Yokogawa Technology Fair & User Conference 2008 Review

Yokogawa Technology Fair & User Conference 2008 Review

April 7 -10, 2008
Houston, Texas
 
By Bill Lydon - Contributing Editor, Automation.com
 
Yokogawa on Plan for # 1 Worldwide Process Control Supplier
 
Yokogawa CEO and President Isao Uchida set a goal in 1995 to be the world’s number one process control supplier by 2010. David Johnson, President & CEO, Yokogawa Corporation of America gave an impressive report on progress towards the goal at the conference. David stated that while most Industrial Automation vendors achieved double-digit sales growth in 2006 Yokogawa has the highest growth ratio of order intake. David illustrated that Yokogawa‘s 5 year revenue trend proves it is the fastest growing IA company in 21st century.
 
Fiscal year growth from 2002 to 2006 has been over 10% compound annual growth.
 
Yokogawa is supporting North American growth by expanding facilities adding 50,000 square feet to the Atlanta Engineering Facility, a new 100,000 square foot facility in the Houston area, a new Calgary Canada facility, and Mexico expansion.
 
In addition a 47,000 square foot building in Stafford, TX was added for staging and engineering for the YMAC (Yokogawa Maverick Alliance for Chevron).   Yokogawa and Maverick Technologies joint alliance was selected as the main automation and control contractor for Chevron’s global refineries in a long-term agreement. Chevron intends to strengthen operations and reliability at its eight wholly owned refineries by standardizing and modernizing process automation and control infrastructure. Yokogawa will provide its control technologies and Maverick will provide the majority of the engineering, construction management and installation services through YMAC (Yokogawa Maverick Alliance for Chevron).   The YMAC scope includes validation of design specifications, field instrumentation, integrated process control and safety systems design and implementation, asset optimization and advanced applications.
 
Attendees at the conference were current and prospective users of Yokogawa offerings in a number of industries. There were many from Chemical, Pharmaceutical, Power, Refinery, Petrochemical and Upstream Oil & Gas companies.
 
Keynote Address by Gordon Bethune, Worst to First
 
Gordon Bethune former Chairman & CEO of Continental Airlines gave a thought provoking keynote address at the Yokogawa User Summit. Gordon spearheaded one of the most dramatic corporate turnarounds in United States history, Continental Airlines. The son of a crop duster, Bethune joined the U.S. Navy at 17 years of age and became a U.S. Navy Aircraft Maintenance Officer. Bethune holds a science degree from Abilene Christian University and is a 1992 graduate of Harvard Business School's Advanced Management Program. Bethune holds a commercial pilot certificate with type ratings in the Douglas DC-3, Boeing 757, and Boeing 767. He is also a licensed airframe and powerplant mechanic.
 
The key focus of his message is you must make customers and employees your focus not sometimes but every day. Gordon is clearly a knowledgeable business and people person.
In his book From Worst to First: Behind the Scenes of Continental¹s Remarkable Comeback--A Flight Plan for Success, he defines 7 principals for a turnaround:
  • Two rules for managers: Get your job done, and work together.
  • Make sure that when the team wins, everyone wins.
  • Tell employees what's going on, fully and honestly.
  • Remember that customers want dependability and predictability.
  • Almost everybody loves predictability.
  • If you're the top guy, every problem is your problem.
  • It's a lot harder to keep things going great than to get them going great in the first place.
We can all learn from someone like Gordon...
Yokogawa VigilantPlant Vision
 
Yokogawa continues to build upon their VigilantPlant automation concept for safe, reliable, and profitable plant operations. The VigilantPlant concept is built on three elements: See Clearly, Know in Advance and Act with Agility. Yokogawa’s Isao Uchida frames it this way:
“The famed futurist Peter Drucker once mentioned that a well-managed plant looks silent and boring. I share the same feeling based on my experience in factory and production control. What I hated most was surprise. VigilantPlant is our vision of the ideal plant, where people are focusing their time and energy on building tomorrow’s successes rather than solving yesterday’s mistakes.”
VigilantPlant aims to enable an ongoing state of Operational Excellence where plant personnel are watchful and attentive, well-informed, and ready to take actions that optimize plant and business performance. This initiative eliminates unplanned downtime, improves asset utilization, and allows businesses to adapt to shifting market conditions quickly and efficiently.
 
Centrum VP
 
CENTUM VP is the core platform for Yokogawa’s VigilantPlant Solutions delivering an integrated production control system. In keeping with VigilantPlant concepts CENTUM VP enables personnel to be watchful and attentive, well-informed, and ready to take actions that optimize plant and business performance.
 
CENTUM VP is the 8th generation of the CENTUM series, and succeeds the CENTUM CS 1000/CENTUM CS 3000. While providing backward compatibility and consistency with previous CENTUM systems, CENTUM VP goes beyond the traditional DCS function of controlling and monitoring a plant by integrating plant information management, asset management, and operation support functions.
 
Key Features
  • Unified Architecture Based on a Single Real-time Plant Database
  • Continued High Reliability and Compatibility, CENTUM VP utilizes Yokogawa's unique Pair & Spare reliability technology that leaves no single point of failure and maintains an industry-leading seven 9s (99.99999%) system availability. In addition, CENTUM VP is fully backward compatible with the CENTUM CS 1000/CS 3000 systems.
  • Control LAN (Vnet/IP), Vnet/IP, an IEEE802.3 Ethernet compliant redundant network operating at 1 Gbps, incorporates The major claims for this network architecture are deterministic, reliable, and secure communications.
  • CENTUM VP supports FOUNDATION™ fieldbus, HART, PROFIBUS-DP, DeviceNet, Modbus, Modbus/TCP, and Ethernet/IP.
  • The System Integration OPC Station (SIOS) is used to integrate other companies' process control systems (PCSs) with the CENTUM VP system.
Vnet/IP® Accepted as IEC Standard
 
The Vnet/IP® control network protocol for process automation developed by Yokogawa Electric Corporation has been accepted by the International Electrotechnical Commission (IEC) as a part of international standard IEC 61784-2 Ed.1.0. Activities for the international standardization of Vnet/IP are being carried out in TC65, the IEC's industrial process measurement and control working group.
 
The Vnet/IP plant control network protocol is based on 1 Gbps high-speed Ethernet and features both the openness of Ethernet and the reliability/real-time capability required in plant control.
 
Vnet/IP allows both TCP/IP general-purpose communications and UDP/IP-based control communications on a single network. TCP/IP is used for general-purpose communications with PCs, subsystems, and human interface stations (HISs). UDP/IP is used for control communications between HISs and field control stations. Even with large-scale plants, Vnet/IP achieves rapid response, with data update intervals of one second or less. In addition, the network can be made dual-redundant to instantly switch to another network path if a network path fails. Networks can also be configured with general-purpose network equipment such as layer 2 or layer 3 switches.
 
Yokogawa Acquires Analytical Specialties, Inc. - Gas Measurements in Tough and Dirty Environments.
 
The acquisition of Analytical Specialties, Inc. (ASI) provides Yokogawa with a unique gas analyzer technology,Tunable Diode Laser Spectroscopy (TDLS).   TDLS enables ASI’s TruePeak Tunable Diode Laser Gas Analyzers to deliver accurate measurements in tough and dirty environments. TDLS is used in many industries for such purposes as measuring oxygen and carbon monoxide concentrations for combustion control, detecting ammonia and hydrochloric acid in exhaust gas, and monitoring moisture levels in natural gas pipelines. TDLS enables the direct high-speed measurement of combustion and other process gases. ASI President Trevor Knittel says, "TDLS enables the direct high-speed measurement of many important process gases, including combustion by-products, impurities and oxygen in many chemical and refining operations. ASI’s TruePeak TDLS analyzer utilizes a very promising and proprietary peak area integration method that offers both high measurement accuracy and repeatability compared to other commonly used products.”
 
Mike Brooks, Staff Technologist – Chevron
 
Mike gave a thought provoking presentation titled, Excellence in Work Process: the next generation of IT in manufacturing. Mike successfully justified the case for total information integration from plant floor to front office. Mike stated the goal for Chevron, “we need a software framework that helps improve the performance of all personnel across all Chevron refineries.” Mike believes the high level requirements are:
  • Collaborative work process enabled by, but separated from the IT underpinnings.
  • Secures data within primary systems, but provides easy data exchange and sharing.
  • Users find information easily, without knowledge of where it is stored.
  • Isolates/abstracts implementation & vendor packages.
Mike believes that this can be accomplished with a framework that implements work processes using services in a Service Oriented Architecture (SOA).
 
Many people have been defining this need; the refreshing part of Mike’s presentation is that he explicitly defined some of the core issues:
Companies are spending too much money on integration & the sustaining & running of existing business capability. Companies want this to change and they know this is possible with SOA.
Basically from his vantage point companies are realizing that they need to quit killing alligators and drain the swamp.
 
He reiterated the value of open standards which lower the total cost of ownership (TCO), share technology costs, are non-proprietary, and allow interoperability. This all sounds good but Mike clearly articulated the big issue which is the elephant in the room. Namely,
“most standards such as ISA95, OPC, MIMOSA and others are reference standards and are not interoperable.”
This just does not solve the problem. Mike laid down the gauntlet saying that vendors need help solve this issue or users will need to make this happen. This reminds of the early days of device networking standards when initially people met the specifications but things did not works together from multiple vendors.
 
Industrial Security
 
Rob Hoffman of the Idaho National Laboratory gave a presentation on the Control Systems Security Program (CSSP) Sponsored by: National Cyber Security Division (NCSD). This is part of Homeland Security. Ron talked about the control system security and the links to resources he provided are worth bookmarking and reviewing:
 
 
Training
 
Training programs were offered at the Yokogawa User Summit.
 
Accredited Training Courses
 
Attendees had the opportunity to earn CEU –credits by participating in four one day courses taught by ISA instructors.
  • Overview of Measurement and Control Fundamentals (FG05C)
  • Securing Industrial Networks: Cyber Protection for Automation, Control and SCADA Systems (IC32C)
  • Safety Instrumented Systems: The Must Know for Implementation (EC50C)
  • Overview of Wireless Technology (IC85C)
Free Training
 
Free two hour courses were offered also offered on, Industrial Connectivity, Fieldbus, and Basic Gas Chromatography.
 
Technical Program
 
Technical workshops provided attendees forums to share problem-solving approaches to practical applications, and see how Yokogawa automation solutions can be applied. The technical program for this year's conference was based on four tracks:
  •  Production Excellence
  •  Asset Excellence
  •  Safety Excellence
  • Life Cycle Excellence
2008 Steering Committee
 
The Yokogawa User Conference Steering Committee did a good job putting the event programs together. They also act as the governing body for the Yokogawa User Conference.
  • Chairman, Matt Arcy, Senior Control Systems Engineer - Chevron Texaco,
  • Vice Chairman, Chuck Fortner, Senior Control and Information Systems Engineer - Precision Engineering, Inc.
  • Stuart Knott, Process Control Engineer - GE Plastics
  • Chuck Hartshorn, Process/Project Engineer – Reichhold
  • Darren Goodlin, Manager, Instrumentation Technologies - Anheuser-Busch
  • Dr. Chin Hieng Yong, Lead Controls & Automation Engineer Shell EP Projects, Shell
 
Exhibiting Partners
 
Thirty complimentary companies exhibited products at the Summit:
Apprion
Burns Engineering
Cape Software
Delta P
Dresser Masoneilan
Evans Consoles
FlowServe
GE Energy
Hirschmann Automation and Control
Matrox Graphics
Maverick Technologies
Metso Automation 
MooreHawke
MTL
Northwire
PAS
Pepperl+Fuchs
Phoenix Contact
PI Components
R. Stahl, Inc
RJ Global Wika
RuggedCom
Samson Controls
Shell Global Solutions
TopWorx
TURCK, Inc.
Tyco Flow Control
Veris, Inc.
WAGO
Weidmuller 
 

Centum VP Operator Console - Diplays Driven by Matrox Extio F1400

 
Interesting Control Industry Products
 
Remote Displays over Fiber Optic
 
Matrox displayed the Extio Series of remote graphics units enables one to power up to 4 displays, 6 USB ports and audio functionality up to 820ft away from the host PC via multi-mode fiber optic cabling: Click for more information
 
Measurements of combustion and other process gases
 
Yokagawa’s TruePeak Tunable Diode Laser Gas Analyzers measure at high temperatures (up to 1500C), with no sensor contact in severe applications (high dust, corrosive, etc.)
 
Oxygen measurements in both combustion processes and process reactors, vent lines, etc. (paramagnetic applications). Typical applications include:
  • Thermal oxidizers and incinerators, including units burning chlorinated and sulfinatedcompounds.
  • Process heaters, providing full path (vs. point) measurements
  • Vent and flare headers, providing interference free measurements at true process conditions
  • Reactors where interference free measurement at near real time (>5s) are required
  • Moisture measurements in-line or at-line installation. Significantly reducing analysis time (seconds vs. minutes or hours with extractive systems). No sensor contact with sample, minimizing problems in corrosive and polymerizing service
 
Streamlined SIL 3 Safety Controller
 
The ProSafe®-RS Safety Instrumented System provides SIL 3 on a single CPU module simplifying safety applications. In addition all I/O modules have redundancy built-in. For integrated DCS applications the controllers network together over Yokogawa’s V net and coexist with Yokogawa DCS on the network. ProSafe®-RS takes advantage of Windows Vista.
 
Local Data Recording & Remote Access
Yokogawa has a refined line of paperless and strip chart recorders for local display and data logging that also support networking including Modbus and Ethernet communications.
 
Yokogawa recently developed EtherNet/IP compatible communication interface for industrial recorders and data acquisition equipment that have passed the ODVA conformance test. Yokogawa will be adding EtherNet/IP communication interfaces to industrial recorders and data acquisition equipment this year.
 
Industrial Controller Security
MTL and Byres Security demonstrated the Tofino™ Industrial Security appliances are installed at each controller (or group of controllers) and provide a layered security solution for industrial automation systems. If a hacker or virus penetrates or bypasses a main corporate firewall, they will still be faced with an array of Tofino™ Industrial Security appliances devices that need to be breached before any damage can be done.
 
The Tofino™ appliance installation only requires a field technician to attach power and two network cables. For a small pre-configured system, that may be the extent of the work. Larger installations will normally make use of a central management platform (CMP) that enables the user to configure and monitor the overall system.
 
The system has the flexibility to protect a small plant with a single PLC, or a multi-national organization with thousands of critical devices scattered around the globe. The Tofino™ uses Loadable Security Modules (LSMs), which are tailored software modules providing protection directly in front of the critical devices.