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Safety Excellence Yokogawa Electric Corporation December 2006
(Self introduction) In this session I would like to share with you the vision and concept of our “Safety Excellence” solutions. December 2006 Yokogawa Electric Corporation
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VigilantPlant Operational Excellence model
Excellence in production, asset, and safety sustained over the life cycle of your plant Production Excellence: for operational agility and adaptability Asset Excellence: for Asset availability and utilization Safety Excellence: for health, safety, and environmental (HSE) protection Sustained over the life cycle of your plant Before I jump into the main theme, let me position the Safety Excellence initiative in the overall context of the VigilantPlant Operational Excellence model. This model is a visual representation of the focus areas of Yokogawa solution development. Through the VigilantPlant initiative, Yokogawa aims to bring excellence in production, asset, and safety sustained over the lifecycle of our customers’ plants. Safety Excellence is an integral part of this model and brings together various Yokogawa initiatives that help our customers to prevent catastrophic failures and ensure HSE protection. Another important element of this model is Asset Excellence, which secures asset availability and utilization. Upon the firm foundation of safe and available plant, Production Excellence enables operational agility and adaptability. As a common centerpiece, the Lifecycle Excellence perspective is firmly embedded in all three, improving and sustaining the three excellence initiatives for long term business success. All of these excellence initiatives are essential for the overall operational excellence, but if the foundation is compromised, the whole model collapses. Therefore Yokogawa is committed to sustaining and further improving our products and services that facilitate Safety Excellence. It is my pleasure to share the latest status of our Safety Excellence initiative today. Safety Excellence
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What is Safety Excellence? The Yokogawa solutions Your benefits
Agenda What is Safety Excellence? The Yokogawa solutions Your benefits Roadmap for the future Safety consulting & services This is the overall agenda of my presentation. First I’d like to quickly define the basic perspectives for Safety Excellence. Then I will introduce the Yokogawa solutions that enable Safety Excellence, and summarize your benefits by comparing the Yokogawa integrated solutions against a less integrated ad-hoc solution. Then I will share our roadmap for the future, and touch on our safety consulting and service capabilities. If this agenda looks OK, I will proceed to the main theme right away. Safety Excellence
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What is Safety Excellence?
Thank you. As a starter, let me briefly introduce the key issues that come into play when we discuss Safety Excellence How to address the entire loop to maximize both safety and availability Safety Excellence
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Maximizing both safety and availability
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 Sensors Logic Solver Asset Management Scheduled partial stroke test (PST) Device status & diagnostics Operations Process alarms & device alarms ProSafe-RS DPharp EJX SVI-Ⅱ ESD Process data Output signal Final Elements In a nutshell, the goal of the Safety Excellence initiative is to maximize both safety and availability of our customer’s plants at the same time. To achieve this goal, integrated solutions designed with the entire safety loop in mind is the best option. Integrated solutions not only reduce engineering time and cost but also minimizes engineering mistakes that compromises safety and availability. Safety Excellence
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Assurance of safety (=safety integrity) is achieved by the entire loop
What is safety? Bring processes to safe conditions when needed Sensor Logic Solver Final Elements + Assurance of safety (=safety integrity) is achieved by the entire loop Going back to the basics, what is safety? Safety is achieved by putting in place mechanisms that bring processes to safe conditions when needed. The basic unit of such safety mechanisms is the safety loop. A safety loop consists of sensors that detect abnormal conditions, the logic solver that executes safety logics, and final control elements that carry out the necessary release and/or shut off actions. As far as such safety loops are properly installed, basic level of safety can be achieved. In the old model that used simple signals to trigger the safety loops, however, there was little room to add mechanisms to prevent false trips. Also missing was the capability to manage the conditions of the installed safety loop devices through diagnostics and online asset management systems. For customers who wish to run their plants safely and efficiently, availability of assets is equally important as safety. The old model was not sufficient to solve the availability side of the equation. 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.) Safety Excellence
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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) 30% 10% 60% Logic solver malfunction Sensor Valve Primary cause of safety applications failure When we look into the availability side of the equation, avoiding false trips caused by safety loop device malfunctioning is the core issue. And by far the biggest source of safety device malfunctioning is the final elements. The sensors come next. So avoiding malfunctioning of valves and sensors can go a long way to improving plant uptime. One of the most typical valve malfunction cases is caused by solenoid malfunction that cuts the air supply and causes a false trip. Another type of valve malfunctioning has a serious safety implication. Moving parts of shut-off valves left motionless for a long period of time can develop problems such as stuck valves. To ensure the required level of safety, the customers needed to implement full stroke tests at a regular interval. 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. Safety Excellence
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The Yokogawa solutions
Now that we have quickly reviewed the basic issues surrounding the Safety Excellence challenge, let me proceed to explain how Yokogawa helps our customers to address those issues in an effective and efficient manner. Addressing the entire loop for safety and availability Safety Excellence
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Why not have the best of both worlds?
The vigilant approach delivers both uptime and peach of mind Operators Asset Manager now have an all-in-one interface to effectively handle both control and safety loops. can easily diagnose asset conditions, ensuring asset availability while optimizing maintenance. ProSafe-RS Integrated Safety System PRM Plant Resource Manager As I mentioned earlier, the Yokogawa approach aims at maximizing both availability and safety at the same time, compromising neither. We achieve this by delivering the right information to the right people at the right time. The unified human machine interface arms the operators with an all-in-one interface to both control loops and safety loops, improving visibility of abnormal situations. Meanwhile, the asset manager can easily diagnose asset conditions, using an integrated asset management system that covers both control loop assets and safety loop assets. Later I will share with you a few cases that underscore the benefits of the integrated approach, but before that, let me quickly introduce the key players that enable Yokogawa integrated solutions. DPharp EJX Digital Transmitter SVI-Ⅱ ESD Digital Positioner Safety Excellence
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Certified transmitters (pressure)
DPharp EJX Pressure Transmitter The world’s first and only fully digital pressure transmitter Standard models are certified for use in SIL2/3 applications Key Features: - Certified IEC 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 EJX series pressure transmitter is the world’s first and only fully digital pressure transmitter. EJX standard models are certified by TÜV for use in SIL2/3 applications. This means our customers do not need to manage special types of transmitters or special option parts for safety applications. We strongly believe that, for our customers, safety is not an option. If so, safety should not be an option in the sensors we deliver, either. That is the philosophy behind making our standard model transmitters certified by TÜV. Safety Excellence
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Certified transmitters (temperature)
YTA110/310/320 Temperature Transmitter ■ 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 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 YTA series temperature transmitter is also certified by TÜV for SIL2/3 applications. Not only the high-end models YTA310/YTA320 but also the middle-range model YTA110 is certified by TÜV. Safety Excellence
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Integrated safety controller
Integrated Safety System 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 (seven 9’s) pair & spare CPU technology of CENTUM DCS - Supports the HART communication; enables PRM to integrate diagnostic information from intelligent safety devices ProSafe-RS is the world’s first truly integrated safety controller. It enables SIL3 protection with simple, single configuration. Its unified human-machine interface with our CENTUM DCS brings improved visibility into abnormal situations. The latest upgrade made ProSafe-RS seamlessly connectable to our open and secure control network Vnet/IP, enabling certified safety communications over the same physical network without compromising the logical separation and integrity. Safety Excellence
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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 - 7:2000 IEC 61511: 2004 IEC : Feb. 2003 EN 298: October EN : NFPA 85: 2001 EN 54-2: NFPA 72: 2002 ProSafe was certified as SIL3 by TÜV on 10th March, And release R1.02 has been certified 23th Oct. 2006, too The ProSafe-RS certification covers not only IEC61508 which is indispensable for safety system but also IEC61511 that defines functional safety for the process industry sector, as well as standards for burner management system and Fire &Gas system. Safety Excellence
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Certified valve positioner
SVI-Ⅱ ESD Digital Positioner Smart solenoid certified for use in SIL3 applications Provides advanced diagnostics using the HART protocol, including partial stroke testing 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 SVI-II ESD is a digital positioner from our business partner, Dresser Masoneilan, which is currently under development. SVI-II with smart solenoid is to be certified for use in SIL3 applications. It provides advanced diagnostics using the HART protocol, including partial stroke testing. In addition to our partnership with Dresser, we are also collaborating with Flowserve, Metso, and Samson to develop diagnostic solutions using open standards. p.s. ESV-II ESD will be released in the 1st half of 2007. Safety Excellence
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Integrated asset management system
Plant Resource Manager 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 PRM is our integrated asset management platform that helps our customers to maximize asset availability. It keeps both operators and maintenance crew fully informed of the current performance and anticipated conditions of plant assets. Safety Excellence
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Your benefits The total impact of the integrated approach
Now that I have quickly introduced the key players, let me demonstrate the benefits of the Yokogawa integrated approach as compared to a less integrated, ad-hoc solution. The total impact of the integrated approach Safety Excellence
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Comparison study by exida
A significant difference in availability, safety, and total cost of ownership Yokogawa integrated solution Ad-hoc solution The Yokogawa integrated solution: Single EJX pressure transmitter, ProSafe-RS SIL3 logic solver, single remote actuated ball valve with SVI-II ESD. 2oo3 Pressure transmitters, SIL3 logic solver, single remote actuated ball valve with 3 way solenoid. Description >Doubles safety loop availability MTTF 39 years 20 years >Triples safety PFDavg / RRF 8.98E-3 / 111 2.68E-2 / 37 >Extends valve proof test interval by ten times Proof test Interval (Valve) 5 years 6 months Let me first share a quick upfront summary of the customer benefits. This comparison table is made by excida, the safety consulting firm, after benchmarking the Yokogawa solution against a less integrated, ad-hoc solution. The first index is an indicator of availability: mean time to failure spurious, or MTTF. While the ad-hoc solution only gets to MTTF of 20 years, the Yokogawa integrated approach doubles this availability index to 39 years. The second index is an indicator of safety: probability of failure on demand or PFD average, and risk reduction factor or RRF. The Yokogawa integrated approach triples safety compared to the ad-hoc solution. The third index is an indicator of maintainability: valve proof test interval. While the ad-hoc solution requires the customer to do a proof test every 6 months, the Yokogawa integrated approach requires a proof test only every five years, extending the proof test interval by ten times. Finally, the Yokogawa integrated approach lowers both initial capital costs and lifecycle costs for the customer. >Lowers capital cost and lifecycle cost Capital cost Lower Higher Lifecycle cost Low Very High MTTFS : mean-time-to-failure spurious PFD : probability of failure on demand RRF : risk reduction factor Safety Excellence
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A case in point - avoiding false trip
For example... The 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 Sensors Logic Solver Asset Management Scheduled partial stroke test (PST) Device status & diagnostics Operations Process alarms & device alarms ProSafe-RS DPharp EJX SVI-Ⅱ ESD Final Elements Operator alert Output Normal No false shutdown Device alarm You might be wondering how the Yokogawa integrated approach creates such a difference, so here is a case in point. Let us suppose that a safety transmitter develops an internal problem, although it is quite a rare case in a Yokogawa transmitter. In the off chance of an internal problem, the EJX transmitter sends a 3.8mA signal to ProSafe-RS. ProSafe-RS recognizes this signal as a diagnostic signal and alerts the operator. Since this is an internal problem of the transmitter, ProSafe-RS keeps sending the normal output signal to the valve, avoiding false shutdown. Both the operators and maintenance crew can take the necessary measures to correct the problem while avoiding an unnecessary downtime. Safety Excellence
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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 Sensors Logic Solver Asset Management Scheduled partial stroke test (PST) Device status & diagnostics Operations Process alarms & device alarms ProSafe-RS DPharp EJX SVI-Ⅱ ESD Final Elements Device condition PST Command Scheduled PST Here’s another illustration of the clear benefits of the integrated approach. Both EJX and SVI-II are intelligent devices equipped with diagnostics capabilities. The diagnostics information is consolidated in PRM through ProSafe-RS, enabling the maintenance crew to manage device conditions in a single unified database. The maintenance crew can implement preventive and predictive maintenance effectively on safety assets as well as control assets. PRM is also equipped with application software that executes and manages scheduled valve partial stroke testing. Yokogawa can guarantee such clear benefits of integration because Yokogawa designs collaborative functionalities into key components with the ultimate customer benefits in mind. Ad hoc integration of systems and devices supplied by separate vendors means more engineering time, more costs, and less collaborative benefits. Safety Excellence
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Roadmap for the future Next let me share with you our roadmap for the future, how we plan to keep improving our Safety Excellence solutions. Upcoming enhancements and future-oriented initiatives Safety Excellence
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VigilantPlant Master Roadmap
Operational Agility & Adaptability Production Excellence Asset Availability & Utilization Production mgt Asset Excellence Health, Safety & Environment Asset mgt Alarm mgt, DCS-SIS integration Safety Excellence Completion of VigilantPlant Operational Excellence solutions VigilantPlant evolution VigilantPlant & SE launch AE launch PE launch Here is the overall roadmap of the VigilantPlant solutions, corresponding to the Operational Excellence model I mentioned at the beginning. The release of the ProSafe-RS in 2005 spearheaded the Safety Excellence initiative, which continue to evolve towards This year we have upgraded ProSafe-RS to R1.02 while releasing the SIL2/3 certified YTA temperature transmitter. FieldMate, PRM ProSafe-RS EJX SIL2/3 RS R1.02 YTA SIL2/3 RS R1.03 DYF YVP SIL 2005 2006 2007 2008 Lifecycle Excellence Safety Excellence
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ProSafe-RS as Safety Excellence platform
“This is beginning of the end of diverse and separated safety system.” ProSafe-RS is the core platform of the Safety Excellence solution and has been well received since its launch. One industry expert commented that “this is the beginning of the end of diverse and separated safety system.” Indeed we see ProSafe-RS as ushering in a new era for safety applications. Safety Excellence
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ProSafe-RS - technical evolution of SIS
SIS is core platform of Safety excellence. True Integration DCS Evolution # High performance/Reliable technology - Control BUS / IO BUS - HMI # Pursuing new technology - Fieldbus integration 1993 1998 ABC CENTUM CS ICS EWS PICS Vnet 10 MBPS Dual Redundant Token Pass CENTUM CS3000 HIS PFCS KFCS LFCS 2005 1983 1988 New SIS COPS2 CENTUM V CFFS CFCS2 COPSV CFCD2 HF-Bus 1MBPS Dual Redundant Token Pass CENTUM-XL EOPS CFCS EFCD ENGS SIS Evolution # Unified Architecture # Scalable System # Flexible System # Robust, reliable and integrated comm. # Integrated HMI # Sensor Validation # PST 1975 Despite the fact that both DCS and SIS are installed in the same processes, they used to be completely independent in the past. While DCS made a lot of progress by incorporating many user-oriented new functionalities, SIS stayed more or less the same. The release of ProSafe-RS in 2005 brought a significant breakthrough both in terms of SIS functionalities and DCS-SIS integration. CENTUM CFCD CFCS COPS F-Bus 250 KBPS Dual Redundant Token Pass ModBus PLC Panel/ Single Loop Solid-State Relay Safety Excellence
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ProSafe-RS - vote of confidence
Total 70,000 IOs with 102 projects (as of August 2006) 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 z Mitsubishi Chemical TOTAL Air Liquide BP ChevronTexaco ExxonMobil SABIC(Al-Razi) PEMEX Petrobras ONGC Shell China E&P BA Energy The best proof of the innovativeness of the ProSafe-RS is the vote of confidence we received from customers around the world. Since its release in February 2005, we have already booked over 100 ProSafe-RS projects from first class customers all over the world. Please take a look at these stellar names of uses, who decided to become the early adopters of the integrated approach. The safety system market is known as a very conservative market. This rapid rate of ProSafe-RS adoption surprised the industry experts. Safety Excellence
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ProSafe-RS - further improvements in 2006
Vnet/IP Integration -Enhancements of CS3000 Integration Functional Improvements - AO - Remote I/O The initial release of ProSafe-RS, however, was just the beginning. This year, we released ProSafe-RS R1.02, which represents our continued efforts to improve ProSafe-RS as the core platform for Safety Excellence. In addition to core functionality improvements such as AO and remote I/O, this new release enables ProSafe-RS to be seamlessly connected to Vnet/IP. This further improves ProSafe-RS integration with CENTUM CS 3000 and set the stage right for the Production Excellence imitative. The new release also enables better integration of device diagnostic information through ProSafe-RS and PRM, using the HART protocol. Integration of safety assets into a unified asset management database makes the Asset Excellence initiative more comprehensive and well integrated. Here again, the overall Operational Excellence model is helping us drive the Safety Excellence initiative in the right direction, ensuring synergy with the other key excellence initiatives. Integration with PRM and Field Devices -AI with HART -AO with HART Safety Excellence
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Safety Excellence initiative continues
DYF -SIL2/3 2010 ProSafe R1.02 -Vnet/IP Integration -Enhancements of CS3000 integration 2008 2007 YVP/FVP -SIL2/3 YTA - SIL2/3 ProSafe-RS R1.03 ProSafe R1.02 -AI with HART -AO with HART ProSafe-RS R.1.01 - SIL3 ProSafe SLS -SIL4 2005 ProSafe-RS - ABS, Lloyds, BV Type n, FM NI To take a longer-range view, Yokogawa has been investing in safety technologies since 1960. Towards 2010, we keep expanding our safety solutions to serve our customers’ safety related needs in a more comprehensive manner. 2000 EJX -SIL2/3 1997 ProSafe PLC 1960 ProSafe SLS -AK7 Safety Excellence
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Expanding certified field instruments line up
Safety is not an option - standard field instruments certified for SIL2/3 applications without any add-on component. Pressure Temperature Flow Positioner SIL2/3 SIL2/3 SIL2/3 SIL2/3 We will further expand our certified field devices, applying the same “safety is not an option” philosophy. Next in line is the vortex flowmeter, which we plan to get certified in 2007. EJX YTA DYF YVP/FVP Done Done 2007 2008 Safety Excellence
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Keep supplying the SIL4 system
ProSafe series cover all safety levels (SIL1 to SIL4). Inherent safety system Over 1,000 systems from 1960’s Top level of sophisticated and superior Fail-safe design Meets AK7/SIL4 requirements SIL4 Certification by Solid-state base We are also unique in our safety system line up that covers from SIL1 to SIL4 applications. We keep supplying the SIL4 certified ProSafe-SLS, which is well accepted in very severe applications such as high integrity pressure protection systems (HIPPS). Safety Excellence
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Safety consulting & services
In addition to all these best-in-class products, Yokogawa delivers professional safety consulting and services. Certified organization and experts at your service Safety Excellence
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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. We have a worldwide network of over 200 engineering experts that ensures IEC61508/61511 compliant safety solution implementation. Safety experts in your region are at your service for Hazop studies, loop SIL calculation and so on. Safety Excellence
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Conclusion Yokogawa value propositions with Safety Excellence
Now let me wrap up my presentation by repeating the Yokogawa Safety Excellence value proposition. Yokogawa value propositions with Safety Excellence Safety Excellence
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For your Safety Excellence Yokogawa helps to:
Reduce blind spots Unified operator interface to control and safety SEE CLEARLY Avoid surprises Integrated diagnostics and asset management KNOW IN ADVANCE Preempt bottlenecks Optimum safety and maximum uptime ACT WITH AGILITY For your Safety Excellence, Yokogawa helps to: reduce blind spots with unified operator interface to control and safety; avoid surprises with integrated diagnostics and asset management; and preempt bottlenecks to achieve optimum safety and maximum uptime. Yokogawa integrated solutions cover all your safety requirements, maximizing safety and availability Yokogawa integrated solutions covers all your safety requirement, maximizing safety and availability. Safety Excellence
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Safety Excellence Solutions that maximize both safety and availability.
Thank you very much for your attention. Safety Excellence
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Appendix Safety Excellence
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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 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
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FF-SIS Yokogawa is an active member of the FF-SIS work group
Safety Excellence
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