Yokogawa Indonesia ＜ Document Number> Copyright © 2004, Yokogawa Indonesia PT.YOKOGAWA INDONESIA ENVIRONMENT DIAGNOSTIC ( PART.1.) by Service & Business Department

Copyright © 2004, Yokogawa Indonesia Maintenance Technology Risk evaluation & Management from time base maintenance to condition base maintenance Diagnosis technology to evaluates constant loss Introduction of actual examples

Copyright © 2004, Yokogawa Indonesia 1. Risk evaluation with a prolong of maintenance cycle (1) Evaluation of trouble history ( In case of DCS) (2) Evaluation with bathtub curb and deterioration curb relationship (3) Evaluation with Environmental Diagnosis 2. Risk Management (with actual sample) (1) replacement of lifetime parts (Aluminum Condenser) (2) Renewal Service (Washing, Coating) (3) Environmental Optimizing work (with Optimizing unit) Risk Evaluation & Management

Copyright © 2004, Yokogawa Indonesia Initial failure Random failure Time Correlation of Bathtub Curv and Lifecycle Failure rate ↑ Acceptable failure rate ↑Renewal (Treatment to extend life) Life extension Random failure ＞ Wear-out failure Random failure ≦ Wear-out failure Wear-out failure System life = Up to the intersecting point of random failure and deterioration Deterioration Temperature ・ Relative humidity Dust ・ Corrosive gas

Copyright © 2004, Yokogawa Indonesia Evaluation Corrosion Dust Humidity Temperature Assessment of Environmental Diagnosis （ Kansai Branch Office ） ‘95 ～ ’97 12 points: every 4 years 4 years 3% 3 years 13% 2 years 47% 1 year 12% Recommended periodical inspection cycle: (1 ～ 4 years) 90 Jobs Requires Improvement 25% 30 points: every 3 years 60 points: every 2 years 80 points: every year Necessity of Improvement

Copyright © 2004, Yokogawa Indonesia CENTUM’S Failure by factor Preventative replacement of limited-life parts renders failure to zero External factors: 25% Internal factors: 23% Limited-life parts

Copyright © 2004, Yokogawa Indonesia Example of External factor (1)

Copyright © 2004, Yokogawa Indonesia Pattern Break !! Mist Pattern Break （ Pattern Break & Spots ） Example of External factor (2)

Copyright © 2004, Yokogawa Indonesia Cycle of Environmental Diagnosis and Periodical Inspection Measurement range Temperature Others Silver sulfide Silver chloride Oxidized copper Copper sulfide Corrosion Measurement of Airborne Dust Humidity Industrial Computers Installation Environment Standards JEIDA Standard ISA-S Silver Copper

Copyright © 2004, Yokogawa Indonesia A. Risk evaluation with a prolong of maintenance cycle (1) Evaluation of trouble history ( In case of DCS) (2) Evaluation with bathtub curb and deterioration curb relationship deterioration curb relationship (3) Evaluation with Environmental Diagnosis B. Risk Management (with actual sample) (with actual sample) (1) replacement of lifetime parts (Aluminum Condenser) (Aluminum Condenser) (2) Renewal Service (Washing, Coating) (3) Environmental Optimizing work (with Optimizing unit) (with Optimizing unit) Risk Evaluation & Management

Copyright © 2004, Yokogawa Indonesia Option Renewal service Renewal Serice (Washing, Coating) Washing Using special detergent, wash off dust and electrolytes accumulated on cards Recovery service High efficiency (low cost & reduce SD) Replacement of wear-out parts Replacement of severely deteriorated parts and worn-out parts Coating Resin coating (seals from external air) Performance improvement against environmental stress Restoration of reliability and Performance improvement against environmental stresses

Copyright © 2004, Yokogawa Indonesia Example of Renewal effect Accuracy Error diminished from 9.75% as Max. To 0.03%

Copyright © 2004, Yokogawa Indonesia Blow-in type fun Ex. Installed ‘blow-in type’ fun Environmental Improvement Ordinary Type - Pressure + Pressure

Copyright © 2004, Yokogawa Indonesia Environmental Improvement Heated Pipe type Electronics cooling type FA Cooling type Seal from external stress factors and reduce running cost Intensify cooling effect, and seal from external stress factors +α Cooling effect Sealed type environmental improvement unit

Copyright © 2004, Yokogawa Indonesia Subject to improvement *Improvement of sealing of cable inlet *Improvement of sealing *Installation of blow-in type fun Sealing condition of room: normal Sealing condition of cabinet: a little poor Cool air blows out of free access when it’s opened. Improve Environment through Environmental Diagnosis Internal Temperature ・ Lower temperature ・ Higher relative humidity Temperature （℃） Relative Humidity (%) Temp. ・ Humidity contained graph Room Temperature Mixture Ratio （ kg/kg ）

Copyright © 2004, Yokogawa Indonesia Room Under ground Combined value （ kg/kg ） Temperature ( ℃ ) Relative humidity (%) Inside cabinet With optimizing Unit, A temperature is almost the same as room temperature. Also,dust is prevented. Environmental Improvement with optimizing unit

Copyright © 2004, Yokogawa Indonesia Installation Migration test Renewal Ex. Extension of Product life Number of trouble Not coated Coated Trouble-free

Copyright © 2004, Yokogawa Indonesia Humidity Cycle Test Before wash After wash 9 ch output Temperature Humidity Occurrence Recovery No occurrence of accuracy error

Copyright © 2004, Yokogawa Indonesia Countermeasures to Extend Life/Actual Renewal Service No. of cards replacement ( forecast) Chemical 36% Public/others 23% Paper/Pulp 12% Iron/Steal 10% Drag/Food 6% Oil refinery 6% Electric power/Gas 3% Carbon/Ceramics 4% Industry Actual Job Actual example of nonconformityEffectFuture plan Chemical90 Cards corroded by chloride gas/Severed pattern Normally operated Execution of environmental improvement by ＢＥＳＴ Contract Paper/Pulp30 No inspection, Many occurrence of I/O error, (Operation stop) Corrosion occurred after 2 years operation,many occurrence of output errorCard wash, replacement of cabinet with optimizing unit Medicine/Food15 Occurrence of no repeatability,attachment of molasses Salt water attached upon typhoon: frequent occurrence of trouble after the few months Card/nest wash Oil refinery16 Increase of I/O nest error due toair conditioning trouble Periodical inspection in a 4 year-cycle executed by ＢＥＳ Ｔ Contract Iron/Steal26 Cards corroded by blast furnace gas/ Severed pattern Execution of renewal service every 3 years Carbon/Ceramics10 Many trouble by corrosion and carbon attachment Renewal service has been gradually executed Electric power/Gas7 Occurrence of corrosion, Poor sealing condition of the site Periodical inspection in a 3 year-cycle has been offered. Construction to improve environment Public etc. Occurrence of corrosion and non repeatability on cardsExecution of environmental improvement construction 59 Occurrence of corrosion by sulfurous acid gas, increase of non repeatability Trouble recovered Elimination of gas, execution of the same at the rest of sites Accumulation of water soluble lubricating oil mist and dust, occurrence of non repeatability Planning periodical wash Normally operated Periodical inspection in a 3 year-cycle has been executed by ＢＥＳＴ Contract Renewal service has beengradually executed

Copyright © 2004, Yokogawa Indonesia Conclusion Risk Evaluation Environmental Diagnosis Risk Management (1) Replace limited life time parts in advance (2) Renewal Service (Washing, Coating) (3) Optimizing Unit

Copyright © 2004, Yokogawa Indonesia Thank you for your attention