by Cloud Computing & Data Analysis Yokogawa Electric ... · January 29, 2013 Yokogawa Electric Corporation Plant Energy Conservation by Cloud Computing & Data Analysis

January 29, 2013

Yokogawa Electric Corporation

Plant Energy Conservationby Cloud Computing & Data Analysis

All Rights Reserved, Copyright © GIPC 2013

1. Introduction of Yokogawa 2. Introduction of the previous best

practices3. 2012 Green IT initiative Introduction of the target company Schedule overview 2012 program contents Summary Contact information

Table of Contents

1


Introduction of Yokogawa

Name: Yokogawa Electric Corporation

Subsidiaries/Affiliates: 89 in 55 countries

(19 in Japan, 70 outside Japan)

Employees：

Installed nearly 24,000 control systems

As of March, 2012

Japan affiliates5,190

Global Total19,437

Overseas affiliates10,036

Yokogawa ElectricJapan 4,211

Our goal:Contribute to society through broad-ranging activities in the area of Measurement, Control and Information

ERP

MES

Digital Sensing Technology Process AnalyzersSafety system

Control System& Field devices

Distributed Control System

Advanced Process Control

Software/solutions

Operation Efficiency Improvement

Software/Solutions Plant Information Management System

Asset Diagnostics Software/Solutions

A suite of solution services for continual improvement

of plant productivity and energy efficiency

A large range of green products lineups

Advanced PLC

Network-based control system

Sustainable synergy

2


What is VigilantPlant Services?

Help customers to realize “VigilantPlant” by improving the effectiveness of automation systems/products over the entire plant lifecycle

Provided based on a solution approach in consideration of the current stage of each client’s continuous improvement programs

PlantLife-cycle

PlantConstruction

Operation

PlantDecommi-ssioning

Plant ExpansionSystem Migration

Operation

Identify new improvement possibilities & prepare for solution implementation

Opportunity Identification Services TM

Solution Implementation Services TM

Lifecycle Effectiveness Services TM

Implement identified solution based on a best practice

Sustain the effectiveness of implemented solution through plant lifecycle


VPS for Energy Conservation

Lifecycle Effectiveness Services

Power PlantAPCBTG

OptimizationBTG

Optimization

Systems/Packages for Solution

Implementation

Asset Asset PerformanceImprovement

FurnaceFurnaceEfficiency

Improvement

Regulatory Regulatory Control

Stabilization

Energy Monitoring System - For Entire Plant

Energy Monitoring System - For Process UnitsData Drilling Down

Data Drilling Down

Asset

maintenance

Asset management & maintenance

Plant wide utility optimization

Utility Section Production SectionProduction

Quality

Production/Operation/

Quality

Electricity

WaterSteamHeavy oil

Gas

Energy-supplying

Energy-receiving

Other Products Lineups Other Solutions LineupsEnergy Energy

conservation master planning

Wide variety of green products

Opportunity IdentificationVisualization by EnPIsmonitoring, Comparison & Further drilling down, taking measures

Analysis & SimulationAnalyze data, findopportunity, improvementplanning, benefit simulation

SolutionImplementationImplement New function, re-tuning, Control systemmodification

Operation & MaintenanceKeep benefit, Verification ofthe result

Plant Remote Analysis

4


Regulatory Control Stabilization – Example 1.1

Manipulated Variable

PV MV

Process

SV（Set Point）

Cnt’l Parameters

Control Variable

DCS

Field Instruments

Cnt’l

PID

Control Loop

Energy Saving by RCS

①

①Retuning of PID parameters

②Reduced Set Point ⇒ Lower Energy

②

Set Point(After)

Additional Space

Deviation

Constraints

Set Point(Before)

Time

Process Variables Deviation＝SV-PV

SV

How stable operation contributes “ Energy Conservation”

5


Regulatory Control Stabilization – Example 1.2

Oscillations suppressed to 1/16⇒ Enabling Energy Conservation by set point changes

After

Potential for energy saving

SV Change

Before Optimization After

Before

Economical impactsExpected Savings

Test Plant (1 line) As COG 569,400 Nm3/yPotential (30 lines) 17,082,000 Nm3/y

Even a small step, impacts are large

14,519.7 t-CO2/yCOG: 0.85t-CO2/1,000Nm3 (METI Guideline)

A study of energy saving in a steel company in China

6


Asset Performance Diagnostics – Example 2.1

Clear path to CBM(Condition based maintenance) Issues: As no heat performance monitoring tools are available

for hundreds of heat exchangers, maintenance targets and timings are listed up only on human experiences(TBM=Time based maintenance)

Solutions: Energy condition monitoring and analysis using asset performance diagnostics technology

7Heat exchanger(HEX)diagnostics systemHeat exchanger


Asset Performance Diagnostics – Example 2.2

Future condition and best maintenance timings of four target HEXs were precisely forecasted using 1.5 year past data with advanced curve fitting technology for accurate predictions (=CBM)

Energy efficiency improvement (= Energy saving) HEX pumping power saving HEX heat transfer efficiency improvement Extraction of plant wide bad acting HEXs

Heat transferefficiency

Time

Turn around Turn around

Cleaned

Not Cleaned

Operationcycle

Current HEXperformance

Differenceof energyconsumption

Fig-1: Heat transfer efficiency deterioration by fouling

8Advanced curve fitting technology


Naphtha flow

Dilution steamflow

Air

6 paths

(For decoking)

6 paths6 paths

Olefins (Ethylene, propylene, etc)

Released at decoking

Combustion air

Fuel gas

Ambient temperature

Tube metal temperature

Coil outlet temperatureCoil outlet pressure

Furnace temperature

6 paths/ 24 tubes

Coil inlet pressure

Furnace pressure

Coil inlet temperature

Exhaust CO2 density

Raw materials are supplied to metal tube.

Cokes are stacked at inner tube wall as production goes by and it deteriorate heat transfer efficiency , then finally tube metal temperature (TMT) reaches to the mechanical limit.

Hence periodic De-coking is performed every 45 days by stopping the furnace.

Decoking furnace is stopped but the plant is kept operating.

Furnace Decoking Optimization – Example 3.1


Furnace Decoking Optimization – Example 3.2

A study to reduce energy usage by the improvement of asset performance in a petrochemical company in Thailand Solutions: Energy condition monitoring and analysis using asset

performance diagnostics technology Targets Ethylene cracking furnace coking tubes conditions (Fig-2) Actions Optimized utility supply for decoking process as per the coke

level of each coil tube

Coil-tubes

Rel

ativ

ely

clea

n tu

bes

Dirt

y tu

bes

Mod

erat

e di

rty tu

bes

Mod

erat

ely

dirty

tube

s

Steamand air flow

Steam and air flow

Rel

ativ

ely

clea

n tu

bes

Dirt

y tu

bes

Mod

erat

e di

rty tu

bes

Mod

erat

ely

dirty

tube

s

Coil-tubes

If coking tube dirtiness is measured, then…Energy conservation by variable steam feed would be available

Coking severity indices were measuredusing statistical diagnostics system

Worst 5 severely coking tubes

Before After

10


Green IT Initiative 2012

Production volume

Ene

rgy

Con

sum

ptio

n

Reduction

Ene

rgy

Con

sum

ptio

nProduction volume

11

Application of emerging IT technology (Cloud Computing) Opportunity identification of cloud computing

applications Implementation of applications and demonstration

Application of advanced analytical technology Opportunity identification of advanced plant

analytical tools Implementation of analytical tools to actual plant

operation analysis

All Rights Reserved, Copyright © GIPC 2013 12

Introduction of the Target Company

Target company: A company in process industry (Oil and Gas)

that has centralized engineering organization lots of travels for data monitoring and analysis are

required between the center and the sitesitem Overview

Targetcompany

A

Time of survey

June, 2012 – Dec,2012

Company overview

A company that operates process plants in Malaysia


Schedule Overview

May to Sep Oct Nov Dec Jan Feb Mar

Jan 29

Seminar 　 Presentation

Selection of Target CoCompany Visit 6/26 ~ 30Cloud Tool Development

Data Collection & Analysis

Site Visit for AnalysisInterim Reporting

Final Report Preparation

Final Report Submission

Financial $ Project Report

Item

CalendarFiscal Year 2012

12/3 7


Project Outline

Remote Monitoring and Analysis of Plant Operation by Utilizing Cloud Technology Energy saving on

travels for site visit

Process Analysis for Identifying Energy Saving Opportunities


Cloud Computing Architecture

Hybrid Cloud Model where Applications reside in the cloud and the database is hosted privately

Cloud Data Center

File server3rd Party Consultants

Customer Engineers

Engineering Center

Cloud Applications Authentication by live ID

Process Data


Process Analytical Tools - Development -

• The following products and tools have been developed and/or customized

- Plant Wide Oscillation (Loop oscillation analysis)- (Loop diagnostics)- (Alarm & event analyzer for cloud) - Process analyzer (Statistical data analysis)- ^ (Loop tuning simulator)

Functional tests Connectivity tests Other crucial tests

Trial run at sites Customization

Step 1- Preparation Step 2- Verification Step 3- Implementation Planning of analysis

tools Develop prototypes

16


Process Analytical Tools - Features -

Yokogawa Analyzer Client Unit: comparing trend charts of multi process variables. Good tool to analyze temporal behavior of variables

Statistical Analyzer: PPCL’s C Visual Explorer (CVE) provides a graphical representation of multi variables. Good tool to identify correlations between variables


Identified Opportunities for CO2 Reduction

Reduction of business travels of engineers A company has centered engineers for servicing many

sites by minimum engineers Engineers at the center travels back and forth with sites

distributed in the country for process monitoring and analysis as much as 1000 man-times/year

In cloud environment engineers can analyze plant operation in remote without limitations of time and place as if they are sitting at the site

Reduction of process steam consumption Process analysis revealed variation in steam

consumption at the one process unit 20% of steam consumption could be saved by reducing

the flow as low as its minimum requirement


Potential Energy Saving and CO2 Reduction

The identified potential reduction of CO2 emission by the proposed schemes is about 3,000 ton-CO2 per year

CO2 emission reduced by the proposed scheme Result details

Proposal

Reduction

Fuel Energy(KL/Y)

CO2 eq.

(ton/Y)

Monetary Effect

(MYR/US$)

Reduction

(%)

Cloud 10 27 400K / 130K

20

Process 1,000 2,700 4M /1.3M

20


Summary

Cloud computing can trim unnecessary travels of customer engineers Security of data is still a major concern for a customer Needs more applications as SaaS to attract customers

Cloud computing makes it easier for 3rd party consultants such as Yokogawa to analyze plant data from remote place

Powerful process analytical tools are very effective for identifying process improvement opportunities Full lineup of tools for analyzing process dynamics is

preferable The government should stimulate private sectors

for promoting energy saving by incentives


Contact Information

Yokogawa Electric Corporation：

2-9-32 Nakacho, Musashino, Tokyo 180-8750, JapanTEL: +81-422-52-5530http://www.yokogwa.com/

Yokogawa Electric (Malaysia) Sdn. Bhd.:No. 9 Jalan Industri PBP 3, Taman Industri Pusat Bandar Puchong, 47100 Puchong Selangor Darul Ehsan, MalaysiaTEL: +60-3-8064-9888

by Cloud Computing & Data Analysis Yokogawa Electric ... · January 29, 2013 Yokogawa Electric Corporation Plant Energy Conservation by Cloud Computing & Data Analysis

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