YOKOGAWA AUSTRALASIAN NETWORKNational toll free number: 1300 558 965

Sydney: 02 8870 1100, Adelaide: 08 8415 2600, Brisbane: 07 3902 6600, Melbourne: 03 8804 8800Newcastle: 02 4016 2100, Perth: 08 6465 6600, Gladstone: 07 4972 6044, Townsville: 07 4779 9155

Auckland: 09 255 0496, Christchurch: 03 348 0066, New Plymouth: 027 667 7226Internet: www.yokogawa.com/au Email inquiries: inquiries@au.yokogawa.com

Contributors to this issue: Megan Fisher, John Kemp, Simon Lillie, Philip Nicholson, Paul Twigg, David Walker, Mike Wallis

Editor: Lindsay Hadland

The Newsletter of Yokogawa in Australasia Third Quarter 2009

The Foundation in Australia 2

7State of the Art AnalysisA Century of Excellence

3Automation Replacement Completed at Large Onshore Oilfield

6Product Releases

5Integrating DCS & SCADA Migrating to Centum usung SIOS

1 Zenith Award for Energy Brix and Yokogawa

4Integration Made Easy

8

Continued on page 2

Yokogawa Australia and our customer

Energy Brix Australia Corporation (EBAC)

have won the 2009 PACE Zenith Award in

the Transport, Power and Infrastructure

category. This is the third year in a row

that a Yokogawa Australia project has

been a finalist in the Zenith Awards.

This year’s award was for the project to

modernise the control systems at the

Energy Brix power station in Morwell,

Victoria. Completed in 2008, the project

was successful in:

Zenith Award for Energy Brix and Yokogawa

To celebrate the release of FieldMate R1.03, Yokogawa is offering readers of Connections a special price on FieldMate and Yokogawa hand-held

communication products on orders placed by August 31, 2008.

8Expert Safety Training

News Tid Bits

reducing station operating costs

generating additional power for export

improving plant operating flexibility

providing modern conditions for plant

operators

reducing station operating and

maintenance costs

improving plant emissions.

“This project was quite remarkable for

the complexity and innovation of the

engineering involved in installing 21st

to reapply to TÜV Rheinland for

revalidation. Suitable evidence of

continuing experience and education

must be submitted.

Yokogawa has three TÜV certified

Functional Safety Expert trainers who

are able to conduct the training course

on a world-wide basis, and to date, over

10 courses have been completed and

many others scheduled.

The course comprises three and a

half days of training lectures, followed

by a four hour examination. Prerequisites

include three years’ functional safety

experience and a bachelor degree or

News Tid Bits

This month marks the 10th anniversary of the introduction of

Yokogawa’s DAQstation, which replaced paper chart recorders with

digital data acquisition and display stations in control rooms around

the world. Revolutionary at the time, the DAQstation was a stepping

stone to a full-blown DCS; it visually mimicked what chart recorders

had provided but added a lot more functionality. The DAQstation has

evolved to provide additional functionality, with the latest model, the

DXAdvanced R3, offering user-customisable display screens and an

intelligent annunciator system with data display and recording

functions that can replace common annunciator lamp panels.

Yokogawa’s WT3000-2A and WT210 digital power

meters are now certified to carry out the standby power tests specified in

the new IEC 62301 standard. Key parameters whose limits are specified in

IEC 62301 are total harmonic distortion (THD), crest factor, accuracy,

resolution and stability at different power levels, and the ability to record

true average power over a period of more than five minutes

Expert Safety TrainingDid you know that Yokogawa has been

authorised by TÜV Rheinland to

conduct Safety Training, and at the end

of the training, subject to successfully

passing an examination, attendees

receive a certificate from TÜV Reinland

certifying them as a TÜV Functional

Safety Engineer?

Successful students also have the right

to use the TÜV logo on their business

cards and correspondence, and will be

listed on the TÜV website as FS

Engineers.

Each certificate is valid for five years,

after which time the FS Engineer needs

equivalent engineering experience. The

cumulative pass rate to date has been just

under 70% of students attempting the

examination. Any student who does not

pass may re-sit it within one year of their

first attempt.

Yokogawa is planning to run a course

in Australia within the next six months.

Readers may submit expressions of

interest in attending the course to

inquiries@au.yokogawa.com

Yokogawa New Zealand has been selected by Environment Canterbury (ECan) as an Authorised Water Meter Equipment Supplier for the Rakaia Selwyn Groundwater Zone. The two Yokogawa flowmeters that have been approved by ECan meet the needs of farmers who are now required as part of their water consent to install approved water meters to measure their irrigation water take.

Yokogawa has won a contract to supply control systems and

instrumentation for the Vung Ang 1 power plant in Vietnam. The plant

will have two 600MW units, with the first planned to be operational

by mid-2012. Situated in the Ha Tihn province, the plant is being built

for the Vietnam Oil and Gas Group (Petrovietnam). The Yokogawa

contract has an estimated value of US$16.6 million.

The Energy Brix power plant in Morwell, Vic.

Pho

tog

rap

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y Lu

ke S

hort

al

Yokogawa has published its annual report

for the financial year ended March 31,

2009. Highlights of the year included the

strengthening of product lineup in

response to market needs, with the launch

of a new manufacturing execution system

platform that contributes to improved

production efficiency, and the release of

highly durable, low power consumption

control and monitoring modules. More

than 60% of sales in the industrial

automation and control business were

made outside Japan.

2 7

century control systems

technology onto older plant,” said

John Hewitt, Managing Director

of Yokogawa Australia. “Not only

has the project increased the

reliability of the electricity

supply, it has done so while

simultaneously improving

protection of the plant,

reducing maintenance costs

and optimising the use of

raw fuels.”

Yokogawa has been provid-

ing control systems for power

plants for many years. However,

Energy Brix presented some

unique challenges, particularly for

Yokogawa’s younger engineers.

Some of them were working for the

first time with a power plant equipped

with steam ranges and pass-out turbines

— where all boilers feed a common

steam range supplying multiple turbines,

some of which then supply a process

steam range and a low pressure

condensing turbine. This complex interac-

tive configuration contrasts with most

modern plants, where boilers and

turbines are installed as unit plants in a

much simpler one-to-one arrangement.

One significant achievement of the

project was the automated optimisation

of energy used for total plant operation,

replacing what had been a much more

manual approach. This was made possible

by the installation of digital controllers on

the turbines and load sharing controllers

on the boilers.

The PACE Zenith Awards were

established in 2004 by Process Control

and Engineering (PACE) magazine to

publicly recognise companies that show

leadership in engineering and

technological excellence and innovation.

The awards are presented annually, with a

record number of entries received in

2009. Yokogawa projects have previously

won awards in 2005, 2007 and 2008.

The Fieldbus Foundation visited Australia

in August to meet with local equipment

suppliers, with a view to establishing an

Australian Marketing Committee to pro-

mote the features and benefits of

Foundation Fieldbus to the local market.

The Foundation has been championed

in Australia for many years by the

Foundation Fieldbus End Users’ Council,

however the Foundation feels that a sep-

arate Marketing Committee would pro-

vide a supplementary function and more

focussed approach to promotion of the

technology. Such a structure is similar to

that existing in many other countries

The Foundation in Australiawithin the region and the rest of the

world.

Mr Hisashi Sasajima, Vice President for

Asia Pacific, and Mr Shane Parr, Chairman

of the Asia Pacific Executive Advisory

Council, visited Australia to share the

Foundation’s vision.

All delegates to the meeting were

enthusiastic and agreed to the formation

of a Marketing Committee. Mr Tom Rolton

of Emerson was elected Chairman of the

Committee. He will be assisted by

Committee members Shaun Loesch of

ABB, Lindsay Hadland of Yokogawa, and

Andrew Sia of Rockwell.

Delta Electricity has ordered two

Yokogawa generator analyser panels for

installation at its Munmorah Power Station

on the NSW Central Coast.

At this plant, hydrogen (H2) is used to

cool the generators. The merits of H2 as a

coolant are its capacity to cool while

causing only minimal drag or friction

between the generators’ moving parts,

thus increasing efficiency. The potential

downside, however, is that if the H2

becomes mixed with oxygen, it can

become explosive, and thus a significant

safety hazard.

In normal operation, the gas blanket

inside the generator is monitored to

ensure that the H2 is pure. When the

generator needs to be shut down for

maintenance, the hydrogen is removed by

flushing it out with carbon dioxide (CO2);

the CO2, in turn, is flushed out with

breathable air so that access to the

generator is safe. When the generator is

put back into service, the process is

reversed: air is flushed out with CO2,

then the CO2 is swept away with H2. The

process is referred to as the Generator

Purge Cycle.

Using traditional gas analysis

techniques, three separate analysers

would be needed to monitor all stages

of operation and the purge cycle.

But, using state of the art

technology from Yokogawa, only a

single GD402 Gas Density Analyser is

required. Delta however chose to use

two analysers for operational reasons.

The GD402 is exceptionally stable and

reliable and is becoming the choice of

the power generation industry for

these applications.

In conjunction with Delta,

Yokogawa has designed,

manufactured, commissioned and

documented a complete process

analyser system that enables the

operation and purge cycle for the

two Munmorah 350 MW

generators to be measured. The

system was designed so that it

minimises the effects of oil and

moisture in the sample stream. Pressure

measurement was included to provide

compensation for changes in operating

pressure in the generator

cooling hydrogen; such compensation

State of the art analysis

can be performed by the GD402 Analyser.

The first system was installed and com-

missioned in June and a second identical

system has now been delivered.

Local suppliers meet with Fieldbus Foundation executives.

The analyser system installed at the Munmorah Power Station.

Celebrating a century of excellenceRota Yokogawa will be celebrating 100

years of production of high quality

flowmeters for industrial applications

next month. Founded as Deutsche

increasingly automated with sizeable

investment in production equipment,

robots and automated test rigs. Further

investment of tens of millions of Euros is

planned in buildings and plant in the next

few years.

Today, Rota Yokogawa develops and

manufactures high-quality flowmeters

based on five measuring principles: floats,

magnetic-inductive, vortex flowmeters,

Coriolis and differential head. Calibrations

are carried out in the company’s own

DKD-certified facility, which also provides

a calibration service to other companies.

With outstanding products and an

excellent business performance in recent

years, Rota Yokogawa is in good shape for

the future. The continuous development

of new and existing measuring devices

will ensure that customers around the

world are supplied with top quality

Yokogawa flowmeters.

An RAMC02 Rotameter from Rota Yokogawa.

Rotawerke in the German town of

Aachen in 1909, Rota Yokogawa became

part of the Yokogawa Electric Corporation

in 1995.

The early years of the business were

focussed on production of the recently-

invented Rotameter, a float-based

flowmeter. The company was so

successful that ‘Rotameter’ is often used

as a generic term for any flowmeter of

this kind, not just Yokogawa’s.

Today, Rota Yokogawa continues as

the company’s worldwide centre of

excellence for flowmeters, which

now include mass f low

measurement using the Coriolis

principle as well as Rotameters.

Manufacturing floor space has

recently been enlarged by 40% with

the opening of one of the most modern

and innovative production lines of its

kind. Production has also been

Main Benefits of Foundation Fieldbus Technology

reduced wiring and installation costs

reduced control/equipment room space (no marshalling)

easy integration with asset management systems

saving in operations and maintenance through superior diagnostic availability

Peter Morrow, General Manager of EBAC (left) and Philip Nicholson, Principal Engineer of Yokogawa Australia (centre) accepted the PACE Zenith Award from Jeremy Needham of Mitsubishi Electric, sponsors of the Transport, Power and Infrastructure category.

Zenith Award for Energy Brix and Yokogawa cont'd

6 3

Automation replacement completed at Western Europe’s largest onshore oilfieldYokogawa UK has successfully completed

a full replacement of the control and

safety systems for BP’s Wytch Farm

oilfield project in Dorset.

Developed by BP, Wytch Farm is Western

Europe’s largest onshore oil field, with

estimated recoverable reserves of 480

million barrels. It is located in one of the

most environmentally sensitive areas of

the UK.

The Wytch Farm oilfield comprises

three separate oil reservoirs that lie under

Poole Harbour and Poole Bay in Dorset

on the south coast of England. The

operation, comprising a central oil

gathering station and a number of remote

well sites, was established in the early

1980s, and the recently completed

automation replacement project was part

of a development plan that will enable its

operational life to be extended.

Yokogawa was selected by BP as the

main automation contractor (MAC) for

the project, and the Yokogawa project

team worked closely with the BP team

during the project implementation. The

major challenges were the initial

definition of the project scope and

requirements in a front-end engineering

and design (FEED) study. It included a

site survey, document verification,

changeover planning and interface with

existing infrastructure. This was followed

by the implementation of a smooth hot

cutover to the new integrated control

and safety system during the

commissioning phase.

The integrated control and safety

system is based on the Yokogawa CENTUM

CS 3000-Vnet/IP distributed control

system, the ProSafe-RS safety system for

emergency shutdown and burner

management, and STARDOM network-

based controllers for use as remote

terminal units.

This project replaced the existing

control system, safety system, dual

redundant PLC system, process

automation controllers, and SCADA/RTU

previously used to monitor and control

the gathering and processing operations.

During the FEED phase, the Yokogawa

FEED team was resident at Wytch Farm for

site survey work, liaising with the BP

engineers and collecting the engineering

data necessary to complete the FEED

before commencement of the detailed

design. A one-team approach by BP

and Yokogawa was achieved by

managing the business relationship in an

open, performance-focused and

collaborative manner.

“Yokogawa worked collaboratively with

the on-site BP team through the many

challenges of the FEED phase and

subsequent design, build and test phases,

delivering the system on time,” said Ian

Bennett, project manager, Automation

Excellence, at BP Wytch Farm. “Lessons

have been learned, especially those

associated with the preparation of the

loop diagrams and subsequent

commissioning phase, which will benefit

the management and planning of future

retrofit projects. We commend Yokogawa

for the open and honest way they have

accepted responsibility in taking the

lessons process forward.”

BP confirmed its satisfaction in the

way Yokogawa completed the Wytch

Farm distributed control system (DCS)

and safety instrumented system (SIS)

upgrade project. Key project

performance achievements included:

100% health, safety, security, and

environment performance; no plant shut-

down as a result of the project; on-time

delivery; a smooth and safe changeover

to the new system; a ‘one team’ approach

with the client project team; and a high

level of customer satisfaction.

The Yokogawa DL9000/DL9700/9500 series and SB5000,

with the LXI compliant Ethernet option (/C9 or /C12)

installed, are now fully compliant with LXI Class C.

LXI (Lan eXtensions for Instrumentation) is a

communication platform for test and measurement

instruments, built on LAN technology. It provides

improved transfer speeds with enhanced

usability and lower cost than traditional

instrument interfaces. It’s easy to migrate

over from traditional GPIB systems, because

LXI utilises existing technologies such as

VXI-11 or IVI.

More than 20 test and measurement

manufacturers provide LXI compliant products,

and the total number of supported products is

already above 1100. As a new communication

platform for applications requiring high transfer

speed, low cost and usability, LXI will become

more widespread in the future and Yokogawa

will be including this feature on many more

new products.

Product Releases

Yokogawa has developed a retractable sensor fitting

that offers a flexible approach to online liquid analytical

measurements in a wide range of process industries.

The Yokogawa PR10 has been designed for online

process applications where the sensor has to be

removed safely without interrupting process continuity

– in anaerobic, toxic or pressurised environments, for

example. The PR10 is suited to pH, ORP, conductivity,

inductive conductivity and dissolved oxygen

measurements.

The unit is available with a wide range of adaptors,

ball valves and flanges, and the insertion depth can be

adjusted to achieve optimum measurement conditions.

Total disassembly without interruption to the process is

possible when the ball valve is closed, and safe

retraction is possible at pressures up to 5barG.

For ease of maintenance, a scraper is built in, and

maintenance time is further reduced because fewer

O-rings are needed for a good process seal. An optional

flush port makes it easy to keep pH and dissolved

oxygen sensors moist and clean, and also provides

access for calibration.

The PR10 will accommodate most commercially

Pho

to c

our

tesy

of

BP

available pH electrodes with PG 13.5mm

thread or DIN connections, as well as

Yokogawa’s SC4A conductivity and ISC40

inductive conductivity sensors (with a

built-in protection cage for the latter).

For dissolved oxygen measurements,

the Yokogawa-Hamilton Visiferm,

Oxyferm and Oxygold sensors can be

installed. These sensors are

typically used in nitrogen

blanketing applications,

where the optional flush

port will allow regular

moisturising of the sensor to

prevent the membrane from

drying out.

Applications for the Yokogawa

PR10 include the chemical

industry, power plants, pulp and

paper manufacture, water and

effluent treatment,

pharmaceuticals and the

semiconductor industry.

LXI Support for Yokogawa Digital Oscilloscopes, MSOs and Serial Bus Analysers

Retractable sensor fitting for analytical measurement of liquids

Wytch Farm

Wytch Farm is Western Europe’s largest onshore oil field.

4 5

DCS and SCADA have always been mutu-

ally opposing control system architec-

tures. Each has its advantages and disad-

vantages and each is applied to different

types of applications. Until now, it hasn’t

been possible to realise the advantages of

both architectures within a single sys-

tem.

Now, Yokogawa is blurring the bounda-

ries of the two architectures with the

integration of the STARDOM SCADA sys-

tem with the CENTUM VP DCS. Using

SIOS (System Integration OPC client

Station), all STARDOM variables and func-

tion blocks are automatically mapped

into the CENTUM DCS, providing seam-

less and transparent connection between

the two systems.

The Yokogawa CENTUM VP DCS pro-

vides high integrity control of medium to

large processing sites. Being a DCS, engi-

neering is greatly reduced by the single

database and function block style pro-

gramming. In addition, the level of availa-

bility, redundancy and reliability in hard-

ware and software make this the clear

choice for critical applications.

The STARDOM control family includes

the FCN and FCJ high performance PLC

type controllers and the FCN-RTU for

remote applications. Programmed using

the IEC 61131-3 suite of programming

languages and supplied with a wide range

of communication options, the STARDOM

controllers are suitable for remote and

PLC type applications. The FAST/TOOLS

SCADA HMI provides a high performance

user interface to the STARDOM control-

lers for a highly integrated SCADA sys-

tem.

The SIOS gateway provides seamless

integration between STARDOM and

CENTUM. Tags created in STARDOM are

automatically recognised by the CENTUM

Integrating DCS and SCADA using SIOS

If you are considering upgrading your old

DCS and it is not a Yokogawa system, then

you may have a problem.

One of Yokogawa’s basic design philos-

ophies in developing latest technology

DCS is to ensure full backwards compati-

bility with previous systems. This means

that any generation of Yokogawa’s DCS

will integrate seamlessly with any other

generation, which protects your invest-

ment and ensures minimal downtime

with each upgrade process. However, it’s

a philosophy that is not typically adopted

by other equipment providers.

The good news is that Yokogawa is

now applying its expertise in systems

migration not only to legacy Yokogawa

systems, but also to systems from just

about any vendor, using a range of tech-

nologies.

When replacing the field control hard-

ware, downtime can be minimised by

keeping the existing terminal boards. This

saves a considerable amount of time in

rewiring and testing and reduces errors

in the changeover process. Yokogawa

provides a range of cables and interpos-

ing boards for interfacing between

Yokogawa I/O modules and a range of

different vendors’ terminal boards.

Sometimes it is not feasible to change

over the system in one go. It may be desir-

able to run the new system in parallel

with the legacy system for a period of

time. Yokogawa provides a range of inte-

gration options that allow the legacy sys-

tem to be seamlessly integrated into the

Yokogawa CENTUM system.

The SIOS (System Integration OPC cli-

ent Station) is an OPC based gateway that

interfaces to OPC servers and maps vari-

ables and function blocks from another

system to the Yokogawa CENTUM VP sys-

tem. For example, a PID function block in

a Honeywell DCS can be mapped to a

Yokogawa PID function block faceplate.

The SIOS will read the parameters from

the Honeywell PID function block and

convert the variables into the correct for-

mat for the Yokogawa PID function block.

Migrating to Centum using SIOSThe operator monitors and operates

through the standard Yokogawa faceplate

without being aware of the fact that the

associated functions are located in the

other control system.

By this method, SIOS seamlessly inte-

grates variables and function blocks from

the legacy system into the Yokogawa

CENTUM system. As a result, standard

Yokogawa functions such as peer-to-peer

communication between controllers

across the two systems, alarm detection,

trending, operation and monitoring can

be performed without regard for the

source of the data.

SIOS is the most

recently released

product, and forms a

very convenient and

easy to implement

methodology for

communicating via

OPC DA and A&E with

other vendors’ higher-

level systems – includ-

ing foreign DCS-type

control systems. It allows

co-existence of Yokogawa and

competitors’ control systems on

the same plant, and can facilitate

migration of older style foreign legacy

DCSs to the latest CENTUM VP system.

Yokogawa Australia has tested SIOS on

integration with a competitive DCS

system with good results. SIOS has also

found extensive use globally in integrating

Yokogawa’s STARDOM network control

system and remote terminal units with

CENTUM.

Both SIOS and GSGW run on a generic

PC hardware platform containing

Integration made easyProcess users have always found

themselves with automation and control

equipment from a number of different

manufacturers in their plant, be it

packaged with the original process

equipment supply or necessary for their

special purpose application.

Examples may include a turbine

controller from the turbine manufacturer

and intelligent electrical devices

associated with the electrical switchgear.

In other cases, the original plant builder

may not have been sufficiently

disciplined to specify common

automation equipment. And in still other

cases, the user has elected to implement

a best-in-class type of unit application

solution.

For whatever reason, it has always been

necessary for the main automation

system supplier to have to communicate

with, or integrate, control equipment

from a number of different suppliers into

the overall control system.

Yokogawa has handled these

communications issues quietly and with-

out fuss for many years. Few systems

would have ever been supplied in the

early days of CENTUM without at least

one RS232 serial interface being

installed.

Modbus over serial link was generally

preferred over custom serial protocols,

Profibus was and still is popular with

equipment of European extraction,

Modbus over Ethernet is still a favourite,

and OPC over Ethernet is the current

communication system of choice today.

CENTUM generally interfaces to

third-party equipment via one of three

physical connection mechanisms:

1. a communications card in the Controller

– serial, Profibus, Foundation Fieldbus or

Ethernet

2. a Generic Subsystem Gateway (GSGW)

station on the control network, which

acts as an OPC client to third-party OPC

servers for the purpose of integration to

subsystems

3. a System Integration OPC Client Station

(SIOS) on the control network for large-

volume, high-performance integration to

peer-level systems

system and are immediately available to

the user as standard CENTUM-style face-

plates on the operator station. The opera-

tor is not aware of the source of the data

for the faceplate.

Because of the transparent nature of the

connection between the systems, full

CENTUM connectivity can be realised,

including peer-to-peer communication

between controllers across the two sys-

tems, alarm monitoring, trending, monitor-

ing and operation. The user can monitor

and operate entirely through the CENTUM

HIS operator station. However, the FAST/

TOOLS SCADA HMI can also be connect-

ed for local monitoring and operations of

the STARDOM controllers in remote loca-

tions as required.

Now the full benefits of both DCS and

SCADA can be realised within a single

system using the Yokogawa CENTUM and

STARDOM technologies.

Reference Interfaces (Partial List)

ABB – drives, IEDs, GCs, etcAllen-Bradley – PLC5, SLC5, ControlLogixAmdelATMOS Leak DetectionASi-BusBentlyNevadaBristol Babcock RTUContrec Counters and BatchersDanfoss VSDEnrafFMC SubseaFoxboro – GC, tank gaugesGastech – fire & gas sensorsGE – PLCs, Multilin, Mark IV, Mark VHarris RTUHIMAHoneywellModicon – 584, 984, QuantumOutokumpu CourierProFace touch panelsSchneider TelemechaniqueSiemens – S5, S7, 1135. VSDSquare DToshiba – PLC, VSDTriconexWoodward Governor

Communications Special Feature

CENTUM Vnet/IP communication cards.

SIOS can handle 100,000 data points

with 4,000 tags in GSGW. GSGW can

handle OPC-DA only, while SIOS can

accommodate OPC-A&E alarm and

events message traffic as well.

No matter which Yokogawa integra-

tion solution is adopted, the end result

for the operator is complete

transparency of information from

across the plant

Communications Glossary of Terms

RS232 – serial connection standard

Modbus – defacto standard serial protocol

OPC – OLE for Process Control – international std comms protocols across Ethernet

Profibus – a suite of field and network protocols originating in Europe

Ethernet – standard office and industrial network technology

Foundation Fieldbus – international standard fieldbus technology

OPC-DA – OPC Data Acquisition protocol

OPC-A&E – OPC Alarm & Events protocol

6 3

Automation replacement completed at Western Europe’s largest onshore oilfieldYokogawa UK has successfully completed

a full replacement of the control and

safety systems for BP’s Wytch Farm

oilfield project in Dorset.

Developed by BP, Wytch Farm is Western

Europe’s largest onshore oil field, with

estimated recoverable reserves of 480

million barrels. It is located in one of the

most environmentally sensitive areas of

the UK.

The Wytch Farm oilfield comprises

three separate oil reservoirs that lie under

Poole Harbour and Poole Bay in Dorset

on the south coast of England. The

operation, comprising a central oil

gathering station and a number of remote

well sites, was established in the early

1980s, and the recently completed

automation replacement project was part

of a development plan that will enable its

operational life to be extended.

Yokogawa was selected by BP as the

main automation contractor (MAC) for

the project, and the Yokogawa project

team worked closely with the BP team

during the project implementation. The

major challenges were the initial

definition of the project scope and

requirements in a front-end engineering

and design (FEED) study. It included a

site survey, document verification,

changeover planning and interface with

existing infrastructure. This was followed

by the implementation of a smooth hot

cutover to the new integrated control

and safety system during the

commissioning phase.

The integrated control and safety

system is based on the Yokogawa CENTUM

CS 3000-Vnet/IP distributed control

system, the ProSafe-RS safety system for

emergency shutdown and burner

management, and STARDOM network-

based controllers for use as remote

terminal units.

This project replaced the existing

control system, safety system, dual

redundant PLC system, process

automation controllers, and SCADA/RTU

previously used to monitor and control

the gathering and processing operations.

During the FEED phase, the Yokogawa

FEED team was resident at Wytch Farm for

site survey work, liaising with the BP

engineers and collecting the engineering

data necessary to complete the FEED

before commencement of the detailed

design. A one-team approach by BP

and Yokogawa was achieved by

managing the business relationship in an

open, performance-focused and

collaborative manner.

“Yokogawa worked collaboratively with

the on-site BP team through the many

challenges of the FEED phase and

subsequent design, build and test phases,

delivering the system on time,” said Ian

Bennett, project manager, Automation

Excellence, at BP Wytch Farm. “Lessons

have been learned, especially those

associated with the preparation of the

loop diagrams and subsequent

commissioning phase, which will benefit

the management and planning of future

retrofit projects. We commend Yokogawa

for the open and honest way they have

accepted responsibility in taking the

lessons process forward.”

BP confirmed its satisfaction in the

way Yokogawa completed the Wytch

Farm distributed control system (DCS)

and safety instrumented system (SIS)

upgrade project. Key project

performance achievements included:

100% health, safety, security, and

environment performance; no plant shut-

down as a result of the project; on-time

delivery; a smooth and safe changeover

to the new system; a ‘one team’ approach

with the client project team; and a high

level of customer satisfaction.

The Yokogawa DL9000/DL9700/9500 series and SB5000,

with the LXI compliant Ethernet option (/C9 or /C12)

installed, are now fully compliant with LXI Class C.

LXI (Lan eXtensions for Instrumentation) is a

communication platform for test and measurement

instruments, built on LAN technology. It provides

improved transfer speeds with enhanced

usability and lower cost than traditional

instrument interfaces. It’s easy to migrate

over from traditional GPIB systems, because

LXI utilises existing technologies such as

VXI-11 or IVI.

More than 20 test and measurement

manufacturers provide LXI compliant products,

and the total number of supported products is

already above 1100. As a new communication

platform for applications requiring high transfer

speed, low cost and usability, LXI will become

more widespread in the future and Yokogawa

will be including this feature on many more

new products.

Product Releases

Yokogawa has developed a retractable sensor fitting

that offers a flexible approach to online liquid analytical

measurements in a wide range of process industries.

The Yokogawa PR10 has been designed for online

process applications where the sensor has to be

removed safely without interrupting process continuity

– in anaerobic, toxic or pressurised environments, for

example. The PR10 is suited to pH, ORP, conductivity,

inductive conductivity and dissolved oxygen

measurements.

The unit is available with a wide range of adaptors,

ball valves and flanges, and the insertion depth can be

adjusted to achieve optimum measurement conditions.

Total disassembly without interruption to the process is

possible when the ball valve is closed, and safe

retraction is possible at pressures up to 5barG.

For ease of maintenance, a scraper is built in, and

maintenance time is further reduced because fewer

O-rings are needed for a good process seal. An optional

flush port makes it easy to keep pH and dissolved

oxygen sensors moist and clean, and also provides

access for calibration.

The PR10 will accommodate most commercially

Pho

to c

our

tesy

of

BP

available pH electrodes with PG 13.5mm

thread or DIN connections, as well as

Yokogawa’s SC4A conductivity and ISC40

inductive conductivity sensors (with a

built-in protection cage for the latter).

For dissolved oxygen measurements,

the Yokogawa-Hamilton Visiferm,

Oxyferm and Oxygold sensors can be

installed. These sensors are

typically used in nitrogen

blanketing applications,

where the optional flush

port will allow regular

moisturising of the sensor to

prevent the membrane from

drying out.

Applications for the Yokogawa

PR10 include the chemical

industry, power plants, pulp and

paper manufacture, water and

effluent treatment,

pharmaceuticals and the

semiconductor industry.

LXI Support for Yokogawa Digital Oscilloscopes, MSOs and Serial Bus Analysers

Retractable sensor fitting for analytical measurement of liquids

Wytch Farm

Wytch Farm is Western Europe’s largest onshore oil field.

2 7

century control systems

technology onto older plant,” said

John Hewitt, Managing Director

of Yokogawa Australia. “Not only

has the project increased the

reliability of the electricity

supply, it has done so while

simultaneously improving

protection of the plant,

reducing maintenance costs

and optimising the use of

raw fuels.”

Yokogawa has been provid-

ing control systems for power

plants for many years. However,

Energy Brix presented some

unique challenges, particularly for

Yokogawa’s younger engineers.

Some of them were working for the

first time with a power plant equipped

with steam ranges and pass-out turbines

— where all boilers feed a common

steam range supplying multiple turbines,

some of which then supply a process

steam range and a low pressure

condensing turbine. This complex interac-

tive configuration contrasts with most

modern plants, where boilers and

turbines are installed as unit plants in a

much simpler one-to-one arrangement.

One significant achievement of the

project was the automated optimisation

of energy used for total plant operation,

replacing what had been a much more

manual approach. This was made possible

by the installation of digital controllers on

the turbines and load sharing controllers

on the boilers.

The PACE Zenith Awards were

established in 2004 by Process Control

and Engineering (PACE) magazine to

publicly recognise companies that show

leadership in engineering and

technological excellence and innovation.

The awards are presented annually, with a

record number of entries received in

2009. Yokogawa projects have previously

won awards in 2005, 2007 and 2008.

The Fieldbus Foundation visited Australia

in August to meet with local equipment

suppliers, with a view to establishing an

Australian Marketing Committee to pro-

mote the features and benefits of

Foundation Fieldbus to the local market.

The Foundation has been championed

in Australia for many years by the

Foundation Fieldbus End Users’ Council,

however the Foundation feels that a sep-

arate Marketing Committee would pro-

vide a supplementary function and more

focussed approach to promotion of the

technology. Such a structure is similar to

that existing in many other countries

The Foundation in Australiawithin the region and the rest of the

world.

Mr Hisashi Sasajima, Vice President for

Asia Pacific, and Mr Shane Parr, Chairman

of the Asia Pacific Executive Advisory

Council, visited Australia to share the

Foundation’s vision.

All delegates to the meeting were

enthusiastic and agreed to the formation

of a Marketing Committee. Mr Tom Rolton

of Emerson was elected Chairman of the

Committee. He will be assisted by

Committee members Shaun Loesch of

ABB, Lindsay Hadland of Yokogawa, and

Andrew Sia of Rockwell.

Delta Electricity has ordered two

Yokogawa generator analyser panels for

installation at its Munmorah Power Station

on the NSW Central Coast.

At this plant, hydrogen (H2) is used to

cool the generators. The merits of H2 as a

coolant are its capacity to cool while

causing only minimal drag or friction

between the generators’ moving parts,

thus increasing efficiency. The potential

downside, however, is that if the H2

becomes mixed with oxygen, it can

become explosive, and thus a significant

safety hazard.

In normal operation, the gas blanket

inside the generator is monitored to

ensure that the H2 is pure. When the

generator needs to be shut down for

maintenance, the hydrogen is removed by

flushing it out with carbon dioxide (CO2);

the CO2, in turn, is flushed out with

breathable air so that access to the

generator is safe. When the generator is

put back into service, the process is

reversed: air is flushed out with CO2,

then the CO2 is swept away with H2. The

process is referred to as the Generator

Purge Cycle.

Using traditional gas analysis

techniques, three separate analysers

would be needed to monitor all stages

of operation and the purge cycle.

But, using state of the art

technology from Yokogawa, only a

single GD402 Gas Density Analyser is

required. Delta however chose to use

two analysers for operational reasons.

The GD402 is exceptionally stable and

reliable and is becoming the choice of

the power generation industry for

these applications.

In conjunction with Delta,

Yokogawa has designed,

manufactured, commissioned and

documented a complete process

analyser system that enables the

operation and purge cycle for the

two Munmorah 350 MW

generators to be measured. The

system was designed so that it

minimises the effects of oil and

moisture in the sample stream. Pressure

measurement was included to provide

compensation for changes in operating

pressure in the generator

cooling hydrogen; such compensation

State of the art analysis

can be performed by the GD402 Analyser.

The first system was installed and com-

missioned in June and a second identical

system has now been delivered.

Local suppliers meet with Fieldbus Foundation executives.

The analyser system installed at the Munmorah Power Station.

Celebrating a century of excellenceRota Yokogawa will be celebrating 100

years of production of high quality

flowmeters for industrial applications

next month. Founded as Deutsche

increasingly automated with sizeable

investment in production equipment,

robots and automated test rigs. Further

investment of tens of millions of Euros is

planned in buildings and plant in the next

few years.

Today, Rota Yokogawa develops and

manufactures high-quality flowmeters

based on five measuring principles: floats,

magnetic-inductive, vortex flowmeters,

Coriolis and differential head. Calibrations

are carried out in the company’s own

DKD-certified facility, which also provides

a calibration service to other companies.

With outstanding products and an

excellent business performance in recent

years, Rota Yokogawa is in good shape for

the future. The continuous development

of new and existing measuring devices

will ensure that customers around the

world are supplied with top quality

Yokogawa flowmeters.

An RAMC02 Rotameter from Rota Yokogawa.

Rotawerke in the German town of

Aachen in 1909, Rota Yokogawa became

part of the Yokogawa Electric Corporation

in 1995.

The early years of the business were

focussed on production of the recently-

invented Rotameter, a float-based

flowmeter. The company was so

successful that ‘Rotameter’ is often used

as a generic term for any flowmeter of

this kind, not just Yokogawa’s.

Today, Rota Yokogawa continues as

the company’s worldwide centre of

excellence for flowmeters, which

now include mass f low

measurement using the Coriolis

principle as well as Rotameters.

Manufacturing floor space has

recently been enlarged by 40% with

the opening of one of the most modern

and innovative production lines of its

kind. Production has also been

Main Benefits of Foundation Fieldbus Technology

reduced wiring and installation costs

reduced control/equipment room space (no marshalling)

easy integration with asset management systems

saving in operations and maintenance through superior diagnostic availability

Peter Morrow, General Manager of EBAC (left) and Philip Nicholson, Principal Engineer of Yokogawa Australia (centre) accepted the PACE Zenith Award from Jeremy Needham of Mitsubishi Electric, sponsors of the Transport, Power and Infrastructure category.

Zenith Award for Energy Brix and Yokogawa cont'd

YOKOGAWA AUSTRALASIAN NETWORKNational toll free number: 1300 558 965

Sydney: 02 8870 1100, Adelaide: 08 8415 2600, Brisbane: 07 3902 6600, Melbourne: 03 8804 8800Newcastle: 02 4016 2100, Perth: 08 6465 6600, Gladstone: 07 4972 6044, Townsville: 07 4779 9155

Auckland: 09 255 0496, Christchurch: 03 348 0066, New Plymouth: 027 667 7226Internet: www.yokogawa.com/au Email inquiries: inquiries@au.yokogawa.com

Contributors to this issue: Megan Fisher, John Kemp, Simon Lillie, Philip Nicholson, Paul Twigg, David Walker, Mike Wallis

Editor: Lindsay Hadland

The Newsletter of Yokogawa in Australasia Third Quarter 2009

The Foundation in Australia 2

7State of the Art AnalysisA Century of Excellence

3Automation Replacement Completed at Large Onshore Oilfield

6Product Releases

5Integrating DCS & SCADA Migrating to Centum usung SIOS

1 Zenith Award for Energy Brix and Yokogawa

4Integration Made Easy

8

Continued on page 2

Yokogawa Australia and our customer

Energy Brix Australia Corporation (EBAC)

have won the 2009 PACE Zenith Award in

the Transport, Power and Infrastructure

category. This is the third year in a row

that a Yokogawa Australia project has

been a finalist in the Zenith Awards.

This year’s award was for the project to

modernise the control systems at the

Energy Brix power station in Morwell,

Victoria. Completed in 2008, the project

was successful in:

Zenith Award for Energy Brix and Yokogawa

To celebrate the release of FieldMate R1.03, Yokogawa is offering readers of Connections a special price on FieldMate and Yokogawa hand-held

communication products on orders placed by August 31, 2008.

8Expert Safety Training

News Tid Bits

reducing station operating costs

generating additional power for export

improving plant operating flexibility

providing modern conditions for plant

operators

reducing station operating and

maintenance costs

improving plant emissions.

“This project was quite remarkable for

the complexity and innovation of the

engineering involved in installing 21st

to reapply to TÜV Rheinland for

revalidation. Suitable evidence of

continuing experience and education

must be submitted.

Yokogawa has three TÜV certified

Functional Safety Expert trainers who

are able to conduct the training course

on a world-wide basis, and to date, over

10 courses have been completed and

many others scheduled.

The course comprises three and a

half days of training lectures, followed

by a four hour examination. Prerequisites

include three years’ functional safety

experience and a bachelor degree or

News Tid Bits

This month marks the 10th anniversary of the introduction of

Yokogawa’s DAQstation, which replaced paper chart recorders with

digital data acquisition and display stations in control rooms around

the world. Revolutionary at the time, the DAQstation was a stepping

stone to a full-blown DCS; it visually mimicked what chart recorders

had provided but added a lot more functionality. The DAQstation has

evolved to provide additional functionality, with the latest model, the

DXAdvanced R3, offering user-customisable display screens and an

intelligent annunciator system with data display and recording

functions that can replace common annunciator lamp panels.

Yokogawa’s WT3000-2A and WT210 digital power

meters are now certified to carry out the standby power tests specified in

the new IEC 62301 standard. Key parameters whose limits are specified in

IEC 62301 are total harmonic distortion (THD), crest factor, accuracy,

resolution and stability at different power levels, and the ability to record

true average power over a period of more than five minutes

Expert Safety TrainingDid you know that Yokogawa has been

authorised by TÜV Rheinland to

conduct Safety Training, and at the end

of the training, subject to successfully

passing an examination, attendees

receive a certificate from TÜV Reinland

certifying them as a TÜV Functional

Safety Engineer?

Successful students also have the right

to use the TÜV logo on their business

cards and correspondence, and will be

listed on the TÜV website as FS

Engineers.

Each certificate is valid for five years,

after which time the FS Engineer needs

equivalent engineering experience. The

cumulative pass rate to date has been just

under 70% of students attempting the

examination. Any student who does not

pass may re-sit it within one year of their

first attempt.

Yokogawa is planning to run a course

in Australia within the next six months.

Readers may submit expressions of

interest in attending the course to

inquiries@au.yokogawa.com

Yokogawa New Zealand has been selected by Environment Canterbury (ECan) as an Authorised Water Meter Equipment Supplier for the Rakaia Selwyn Groundwater Zone. The two Yokogawa flowmeters that have been approved by ECan meet the needs of farmers who are now required as part of their water consent to install approved water meters to measure their irrigation water take.

Yokogawa has won a contract to supply control systems and

instrumentation for the Vung Ang 1 power plant in Vietnam. The plant

will have two 600MW units, with the first planned to be operational

by mid-2012. Situated in the Ha Tihn province, the plant is being built

for the Vietnam Oil and Gas Group (Petrovietnam). The Yokogawa

contract has an estimated value of US$16.6 million.

The Energy Brix power plant in Morwell, Vic.

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Yokogawa has published its annual report

for the financial year ended March 31,

2009. Highlights of the year included the

strengthening of product lineup in

response to market needs, with the launch

of a new manufacturing execution system

platform that contributes to improved

production efficiency, and the release of

highly durable, low power consumption

control and monitoring modules. More

than 60% of sales in the industrial

automation and control business were

made outside Japan.