61508 compliant by TÜV and Exida

- SIL2 capability for single use and SIL3 capability for dual use

- The unique reverse calculation method secures a safe failure function (SFF) of 92%

- Failure rate of Fail Dangerous Undetected 　 (λdu) = 53 FIT

- Lifetime is 50 years

YTA110/310/320 Temperature Transmitter


Safety Excellence

Integrated safety controller

The world’s first truly integrated safety controller

SIL3 protection with simple, single configuration

Unified human-machine interface

Key Features: - TÜV certified SIL3 protection in single configuration - Compact modules fitting small to large applications - Flexible versatile modular redundant (VMR) architecture - Dual redundant configuration maximizes process availability - SIL3 safety communication between safety controllers using a common network with the control system - Inherits 99.99999 (seven 9’s) pair & spare CPU technology of CENTUM DCS - Supports the HART communication; enables PRM to integrate diagnostic information from intelligent safety devices

Integrated Safety System


Safety Excellence

TÜV Certification

had been certified as SIL3 by TÜV on 10th March, 2005.R1.02 has been certified on 23th October. 2006

IEC 61508, Part1 - 7:2000IEC 61511: 2004IEC 61131-2: Feb. 2003

EN 298: October 2003-9EN 50156-1:2004-10NFPA 85: 2001

EN 54-2: 1999-2NFPA 72: 2002


Safety Excellence

Smart solenoid certified for use in SIL3 applications

Provides advanced diagnostics using the HART protocol, including partial stroke testing

SVI-Ⅱ ESDDigital Positioner

Certified valve positioner

Key Features: - Non-contact position sensor - SIL3 rated when energized - Analog and digital diagnostic feedback - Multiple sensors for diagnostics - User control of stroke testing - Graphic representation of partial stoke - Stroke test completely in concert with / or independent from safety systems

※ Yokogawa is also working with Flowserve, Metso Automation, and Samson SG for safety valve collaboration solutions


Safety Excellence

Integrated asset management system

Integrated asset management platform maximizes asset availability

Keeps operators and maintenance crew fully informed of the current performance and anticipated conditions of plant assets

Key Features: - Intuitive visual interface to manage diagnostics information from intelligent devices

- Polls HART devices regularly to collect and distribute diagnostics information

- ValVueII plug-in applications on PRM manages scheduled PST

Plant Resource Manager


Safety Excellence

Your benefits

The total impact of the integrated approach


Safety Excellence

Comparison study by exida

A significant difference in availability, safety, and total cost of ownership

MTTFS : mean-time-to-failure spurious

PFD : probability of failure on demand

RRF : risk reduction factor

2oo3 Pressure transmitters, SIL3 logic solver, single remote actuated ball valve with 3 way solenoid.

20 years

2.68E-2 / 37

6 months

Higher

Very High

Ad-hoc solution

Single EJX pressure transmitter, ProSafe-RS SIL3 logic solver, single remote actuated ball valve with SVI-II ESD.

39 years

8.98E-3 / 111

5 years

Lower

Low

Yokogawa integrated solution

Description

MTTF

PFDavg /RRF

Proof testInterval

(Valve)

Capital cost

Lifecycle cost

>Doubles safety loop availability>Doubles safety loop availability

>Triples safety>Triples safety

>Extends valve proof test interval by ten times>Extends valve proof test interval by ten times

>Lowers capital cost and lifecycle cost>Lowers capital cost and lifecycle cost

The Yokogawa integrated solution:


Safety Excellence

For example...

　　 The 61508 certified EJX detects internal problem with diagnostics

EJX sends a 3.8mA signal to ProSafe-RS

ProSafe-RS recognize the signal as diagnostics and alerts the operator

Operations and maintenance collaborate to fix the problem while avoiding unnecessary shutdown

A case in point - avoiding false trip




&device alarms


Sensors Logic Solver Final ElementsOperatoralert

Output NormalNo false shutdow

n

Device alarm


Safety Excellence

A case in point - integrated asset management

For example...

PRM integrates EJX and SVI II device conditions through ProSafe-RS. PRM thereby integrates safety devices into a single unified plant asset management database

PRM helps preventive and predictive field device maintenance. PRM manages valve partial stroke test information and executes scheduled PST through ProSafe-RS




&device alarms


Sensors Logic Solver Final Elements

Device condition

PST Command

Device condition

Scheduled PST

Device condition


Safety Excellence

Roadmap for the future

Upcoming enhancements and future-oriented initiatives


Safety Excellence

Asset mgt

Production mgt

Alarm mgt, DCS-SIS integration

Health, Safety &

Environment

Asset Availability

& Utilization

Operational Agility

& Adaptabili

ty

2005 2006 2007 2008 2009-2010

Completion of VigilantPlant Operational Excellence solutions

Lifecycle Excellence

PE launch•FieldMate, PRM

•ProSafe-RS•EJX SIL2/3

VigilantPlant evolution

VigilantPlant & SE launch

AE launch

Safety Excellence

Asset Excellence

Production

Excellence

VigilantPlant Master Roadmap

•RS 　 R1.02•YTA SIL2/3

•RS 　 R1.03•DYF YVP SIL


Safety Excellence

ProSafe-RS as Safety Excellence platform

“This is beginning of the end of diverse and separated safety system.”


Safety Excellence

ProSafe-RS - technical evolution of SIS

CENTUM-XLCENTUM-XL

EOPSEOPS

CFCSCFCSEFCDEFCD

ENGSENGS

CENTUM CS3000CENTUM CS3000CENTUM CS3000CENTUM CS3000

HISHIS

PFCSPFCS

KFCSKFCSLFCSLFCS

COPS2COPS2

CENTUM VCENTUM V

CFFSCFFSCFCS2CFCS2

COPSVCOPSV

CFCD2CFCD2

HF-BusHF-Bus

1MBPSDual Redundant

Token Pass

1MBPSDual Redundant

Token PassCENTUMCENTUM

CFCDCFCDCFCSCFCS

COPSCOPSF-BusF-Bus

250 KBPSDual Redundant

Token Pass

250 KBPSDual Redundant

Token Pass

ABCABC

CENTUM CSCENTUM CS

ICSICS

EWSEWS PICSPICS

VnetVnet

10 MBPSDual Redundant

Token Pass

10 MBPSDual Redundant

Token Pass

1975

1983 1988

1993 1998

PLCPLC

RelayRelay

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

Panel/SingleLoop

Panel/SingleLoop Solid-StateSolid-State

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.

True

Inte

gratio

n


Safety Excellence

z

ProSafe-RS - vote of confidence

Ethylene

Lacq Gas Filed, Congo FPSO

4 Projects for Air Separator

Indonesia LNG (on/off-shore), China LPG, UK Offshore Gas

Filed

Angola onshore Terminal, Nerefco (Rotterdam)

LNG Terminal, UK & Italy

Methanol 1 Revamping

Refinery Modernization

Refinery modification

Offshore, Mumbai

Natural Gas Dev.

Sand Oil, Canada

Mitsubishi

Chemical

TOTAL

Air Liquide

BP

ChevronTexaco

ExxonMobil

SABIC(Al-Razi)

PEMEX

Petrobras

ONGC

Shell China E&P

BA Energy

Total 70,000 IOs with 102 projects (as of August 2006)


Safety Excellence

ProSafe-RS - further improvements in 2006

Integration w

ith PRM and Field

Devices

-AI with

HART 　　 -AO w

ith HART

Functional Im

provements

- AO

- Remote I/O

Vnet/IP In

tegration

-Enhancements of CS3000 In

tegration


Safety Excellence

Safety Excellence initiative continues

20102010

1997

2000

2005

1960

20072007

YTA - SIL2/3

ProSafe SLS-AK7

ProSafe PLC

EJX -SIL2/3

ProSafe-RS- ABS, Lloyds, BV- Type n, FM NI

ProSafe SLS-SIL4

ProSafe R1.02-Vnet/IP Integration-Enhancements of CS3000 integration

ProSafe-RS R.1.01- SIL3

2 0 0

6

2 0 0

6

DYF -SIL2/3

ProSafe R1.02-AI with HART-AO with HART

ProSafe-RS R1.03

20082008

YVP/FVP

-SIL2/3


Safety Excellence

EJX

Pressure

SIL2/3

Done

YTA

Temperature

SIL2/3

Done

DYF

Flow

SIL2/3

2007

YVP/FVP

Positioner

SIL2/3

2008

Expanding certified field instruments line up

Safety is not an option - standard field instruments certified for SIL2/3 applications without any add-on component.


Safety Excellence

Keep supplying the SIL4 system

Over 1,000 systems from 1960’s Top level of sophisticated and superior Fail-safe design Meets AK7/SIL4 requirements SIL4 Certification by TÜV @2006 Solid-state base

Inherent safety system

ProSafe series cover all safety levels (SIL1 to SIL4).


Safety Excellence

Safety consulting & services

Certified organization and experts at your service


Safety Excellence

Certified organizations

A worldwide network of over 200 engineering experts ensures IEC61508/61511 compliant safety solution implementation

Safety experts in your region at your service for:

- Hazop studies

- Loop SIL calculation

- etc.


Safety Excellence

Conclusion

Yokogawa value propositions with Safety Excellence


Safety Excellence

Reduce blind spotsUnified operator interface to control and safety

Avoid surprisesIntegrated diagnostics and asset management

For your Safety Excellence Yokogawa helps to:

Yokogawa integrated solutions covers all your safety requirement, maximizing safety and availability.

SEECLEARLY

KNOWIN

ADVANCE

Preempt bottlenecksOptimum safety and maximum uptime

ACTWITH AGILITY


Safety Excellence

Safety Excellence Solutions that maximize both safety and availability.


Safety Excellence

Appendix


Safety Excellence

FF-SIS FF-SIS aims to add safety communications protocol in FOUNDATION fieldbus communications Protocol itself is approved by TÜV. Testing and evaluation using prototype equipment is expected to start towards the end of 2007


Safety Excellence

Yokogawa is an active member of the FF-SIS work group

FF-SIS

Documents

IAMKP-B-A041-SE Copyright © Yokogawa Electric Corporation 2006/12 Safety Excellence December 2006 Yokogawa Electric Corporation