Empowering Excellence: Innovation and Strategies to Optimized Operations

Empower Excellence, The Future of Work

1. Empower Excellence
The Future of Work
February 2025
Paul Unting
Yokogawa Kontrol (M) Sdn Bhd

2. See the entire
operation at a glance
When all data is integrated, customers will be able to better
understand cause and effect and links between plan
utilization, yield, risks, gaps in achieving business goals, etc.
System of Systems
Autonomy extends well beyond boundaries we
know today.
Symbiosis between industry and society
Digital Twin with AI/ML
capability as advisor
Digital twins with AI/ML Analytics will be used
across the asset lifecycle, allowing customers to
plan, design, operate, and maintain their assets in
more optimal ways using “what if” scenario testing
and virtualization.
New ways to
perform inspections
Drones and robots will be able to inspect and repair
equipment in remote locations and extreme environments.
See the unseen
Even in production line that undergoes regular inspections, unexpected pitfalls may be lurking. By using AI to
analyze data from many sensors, it will be possible to estimate deterioration, issue warnings, and identify causes.
How We See the Near Future...
Japan wants to create, in its own words, a “super-smart” society, and
one that will serve as a road map for the rest of the world.
Smart Society 5.0 Consortium

3. 3
IA2IA
•Prone to errors
•Knowledge Loss
•Increased Flexibility
•Improved Safety
•Higher Reliability
•Increased Efficiency
•Lower Costs
Industry Automation to Industry Autonomy (IA2IA)
AUTONOMOUS
OPERATIONS
MANUAL / SEMI
AUTOMATED
AUTOMATED
SEMI AUTONOMOUS
AUTONOMOUS
ORCHESTRATION
INDUSTRIAL
AUTONOMY
AUTOMATED

4. 4
The Shift to Fully Autonomous Operations
Global End- user Survey on the outlook for Industrial Autonomy, Jul 2020 --- based on 500 decision- makers from the process Industry
Level of Autonomy by end users
INDUSTRIAL
AUTONOMY
IA2IA: The transition from
Industrial Automation to
Industrial Autonomy

5. Redefine The-Way -We-Work & Coach for Behaviors
Journey of IA2IA with PETRONAS
5
Unmanned
Facilities
AI Driven
Centralized
Operations
Centralized
Operation
Full Automation
Build Digital Twin and enable DX
Infrastructure
Predictive
Maintenance
Digital Immersive
Planning Tools
Achieve
Optimum
Manning
Maintenance
Connected
Worker
Enable Remote
Operations
Unmanned
Operation
Autonomy
Operation
Maximize Field
Efficiency
Robot Management
Core
Operating
Philosophy
Capability
Leaps
Base
Infrastructure
Business
Goals
Mindset
Transition
Performance
Management System
Centralized
Operational
Control
Safe
Operations
Achieve
Operational
Discipline

6. Topics for the Day
6

7. Topics for the Day
7

8. What’s Next?
8

9. The names of corporations, organizations, products and logos herein are either registered trademarks or
trademarks of Yokogawa Electric Corporation and their respective holders. 9
LET’S START…

10. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
The Human Factor:
EnablingSmart Operator Insights &
Decision Making
Sujit John
Head- System Marketing
Yokogawa Engineering Asia Pte Ltd

11. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Agenda
2
1.Advanced Operating Graphics (AOG)
•Success cases
2.Modular Procedural Automation:ExaPilot
•Success Case

12. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Why do we need to think about Human Factor?
Now, human factor became one of the most important factor for plant safety and stability.
123
People
Source: ARC white paper, January 2010
Proces
s
Equipment
42%
22%
32%
Causes of Unscheduled Shutdowns or Slowdowns

13. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Console operator challenges
•Being overwhelmed with alarms
•Graphics that make the job harder rather than easier
•An explosion of hard to use procedures
•High variability in the quality of operator decisions
Central control room with historians and automated systems forcing operator to pay
attention to multiple data in a very configurable environment

14. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
How can we improve Human factor?
A Keyword:
Situation awareness Decision
Performance of
action
Perception of element
Comprehension of meaning
Projection of status in near future
Environment
Situation Awareness
What we need is;
Accelerating speed & accuracy of Operator’s Situation Awareness.

15. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Symbol usage
Regardless of language, the symbols support faster recognition, enabling reduce
mental load
Picture Superiority Effect
SINGLE ENCODING
(Verbal / Written)
PUMP
10%
Recall
DUAL ENCODING
(Verbal / Written + Visual)
65%
Recall

16. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Data? Information?
Operator only cares if the temperature profile is within the targets given by
the process engineers
TC151 253.2°C
TI159 253.1°C
TI147 266.2°C
TI157 275.3°C
TI142 279.2°C
TI155 286.3°C
TI137 300.2°C
TI130 315.2°C
TI131 332.5°C
TC151
TI159
TI147
TI157
TI142
TI155
TI137
TI130
TI131

17. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
How does Advanced Operating Graphics (AOG) address
HMI improvement?

18. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Our value proposition
Plant OV
Unit OV
Equipment
based display
HP Plant OV
HP Unit OV
HP Equipment
based display
KPI display
Task based
display
HMI design aligned with operator’s tasks and behaviors
Process info + Ergonomics
+ Ergonomics
+ Operation knowledge
L1
L2
L3
HP-HMI:
High Performance HMI
AOG:
Advanced Operating Graphics
CONVERSION
ADDITION
HP-HMI
Conventional
Graphics
AOG

19. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
How our value generates business outcomes
Combining two different skills to achieve safe, reliable, and profitable operations
OPERATIONS KNOWLEDGE
By knowledge engineering we
reflect operating know-how of
operator and process engineer
ERGONOMICS KNOWLEDGE
On the basis, we make
proposals of color, layout,
operation and so on
ADVANCED OPERATING GRAPHICS (AOG)
Increase productivity
Speed up decision- making
Improve safety
Early finding abnormal situation
Blocking false recognition
Improve work environment
Less stress
Ensure skill transfer
Translating skills of operators and process engineers to
explicit knowledge

20. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Before & after examples

21. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Level 3: Equipment-based graphics
BEFORE AFTER
※ Image is a case of refinery plant. Style (ex.: coloring, layout) is different from customer’s environment and operating.

22. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Level 2: Monitoring task graphics

23. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Level 2: Monitoring task graphics
※ Image is a case of refinery plant. Style (ex.: coloring, layout) is different from customer’s environment and operating.
Bar graph
Cobweb chart
Trend graph
Line graph
Bar graph
TRADITIONAL

24. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Level 1: KPI
Level 1 graphics display Operation KPI. These make operators self-conscious
about efficient and safe operation
※ Sample Images are for oil refinery plant. Colors, expressions and layout are different from user’s environment and operation.
Production plan and result
Environment index
Utility
Quality index
Material balance
& Heat balance
Healthy
index

25. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Success stories

26. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Success Story 1
Customer Challenges
Hard to see unit overviews and important operational tasks
Timing: DCS replacement with CENTUM
Their HMI did not sufficiently follow ergonomics
Designed without any consideration on “their” plant operation
Customer
Company:
Plant type: Gas
Location: Sylhet, Bangladesh
Our Solutions
Upgrade HMI recreating/converting the current graphics,
incorporating KPI displays; followed the 3 steps:
Clarify the type of the graphics needs to be needed
Clarify the information needed to be displayed on each graphic
Design graphics based on ergonomics
Customer Benefits
More intuitive and precise operations

27. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Success Story 2
Customer Challenges
Meeting international standards: ASM, ISA-5.5, ISO-9241
Forced to scan many displays to see what’s happening
Confusing layout that is easy to misread, leading to human errors
Overview displays lacked detailed information
Customer
Company:
Plant type: Gas
Location: Niigata, Japan
Our Solutions
Redesign GUI color scheme and layout to ensure task-based
displays while incorporating the following unique technology:
KPI display
Note: The alarm color scheme was also redesigned for their Alarm system*
*Yokogawa Consolidated Alarm Management System for Human Interface StationCustomer Benefits
See next page

28. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Success Story 2 (Continued)
Customer Benefits
Shortened operation monitoring cycle
Timely identification of abnormal conditions
Fewer operator errors
Reduced operator workload / eye fatigue
Improved transfer of skills and expertise
Increased motivation to improve operations

29. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Effective Utilisation of MPA with ExaPilot
20

30. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Software - Exapilot
Tools are designed for operators1
Does NOT require control engineer
Does NOT require DCS expertise
Does NOT require programmer pro
OPERATORS implement
OPERATORS maintain
DCS platform independent2
One solution for all plants
One application to learn
One solution to maintain
One solution that works with all automation platforms
“Procedures can be developed by Operator for Operator”
Exapilot is an Operation efficiency improvement
package to help plant operators by automation /semi-
automation for the non-routine operation states

31. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Procedure Automation
22
•An operator procedure is one that:
•Requires user interaction
•Cannot be fully automated at the
controller level
•The best operators know the best
procedures
•Procedure Automation is a tool that:
•Aids operator decision making
•Provides check lists
•Ensures correct procedures are followed
every time
•Captures experienced operator know- how

32. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Procedure Automation
Check list
Operator Confirmation
Procedure flowchart

33. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
CENTUM VP Integration with Exapilot
24
Standardize & consistent operation
Assist in non- routine operation
Minimize operational variability and
maintain product quality
Prevent operational errors
Operational best practices and Operator’s
knowledge and experience is captured
and shared with team

34. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Installed base & Case Studies

35. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
1.Chemical Plant, Thailand
PM36J6B10-
01E 25
•Process
•Steam Cracking Furnace
•KBR SCORE Furnace
•On-line Decoking
•A~K : every 40 days of running time (11 EA X 9 times/year)
•R : every 80 days of running time (1 EA X 4.5 times/year)
•System configuration
•Yokogawa CENTUM CS
•Engineering
•Naphtha Cracking Furnace (E~K & R, 8 units)
•Naphtha/LPG & Split Cracking Furnace (A~D, 4 units)
•Feed Cut Operation
•Decoking Operation
•Feed In Operation
•Skillful Operators
•1 veteran operators involved
•3 man- months for making main procedure
Automation of stream cracking furnace on-line decoking

36. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
On-line Furnace Decoking Procedure
PM36J6B10-
01E 25

37. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
On-line Furnace Decoking Procedure
PM36J6B10-
01E 25
•Benefits
•High-skilled operation know-how was
shared
•Shorten decoking operating time and miss-
operation
•Reduced operator work load
•Easy to update and optimize the procedure
as the process knowledge improves.

19
492
210
0
100
200
300
400
500
Set MV Set SV Mode Change
69 71
102
0
20
40
60
80
100
120
Monitoring Ramp MV Ramp SV
Total 721 times of DCS
operation per furnace
decoking reduced
Total 242 modules used to assist
decoking operation
242 X 1 min = 4 Hrs operation
hours freed

38. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Advanced Operation – Procedural Automation
29
Benefits of procedural automation
Refinery
(Transition operation)
•Operator workload reduced by 60%
•Product yield loss reduced by 42%
•Feed throughput during transition increased by 18%
•Feed switch transition time reduced by 36%
Console Operator Moves per Hour Comparison from paper “Improving Refinery Unit Transitions Using Process Automation
Technology in a base Oil Hydroprocessing Facility.” AIChE Spring 2011 Robert M. Tsai, Chevron, Richmond, CA

39. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Benefits by using Exapilot
•Improve the operational environment
•Transfer knowledge from Veteran Operator
•Standardize operation know-how
•Operation guidance system
•Prevention of miss-operation
•Reduction of operator’s workload
•Reduction of engineering workload
•Example
•PID parameter input - Procedure announcer
•Charge up / down - Online operation manual
•Products changeover - Product switchover operation
•Unit changeover - Unit startup / shutdown
•Simple controller

40. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
The example of suitable operation
Operation Frequency Required timeNumber of pages of SOP; if
noting, guess
DifficultyA loss when it fails
Plant Start-up Once four years 48 hours 100 pages Difficult The quantity-of-production fall by delay of start-
up time
Unit Start-up 3 times per year1 or 2 days 2 pages Easy The quantity-of-production fall by delay of start-
up time
Change of the
quantity of
production
Once a month 2 hours 1 page Difficult Off-specification, The damage to equipment
Grade change 1 time per 2
weeks
1 day 5 pages Difficult Off-specification
Unit Stop 3 times per year2 hours 2 pages Easy The damage to equipment, Delay of the next
starting
Check of unit 2 times per year4 hours 1 page Easy The performance fall of equipment
Operation after
safety valve
operation
At the time of
generating
2 hours 2 pages Easy The damage to equipment, Delay of the next
starting
Check of safety valve2 times per year4 hours 1 page Difficult Shutdown by miss-operation of safety valve

41. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Keyword - Summary
32
Advanced Operating Graphics (AOG) & Exapilot achieves safe, efficient
and reliable operation by adding operation support function to DCS.
•Achieve safe operation by reducing the incidents caused by
human error.
Safety
•Achieve efficient operation by reducing execution time of procedures.
Efficiency
•Achieve reliable operation by retaining Best Operator practices and automating procedures.
Reliability

42. The names of corporations, organizations, products and logos herein are either registered trademarks or
trademarks of Yokogawa Electric Corporation and their respective holders.
Thank you

43. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Revolutionize Process Monitoring
with
Yokogawa TDLS
M. H. Gandi
Product Manager (TDLS), Regional Analyzer
PSBU, Yokogawa Engineering Asia
email: [email protected]
February 4, 2025

44. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Yokogawa Industrial Automation and Control Portfolio
Sensor to Enterprise Integration
Enterprise Resource Planning,
Supply Chain Management,
Hydrocarbon Management, etc.
and many more…
ISA-95 / IEC/ISO62264 model
Business Planning &
Logistics
Level
4
Level
3
Manufacturing Operations
Management
Manufacturing Control
Intelligent
Devices
Level
2
Level
1
AXF EJX YTA DYFROTAMASS
WirelessZREXA
and many more…
TDLS

45. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Agenda
1.TDLS Introduction
•What is The Laser Gas Analyzer?
2.Process Application
•Combustion Control at Fired Heater / Furnace
oZirconia + COe vs TDLS
•Safety: Limiting Oxygen Concentration
oParamagnetic vs TDLS
3.TDLS Features
•Yokogawa TDLS’s Features and Benefits
4.Summary

46. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
1. TDLS Introduction

- What is The Laser Gas Analyzer?

47. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Principle - How Laser Analyzer Works?
The Tunable Diode Laser Spectrometer (TDLS) operates by measuring
the amount of laser light that is absorbed (weaken) by the target gas.
The amount of lost = gas concentration
Wave length Wave length
Signal
Absorbance
Wave length
Before absorption
Detector sideLaser side
After absorption Measurement absorption
Signal

48. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Principle - Single Peak Spectroscopy
The Tunable Diode lasers have very narrow wavelength emission
The linewidth is typically only around 0.00004nm
The laser scans the bandwidth, measuring the peak & baseline
17131925313743495561677379859197103109115121127133139145151
0.00E+00
5.00E-04
1.00E-03
1.50E-03
2.00E-03
2.50E-03
3.00E-03
3.50E-03
4.00E-03
4.50E-03
5.00E-03
1536
1535
1535
1535
1535
1535
1535
1534
1534
1534
1534
1534
1534
1534
1533
1533
1533
1533
1533
What does a TDLS measure?
One single peak
What does a NDIR measure? All peaks in this area
TDLS can pick one isolated peak that has no cross interferences

49. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Yokogawa TDLS Line-up
TDLS200
2008
Origin of
Yokogawa TDLS
・Compact/lightweight
with enhanced functions
TDLS8000
Touch screenYH8000
・Simultaneous measurement for
O2+COwith 2 laser elements
TDLS8200
TDLS8100
・Reduce construction costs
・Proposal for new installation as probe
2019
2020
2015
2021
Propose this combination with YC8000 as Extractive if direct
installation is difficult
Combination with YC8000(Flow cell)
2023
TDLS8200 Reflective Type
・Short process:
0.25~0.50meter Process Line
TDLS8100
・Works well in difficult condition
for direct installation
・Preparing forstandardization
The best just got even better
TDLS5500
O2, CO, CH4, CO2, H2O, NH3, H2S, HCl
O2, CO, CH4, NH3, HCl
O2, CO, CH4
O2, CO, CH4
H2S, H2O, C2H2

50. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
“Process” Gas Analyzer TDLS
NDIR,
Paramagnetic O2…
Laser gas analyzer： in-situ measurement
Conventional gas analyzer：
with sample conditioning system
Fast response (sec. order); Simple mechanism; No movement parts,
No consumption parts; Contactless measurement ;
High temp (up to 1500 °C)
High pressure (up to 1 MPa abs.)
Corrosive… OK!!
Sampling -> Response delay….
Complex, Heavy maintenance
TDLS; Fast response, Slight maintenance
TDLS8000 Cross
TDLS8200 Probe
Gas
Gas
Max. 850 ºC
Pipe Diameter Min. 0.65
Max. 1500 ºC
Pipe Diameter 0.5 m to 30 m
TDLS8200 Reflective
Max. 850 ºC
Pipe Diameter 0.25 m to 0.5 m
Laser
Laser
Laser

51. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
2. Process Application

- Combustion Control at Fired Heater / Furnace
Zirconia + COe vs TDLS
- Safety: Limiting Oxygen Concentration
Paramagnetic vs TDLS

52. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Combustion Control at Fired Heater / Furnace
Zirconia (O2) + COe
Point Measurement ( API RP-556)
less representative
TDLS (O2 and CO)
Cross measurement (API RP-556)
more representative
Zirconia (O2) + COe TDLSvs
Having consumption parts and need
frequent calibration
high downtime & maintenance
Potential ignition source (API RP-556)
less safe
Delay response (API RP-556)
not real time
No consumption part and no need frequent calibration
very less downtime & maintenance
Fast response (API RP-556)
near real time
No potential ignition source (API RP-556)
safe

53. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Combustion Control at Fired Heater / Furnace
Zirconia (O2) + COe
Point Measurement ( API RP-556)
less representative
TDLS (O2 and CO)
Cross measurement (API RP-556)
more representative
Zirconia (O2) + COe TDLSvs
Having consumption parts and need
frequent calibration
high downtime & maintenance
Potential ignition source (API RP-556)
less safe
Delay response (API RP-556)
not real time
No consumption part and no need frequent calibration
very less downtime & maintenance
Fast response (API RP-556)
near real time
No potential ignition source (API RP-556)
safe
MORE
Accurate
Faster Response
Reliable
Safer
LESS
Downtime
Operational Cost
TDLS8000 Cross TDLS8200 Probe
Zirconia (O2) + COe TDLS
Revolution to
Single Parameter
Measurement
Dual (O2 & CO) Parameter
Measurement
Maintenance

54. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Safety: Limiting Oxygen Concentration
Recipe for fire:
The ideal conditions make fire
and may cause explosion
LOC is required to prevent
fire and explosion in the
following areas:
• Reactors
• Storage Tanks
• Vent Headers
• Waste Gas Recovery
• Flare Lines
• Incinerator Feed
• Barge Loading (Marine
Vapor Recovery)
• Inert Gas System in
Oil/Chemical Tanker
Paramagnetic (O2)
Extractive only
less flexible and complex installation
TDLS (O2)
In-situ or extractive
flexible and simple installation
vs
Paramagnetic TDLS
Prone to interference with some gases
less accurate measurement
Available only for dry-based method
less representative
High drift measurement, it requires frequent calibration high downtime & maintenance
No interference with other gases highly accurate measurement
Available for wet-based and dry-based
method
representative measurement
Negligible drift measurement, no need frequent calibration very less downtime & maintenance

55. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Safety: Limiting Oxygen Concentration
vsParamagnetic TDLS
Prone to interference with some gases
less accurate measurement
Available only for dry-based method
less representative
High drift measurement, it requires
frequent calibration
high downtime & maintenance
No interference with other gases highly accurate measurement
Available for wet-based and dry-based
method
representative measurement
Negligible drift measurement, no need frequent calibration very less downtime & maintenance
Paramagnetic TDLS
Revolution to
TDLS8200
Reflective
TDLS8000
Cross
TDLS8200
Probe
TDLS8200
Flowcell
MORE
Accurate
Faster Response
Reliable
Flexible
LESS
Downtime
Operational Cost
Maintenance
Paramagnetic (O2)
Extractive only
less flexible and complex installation
TDLS (O2)
In-situ or extractive
flexible and simple installation

56. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
3. TDLS Features

Yokogawa TDLS’s Features and Benefits

57. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
TDLS8000 and TDLS8200 Series
•Intuitive Color Touch Screen
•Easy Installation
•HART and Modbus TCP
Communication Standard
•SIL 2 Certified
•DNV Marine Certified*
•Fully field reparable with 50 days of
data and spectrum storage
•Auto Gain
•Adaptation to High dust and moisture
•Reference Cell
•Adaptation to Low concentration
“Simple and Robust”
TDLS8000 Cross
TDLS8000 with YC8000 (Flowcell)
TDLS8200 Probe
TDLS8200 Reflective
TDLS8200 Flowcell
*Available in TDLS8000 only

58. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Stable Performance with Direct Peak Area Method
The 10% O2 in Different Background Gases

59. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Easy Operation by HART and Modbus TCP Communication
Color Touch screenYH8000
(Option)
HART Communication

Field Mate used
Easy Wiring
Pin Terminal
Ethernet
Ethernet
Free software(PC HMI)
The same function as YH8000
Good
selection!
21

60. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Issues: When replacement of Laser unit and CPU
board are required, only factory repair is the choice
and it results in a long down time
Solution: Smart Laser Optics that contains all the
parameter set at factory and Plug & Play is available in the filed
Fully Field-Reparable
TDLShasUSBport
No need return to factory!!
No need calibration after
exchange!!
TDLS stores 50 days of data
and spectrum !!

61. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Adaptation to High Dust and Moisture Application
Issues: When transmission is lowered by dust,
moisture, or vapor the S/N ratio is lowered and it
results in inaccurate measurement.
Received Signal
Wave Length
Absorbance
Absorbance
Wave Length
Received Signal
Received Signal
Wave Length
Transmission Lowered by Dust
Solution: 8-stage Auto Gain keeps the S/N high
With Auto Gain
S/N low
S/N high
Without Auto Gain

62. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Adaptation to Low Concentration Application
Issues: When the concentration is low and the
signal can not be detected well, the TDLS fails to find
the right wavelength and it results in no
measurement.
Solution: Reference Cell is integrated in the Laser Module
for continuous peak locking. No more gas required
Peak Search Example
absorbance
Wavelength
Peak search
failed
Smart Laser Module
Reference Cell
＜Reference Cell＞
・Filled gas：Same as measurement gas
・Structure: Lens, cell body, detector
・Placement：Inside Laser Module

63. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
4. Summary

64. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Summary
Level 1 (ISA-95 model) is crucial because it serves as the bridge between the
physical world (Level 0) and supervisory control systems (Level 2) and above.
Therefore, Level 1 must demonstrate accuracy, reliability, and rapid response
times.
TDLS technology significantly revolutionizes process monitoring capabilities
by providing superior accuracy, reliability, and response speed compared to
legacy technologies such as Zirconia + COe and paramagnetic analyzers.
Furthermore, it delivers substantial reductions in downtime, maintenance
requirements, and operational expenses.
Yokogawa's TDLS offers robust performance, user-friendly operation,
simplified part replacement, automatic gain control for high- dust and high-
moisture application, and an integrated reference cell for accurate low-
concentration measurements.

65. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Summary: TDLS is a Solution for Numerous Applications
Refinery / Petrochemical:
•Combustion at Furnace: O2 and CO
•Combustion at Incinerator: O2
•Safety – flammable gasses
(Vacuum Distillation Column, Storage
Tank; Flare Line; Vent Header; Vapor
Recovery; Flare or Waste Gas Recovery;
Incinerator Feed): O2
•Hydrogen Recycle Line: H2O
•SRU Tail Gas: H2S
•Ethylene: Acetylene (C2H2)
•Regenerator Outlet of FCCU: O2 and CO
•Moisture in Natural Gas: H2O
•Sulphur in Natural Gas: H2S
Chemical:
•Combustion at Furnace: O2 and CO
•Combustion at Incinerator: O2
•Reactor: O2
•Storage Tank: O2
•Chlor Alkali (CA) / Brine Electrolysis:
O2
•Chlor Alkali (CA) / Brine Electrolysis:
H2O
•Vinyl Chloride Monomer (VCM): O2
•Ethylene Dichloride (EDC): O2
•Tail Gas: O2
•Spinning: O2
•Acrylic Acid (AA): O2
Fertilizer:•Emission: NH3
•Combustion at Furnace: O2 and CO
•High Temperature Shift Converter
(HTSC): CO
Power / Captive Power:
•Combustion at Boiler: O2 and CO
•Ammonia (NH3) Slip at Selective Catalytic Reduction (SCR) or non- SCR: NH3
•Coal Mill / Coal Silo or Bunker: CO and O2
TDLS8000 Cross
TDLS8000 with YC8000
(Flowcell)
TDLS8200 Probe
TDLS8200 Reflective TDLS8200
Flowcell
TDLS5500

66. The names of corporations, organizations, products and logos herein are either registered trademarks or
trademarks of Yokogawa Electric Corporation and their respective holders.
Thank you

67. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
OptimisingMaintenance:
SMART Instruments (including Control
Valves)
Sujit John
Head- System Marketing
Yokogawa Engineering Asia Pte Ltd
Toshihiko Kawase
Head- PRM Planning
Yokogawa HQ

68. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Evolution of Field Communication Technology
2
Data
201020001990198019701960
ANALOG DIGITAL

69. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Digitized Data Driven Approach
(L1 SMART Assets)
3

70. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
PRM: Single Window to Asset Management
Instruments
Valves
Multi-Protocol
Support
AND MORE!
Physical Layer
Diagnostics

71. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Alarm Notification – Maintenance Alarm
5
(Blue)
GE System 1 Status -Device
to be investigated
(Orange)
GE System 1 Status –
Device Non Critical
Icon Detail
(Green) Healthy by Device Patrol
(Red) Maintenance alarming
by Device patrol
(Yellow)Maintenance Warning
By Device patrol
(Gray) Communication failure
(White) Status not yet confirmed
(Background
Gray)
Alarm Off
Un-confirmed alarm

72. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Remote Device Configuration - Parameter Manager
6

73. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Device Configuration – DTM Works

74. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
FDT/DTM – Similar to the Hardware Drivers
8

75. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
FDT (Field Device Tool)
•FDT is a vendor-independent, open interface
specification
•Defines an independent method to develop a software component (DTM) to be integrated into host systems
•FDT through these DTM’s provides direct access to all field device data
•FDT can support any protocol – protocol independent
•FDT is an open solution not controlled by one supplier
•It has been established to promote this open interface specification
•FDT is neither a programming nor a DD language
•FDT is complementary to these file types and enhances their functionality

76. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
DTM (Device Type Manager)
•DTM is a device operating programme
•Not running on its own but in a FDT frame application
•Is device specifically programmed by the device vendor
•Is FDT frame application independent
•Features a device specific human machine interface
•A DTM is a driver for:
•Instruments, Components and Communication interfaces
•A DTM includes all:
•instrument-specific data and functions
•all graphical elements and dialogues for ….
displaying measurement data, configuration, diagnostic data etc.

77. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Alarm Notification - Device Diagnosis(Device Viewer function)
* Device Viewer can be shown in both
DCS HMI and PRM Client if
integrated.

78. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Historical and MaintenanceRecords – Historical Messages

79. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Key Values of Plant Resource Manager (PRM)
Remote
Monitoring
Device Status
Visible to
Operator
Device Tuning
Device Parameter
Audit
Predictive
Maintenance
Synchronized
Device Data

80. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Applications of PRM
14

81. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Scene
015
1 Remote Monitoring
Daily maintenance
Challenge
Solution
Function
Benefit
KPI & Goal
Navigator:Show the device status on plant totally
DeviceViewer:
Detailstatus ofdevice
diagnosis
It provides efficient maintenance unitizing digital communication and
intelligent device. It Shift from field-based and experience-based
maintenance to technology-based and data-based maintenance.
It can reduce 60% of the site visit for trouble.
Check the intelligent device anytime. And expert can
investigate the situation remotely.
One can check immediately when something happens.
Optimize Site visits: Respond quickly and efficiently to
troubles
Allow to check devices remotely on PRM. We can check the diagnosis
status of device anytime easily.
Enables prompt and accurate action when the trouble occurs by checking
the device situation remotely.
︖We visit the site regularly to know the situation at the site.
︖Because the site is far (or dangerous), We can't go to the site
easily and we don't know the situation at the site.
︖If something goes wrong during operation, you must go to the
site to check the equipment. (However, in many cases the
equipment is normal ...)

82. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Scene
016
2
Improvement of device availability through early troubleshooting
Reduction of unnecessary field visit in case of trouble
Operator can check device status on trouble
Operation
Challenge
Solution
Function
Benefit
KPI & Goal
The operator can check the status of device and respond quickly
to trouble.
Information sharing between maintenance personnel and
operators advances, improving work efficiency and reducing
human error due to miscommunications.
When PRM is introduced, the operator can check the device status and
important device alarms on HIS(operator station).
In case of trouble, the status of the device can be checked on the HIS
(displayed the DeviceViewer on HIS), so that trouble can be checked
immediately.
PRM informs you of important equipment anomalies and signs of failure, so
you can deal with problems early and operate based on them.
By linking the PRM maintenance mark and the HIS operation mark,
maintenance staff and operators can work while sharing the situation,
which is effective in preventing work mistakes.
︖When trouble occurs, the operator requests maintenance
personnel to confirm the site. (Then there are many cases
where the site is normal)
︖If the operator can check the status of the equipment on
the spot, trouble shooting can be done quickly.
︖Maintenance personnel can work with peace of mind if they
can share the situation with the operator
(A)Process Alarm(Ex：IOP)HIS
DeviceViewer （Display
Device Diagnosis status）
Before
Check
on site
Call from
faceplate
(B) Opeguide Message
Call from
opeguide display
Critical
device alarm
PRM
Benefit

83. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Scene
017
3
It will be efficiently tuning of devices.
It will be 1/10 the time of valve tuning by utilize of valve software.
Device Tuning (DTM, Valve Software)
Commissioning, Daily maintenance
Challenge
Solution
Benefit
KPI & Goal
Signature
FDT/DTM
Valve software(PLUG-IN Application)
Function
It is possible to compare and re-use the data and reduces work time
and mistake for commissioning.
Valve Software reduces the work time for valve.
Valve Software
provides the
capability of auto
setup and
calibration, getting
valve signature
efficiently.
DTM provides the
specialized GUI for
efficiently tuning work for
each device.
It is possible to set remotely from PRM. PRM provides common GUI called
FDT(Field Device Tool) flame application for DTM for multi- vendors.
User can execute tuning devices using graphical interface by DTM(Device
Type Manager）which is designed and provided by device vendor.
It can be used for valve tuning efficiently by using valve software from
valve vendor on PRM (PLUG-IN Application)
It is useful the signature date of valve can get by valve software on PRM
for planning for periodically maintenance.
It can compare parameters with other device and saved data. (Parameter
Manager)
︖It is tough work to set large number of numerical
parameters on smart devices.
︖It is expected to set parameters effectively for many
models of devices from different vendors.
︖We want to re-use the parameters that have already been
set.

84. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Scene
018
4
It will help to cut down the time to check the
parameters in commissioning time and reduce the
trouble after commissioning. (Typical case : few days
→ few hours)
Device Parameter Audit
It shows the parameter values that are different from the baseline values in all compared devices.
Value differences are listed and highlighted.
Compare with A) Device B) Template
Commissioning, Daily maintenance
Challenge
Solution
Function
Benefit
KPI & Goal
︖There are hundreds of parameters on intelligent devices.
Managing these parameters on Excel or Paper is not
efficient.
︖It is required to check the setting parameter’s value
initially, and it is time consuming to check these one by
one.
︖It Identification of any wrong parameters setting is
difficcult
Allows device parameter comparison for multiple devices, validates
incorrect parameter values.
Compare device actual parameter data/last saved parameter set with
baseline parameter set of a device for multiple devices concurrently. It is
possible to set template as baseline parameter set.
It is possible to know the audit and the difference by comparison of the
parameters (Parameter manager).
It reduces the time to check and human influence by allowing
device parameter comparison and checking after initial
installation.
Device parameter setting can be easily changed and confirmed
to help trouble shoot.

85. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Scene
019
5
It provides efficiently replacement of device and reduce the mistake by
share the data and using the common tool
It realizes the centralized management including audit.
Utilize device data when replacing devices (FieldMate Sync)
︖When replacing the device, it is set based on the initial data which could be stored on paper. Human error should be eliminated
︖We expect to manage the information on PRM not only after commissioning but also work bench and site work.
︖It is expected to use common operation platform for both site work and remote environment.
Commissioning, Daily maintenance
Challenge
Solution
Benefit
KPI & Goal
DTM (Device Type Manager)
Parameter Manager
Function
PRMFieldMate
PRM-FieldMate Synchronization
It is possible to have a centralized management for all the device
information on PRM.
When replacing the device, parameter information of the earlier device can be used.
FieldMate is tool for site work. PRM provides remote work platform. PRM provides synchronization with FieldMate. PRM can manage site work
remotely and efficiently.
Device information (parameter data) stored in PRM can be used with FieldMate during device replacement.
In tuning work, field work by FieldMate and remote work by PRM can be
performed using the same GUI, and information can be exchanged between them.

86. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Scene
020
6
For example, reduce the number of sudden failures to cause of unplanned
shutdown by 5% within one year
For example, reduce maintenance costs by 5% within one year
Predictive Maintenance by Parameter Monitoring
Daily maintenance
Challenge
Solution
Function
Benefit
KPI & Goal
Identify abnormal device to prevent sudden failure and realize stable operation.
Trouble analysis after a problem occurs is easy, and problems are resolved early.
The inspection plan according to the deterioration state of device becomes easy.
It is possible to monitor the condition od device by accumulating the parameters of device.
It can know the degradation of device easily by the trend display of device parameters.
It will send an alarm if the parameter exceeded the threshold.
It can start easily because Yokogawa prepares the parameters for this function.
︖Expect to monitor device degradation in real time using device parameters
︖Expect to realize predictive maintenance for failure of device to prevent unplanned plant shutdown.
Bad!
InsightSuiteAE Starter Edition
Monitoring of
device parameter
related cause of
failure
Threshold
Parameter Monitoring

87. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Integration of ICSS & PRM

88. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Typical System Architecture of PRM
Ethernet
Vnet/IP
（Control Network)
PROFIBUS DP
Communication Module
Ethernet Module
Temperature
Transmitter
Wireless Gateway
Pressure Transmitter
PROFIBUS DP
ENG
HISSENG
PRM: All-in-One Configuration available

89. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
PRM Benefit
Q. You need to know how your equipment and instruments are performing,
but how do you access the data?
Before
A. We analyse each piece of equipment one by one
manually.
After
A. Key Performance Indicator (KPI) reports for
equipment and instruments run at regular intervals.

90. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Field Asset KPI Report
•Field Asset KPI Report help
users identify bad actors and
improve device availability
•Overall Summary
•Device Status
•PRM
•NAMUR
•Device Availability
•Alarm & Events
Overall Summary

91. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Field Asset KPI Report
Device Status Summary
NAMUR NE107 Summary
Device Status Summary
PRM Device Patrol

92. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Field Asset KPI Report
Alarm & Events Summary
Device Availability Summary

93. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Digitized Data Driven Approach
Critical Assets:
Control Valves
Control Loop

33

94. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Asset Performance Analytics
34

95. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
PRM/ISAE Intelligent Reporting
35
Comprehensive
KPI Report
Control Valve
Diagnostics
Heat Exchanger
Diagnostics
Control Loop
Diagnostics
Fault Monitoring
Diagnostics
Failure Prediction
Diagnostics
Parameter
Monitoring
PAMDCS
Process Data Field Digital Data
Foundation Fieldbus
Segment Monitor
Bad Actor Extraction Root Cause Drill-down
FF and HART Field Devices Control Loops
Field Devices Valve & Loop

96. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
ISAE Benefit
Q. You have a control loop or control valve problem, but when do you first
notice?
Before
A. We don’t. The valve is operated in manual.
After
A. InsightSuiteAE identifies 80% of control loop
root causes.

97. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
[Loop]
Bad controllability
e.g. Sensor problem
Valve design issue
(20%)
Valve problem
(30%)
Loop tuning problem
(30%)
Control Loop & Control Valve Diagnostic
37
[Loop]
MV out of limits
[Loop]
AUT mode
[Loop]
MAN mode
[Valve]
Bad condition
[Valve]
Good condition
Time In Preferred Mode
≦ 50%
Time In Preferred Mode
> 50%
Time In Control
≦ 80%
Time In MV Out Of Limits
≧ 20%
Control Valve Diagnostic
Control Loop Diagnostic
The Control Loop and Valve Diagnostic and the KPIs extract bad
actors and enable to drilldown the root causes.

98. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Control Loop Diagnostic
38

99. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Control Loop Diagnostic
39
MV out of limitsMV out of limits
Bad control
Good control
Good control
No. KPI Description
1Time In Preferred Mode Percentage of time when the loop is operated under
preferred mode (e.g. AUT+ (AUT / CAS / RCAS)).
2Time In Control Percentage of time when the PV is within good
control zone (e.g. SV±5% (of the PV range)).
3Time In MV Out Of LimitsPercentage of time when the MV is out of the limits
(e.g. MV<5% or 95%<MV) .

100. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Control Valve Diagnostic
40
1Controllability
[KPI Definition]
Deviation between MV and the actual
valve position feedback
[Possible Cause]
Time degradation (Drift)
Valve incomplete close
Calibration
2Hunting
[KPI Definition]
Amplitude: Travel stroke / Cycle count
Cycle count per hour
[Possible Cause]
Mechanical stress (Huge number of valve
cycles)
Bad loop tuning

101. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Control Valve Diagnostic
41
3Inadequate Air (Supply air pressure)
[KPI Definition]
Supply air pressure
[Possible Cause]
Supply air pressure lowered
Valve performance lowered
4Linkage
[KPI Definition]
Deviation between MV and the
actual valve position
[Possible Cause]
Deterioration of linkage part of
the valve
Sudden air supply shut

102. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Control Valve Diagnostic
42
5Stiction
[KPI Definition]
Standard deviation of deviation between
MV and the actual valve position
[Possible Cause]
Stick
Slow response
6Packing (Travel stroke, Cycle count increment)
[KPI Definition]
Total distance of travel stroke
Total number of cycle count
[Possible Cause]
Time degradation (Drift)
Mechanical stress

103. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
ISAE Benefit
Q. You need to perform maintenance to ensure ongoing operation, but how
do you decide when?
Before
A. We perform maintenance at predetermined
intervals.
After
A. InsightSuiteAE monitors equipment status and
enables a condition-based monitoring approach.

104. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Fault Monitoring Diagnostic
44
Bad
(Failure mode 1)
Normal
Bad
(Failure mode 2)
These tags cause the failure.
Evaluating plant asset health and failure mode with multivariate analysis
with multiple device data

105. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
ISAE Benefit
Q. You need to know how your equipment and instruments are performing,
but how do you access the data?
Before
A. We analyse each piece of equipment one by one
manually.
After
A. InsightSuiteAE generates Key Performance
Indicator (KPI) reports for equipment and
instruments at regular intervals.

106. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Report can be generated periodically (e.g.
daily) and automatically.
It’s useful for daily maintenance activity.
InsightSuiteAE server name
Analysis period
- Target asset type
- Target KPI
- Ranking format
E-mail
Target hierarchy (assets)
Comprehensive Report Generator
46
Report can be customized with the UI tool and generated automatically.

107. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Comprehensive Report
47
Overall performance KPI
Drill-down root cause
Overall performance of control loops
Overall performance of control valves
Comprehensive Report makes it easy to grasp overall asset
performance and root causes.
Score
Loop Controllability and Valve Overall Performance
0.0
50




20 ≤ Score < 4040
Score < 20 50
Loop Controllability Overall Performance
Extract 'AUTO' operation loops.(Preferred Mode 'Good'.)
Score
80 ≤ Score 10
60 ≤ Score < 8020
40 ≤ Score < 6030
Loop Controllability Overall Performance
11.9
50
Valve Overall Performance
100.0
10
Loop and Valve
Overall Performance Score
Extract Controllability 'Bad' or 'Fair' loops from 'AUTO' operation looExtrac t lo o ps satu rate d MV o r re late d CV KPI 'B ad' f ro m Co n tro llabi
Valve Overall Performance
100
11.86
0
0
67.8
100
0
20.34
0
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
V alve O ver all P e rf o rm an c e
L oop Contr ollab ility O ve ra ll Per for ma nce
L oop Contr ollab ility a nd Va lve O ve ra ll Per for m anc e
Performance Distribution
Ratio of Good/Bad Performer in
Loop Controllability and Valve Overall Performance
Good Pe rform e rBad PerformerUncertain Performer
7, 12%
10, 17%
12, 20%
4, 7%
14, 24%
12, 20%
Performance Distribution
Loop Controllability
Overall Performance
T ime In Cont rol - Good,
MV O u t O f L i m i ts -
Good
(Pr iorit y Hig h+, High: 0)
T ime In Cont rol - Good,
MV O u t O f L i m i ts -
Ba d /Fair
(Pr iorit y Hig h+, High: 0)
T ime In Cont r ol -
Ba d/Fair,M V Out Of
L imit s-G ood
(Pr iorit y Hig h+, High: 0)
T ime In Cont r ol -
Ba d/Fair,M V Out Of
L imit s-Ba d/Fai r
(Pr iorit y Hig h+, High: 0)
N on-AU TO Opera tion,
(Pr iorit y Hig h+, High: 0)
U ncert ain,
(Pr iorit y Hig h+, High: 0)
33, 56%
14, 24%
12, 20%
Performance Distribution
Loop AUTO Operation
A UT O Op e r a t i o n
N on - AU T O Ope ra tion
U n ce rt ai n 17, 52%
16, 48%
0, 0%
Performance Distribution
Loop Controllability in
AUTO Operation
T ime In Cont rol - Good
T ime In Cont r ol - Bad
o r Fair
U n ce rt ai n
12, 75%
4, 25%
0, 0%
0, 0%
Performance Distribution
Recommended Actions for
Bad/Fair Loop Controllability
PID T uning, et c
O per a tion or Va lve
S i zi n g,e tc
V alve
U nknown
47
42
28
25
33
0
3
15
15
12
0
2
4
7
2
12
12
12
12
12
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
T i me In A l ar m O f f S ta tu s
T i me In A l ar m S ta tu s
T ime MV O ut O f L imit s
T ime In Cont rol
T ime In Preferred Mode
Performance Distribution
Loop KPI (Loop Controllability)
Good Pe rform e rF a i r P e rf o rm erBad Performer Uncertain Performer
0
20
40
60
80
100
Time In Preferred
Mode
T ime In Cont rol
Time MV Out Of
L imit s
T ime In A lar m
S t atu s
T ime In A lar m O ff
S t atu s
Performance Distribution
Loop KPI
(Loop Controllability)
P e rf o r m an c e %
3
3
3
3
3
3
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
T o tal B ad P ac kin g T im e
T otal S tic tion T im e
T o tal B ad L in kag e T ime
T otal I nadequat e Air Tim e
T otal H unting Tim e
T otal D evia tion T im e
Performance Distribution
Va l v e KP I
Good Pe rform e rF a i r P e rf o rm erBad Performer Uncertain Performer
0
20
40
60
80
100
T otal D evia tion
T i me
T otal H unting
T i me
T otal I nadequat e
A ir T im e
T o tal B ad L in kag e
T i me
T o tal S ti c ti o n
T i me
T o tal B ad P ac kin g
T i me
Performance Distribution
Va l v e KP I
P e rf o r m an c e %

108. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Field Asset KPI Report
48
Bad actors (Latest status)
Bad actors (Time performance)
Bad actors (Alarm count)
Field Asset KPI Report adds more insights by providing bad actor field
devices by utilizing self-diagnostic results stored in PRM maximally.

109. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
ISAE Features Summary
49
Field Devices
Level 1
Level 2
Level 3
Level 4 Finance
Quality Production Maintenance
Level 0
Control Loops (PID)
Visualization, common workplace and drilldown capability are the
features provided by InsightSuiteAE.
Common Workplace
Visualization
Drilldown
Capability

110. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
ISAE Features Summary
50
Level 1
Level 2
Level 3
Level 4 Finance
Quality Production Maintenance
Level 0
Common Workplace

























7, 12%
10, 17%
12, 20%
4, 7%
14, 24%
12, 20%
Performance Distribution
Loop Controllability
Ove rall Pe rformance
T ime In Cont rol - Good,
MV O u t O f L i m i ts -
Good
(Pr iorit y Hig h+, High: 0)
T ime In Cont rol - Good,
MV O u t O f L i m i ts -
Ba d /Fair
(Pr iorit y Hig h+, High: 0)
T ime In Cont r ol -
Ba d/Fair,M V Out Of
L imit s-G ood
(Pr iorit y Hig h+, High: 0)
T ime In Cont r ol -
Ba d/Fair,M V Out Of
L imit s-Ba d/Fai r
(Pr iorit y Hig h+, High: 0)
N on-AU TO Ope ra tion,
(Pr iorit y Hig h+, High: 0)
U nce rt ain,
(Pr iorit y Hig h+, High: 0)
33, 56%
14, 24%
12, 20%
Performance Distribution
Loop AUTO Operation
A UT O Op e r a t i o n
N on - AU T O Ope ra tion
U n ce rt ai n 17, 52%
16, 48%
0, 0%
Performance Distribution
Loop Controllability in
AUTO Operation
T ime In Cont rol - Good
T ime In Cont r ol - Bad
o r Fair
U n ce rt ai n
12, 75%
4, 25%
0, 0%
0, 0%
Performance Distribution
Recommended Actions for
Bad/Fair Loop Controllability
PID T uning, et c
O per a tion or Va lve
S i zi n g,e tc
V alv e
U nknown



































Drilldown
Visualization, common workplace and drilldown capability are the
features provided by InsightSuiteAE.

111. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Case Studies
51

112. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
PRM Case Study – Nedmag Industries
52
Production site and mine are 5km apart, but PRM centralizes access to
instrument information.
Pre-PRM implementation an incorrectly configured instrument at the mine took
up to half a day to resolve.
Post-PRM implementation this configuration can be done from the PRM client
within a short time.
Plant environment limits work hours on site.
Devices often in locations that are not easy to access.
“Central access makes work so much more convenient.”

113. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
PRM Case Study – Mitsubishi Chemical Corporation
53
Identified a failure in a critical temperature transmitter.
Corrective action was taken before this caused a plant shutdown.
Saved losses of AUD$0.5M and 5 days recovery time.

114. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
ISAE Case Study – Thai Acrylic Fibre
54
InsightSuiteAE Control Loop Monitoring
•Identified inefficient use of steam and instrument air in plant’s dryer section.
•Average temp. setpoint was at a 6% higher value to compensate for inefficient tuning.
•Control valve movement was 12% of range.
•TuneVP was used to tune the loop.
•Control valve movement now 5% of range.
•Air compressor electricity saving is ~6,400kWh.
•Annual steam saving is ~3,100 tons.

115. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Gas field project - Challenges
55
Gas wells are scattered in the fields
Decreased the gas production
volume
Required to reduce the operation
costs further
Yokogawa PRM & InsightSuiteAE
for remote monitoring

116. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Our Solutions for Control Valves
56
•Vendor agnostic & predictive analytics solution
•Daily monitoring performance of 1,850 control valves with HART/FF
positioners.
•Successfully reduce the amount of periodic inspections on control valves.
•Annual cost saving of €60,000!

117. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Challenges & Solutions for Mass Flow Meters
57
•Challenges
•Many mass flow meters were unfairly replaced
•Not the meter but the process caused disruptions
•Forming of unwanted emulsions & clogging
•Our solutions
•Parameter monitoring for health diagnostics on flow meters
•Sort all flow meters & detect bad actors by remote analysis
•Annual cost savings: €40,000

118. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Major Oil & Gas company-Challenges
58
Information from 3 plants is integrated on a dashboard for expert engineers to
provide superior engineering service to each plant.
Field Devices
Control Loops (PID)
PID PID PID PID PID PID PID PID PID
Field DevicesField Devices
Control Loops (PID)Control Loops (PID)
[Plant 2][Plant 1] [Plant 3]
[Engineering Service Center]
Dashboard
(Common Workplace)

119. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Our Solutions
59
•Quick step up for data integration from the 3 domains.
•A holistic view of performance monitoring of control loops,
valves & sensors
•Vendor agnostic & predictive analytics solution
•Ability to drill down to identify the causes of
underperforming loops from “Engineering Service Center”

120. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Electric Power Company -Challenges
60
•Information from asset monitoring system including InsightSuiteAE & SAP is
integrated on a management dashboard.
•Work orders, control loops & asset health conditions

121. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Our Solutions
61
•Quick step-up for data integration
•A holistic view of performance monitoring of control loops, valves & sensors
•Ability to drill down to identify the causes of underperforming loops
•Vendor agnostic & predictive analytics solution
Asset performance Loop performance Work order (from SAP)

122. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
For Internal Use Only
Data Driven Optimization
62
Device status viewing
Audit Trail Tuning, Adjustment
& Calibration
Maintenance Information
Management Maintenance Alarm
Diagnostics
(Control Valve, Control Loop,
Heat Exchanger & Fault Monitoring)
Core Integrated Maintenance & Predictive Diagnostics Platform
Predictive MaintenanceEarly Detection
KPI/PerformancePlant Asset
Organization
AOM IM Hub
.
.
.
.
.

123. The names of corporations, organizations, products and logos herein are either registered trademarks or
trademarks of Yokogawa Electric Corporation and their respective holders.
Thank you

124. Resource o f Field Instrument
Updates & Use Cases
February 2025
Paul Unting
Yokogawa Kontrol (M) Sdn Bhd

125. ROFI – Objectives
2
Better access
to field
instruments
DATA
Ability to use
both diagnostics
and non-
diagnostics
DATA
Ease of use for
monitoring
and managing
fleet of field
instruments

126. ROFI – Block Diagram for Data Flow
3
Engineering Module
Parameter adjustment tools
DTM
Works
Parameter
Manager
Database
DTM
Data
Parameter
Set
Load/Save
Points
Item
Engineering Centre
Diagnostic
Target
OPC Item ID
Target Path
Dashboard
Data Source
Node ID
Value Path
(KPI)
Load/Save
Ethernet. API
OPC UANative Driver

127. PRM DATA
4
Diagnostic Path: PRM to ISAE Non-Diagnostic Path: PRM to CI Server

128. PRM-ISAE Data Flow L2 to L4 POC
5

129. PRM DATA [non-diagnostics]
6
COMMON
address string 0x00
aux1 string blank
aux2 string blank
aux3 string blank
Category string blank
CommType string HART
Comment string TX-ID
DeliveryDate UtcTime 0001- 01-01T00:00:00Z
DeviceID string 3704895747
DevicePath string PRM-to-controller-path
DeviceTag string TX-ID
LoopName string blank
MessagePath string PRM-top-plant
Model string EJA
OperationStartDate UtcTime 2024- 05-04T 16:00:00.000Z
PlantHierarchy string DESK
Priority string 0
RegisteredBy string PRM-username
Revision string 2
SerialNumber string blank
SubModel string blank
UpdateDate UtcTime 2024- 05-05T 15:22:49.000Z
UpdateUser string PRM-username
UserDefinedCategory string blank
Vendor string YOKOGAWA
DETAIL
DDRevision string
0x01
Descriptor string
user-defined- description
DeviceFlag string
0
DeviceRevision string
0x02
DeviceTypeID string
0x000004
HardwareRevision string
1
LongTag string
blank
ManufacturerID string
0x000037
Message string
user-defined- text
PDTag string
TX-ID
PhysicalSignalingCode string
0
ReadDate UtcTime
2024-05-05T 15:17:01.0000z
RequestPreambles string
5
SofwareRevision string
9
UniversalRevision string
5
MTMK
MTMKLabel string
None
MTMKValue int
0
STATUS
DeviceStatus int 20
Health int 0
PARAMETERSET
__COMMUNICATION_RESPONSE string
__DEVICE_STATUS string
__DEVICE_STATUS_CMD3 string
__OPERATIONAL_STATUS_DETAIL string
__PV_LOWER_RANGE float
__PV_RANGE float
__PV_UNIT string
__PV_UPPER_RANGE float
__PV_VALUE float
__SV_UNIT string
__SV_VALUE float
__TV_UNIT string
__TV_VALUE float
analog_output_alarm_select string
analog_output_value f loat
as c _mod el string
asc_serial_no string
bi_dir_mode string
busrt_command_number string
busrt_mode_s elect string
date string
descriptor string
devic e_id int
devic e_type string
disp_func string
disp_mode string
drain_vent_material string
engr_dis p_lrv f loat
engr_dis p_point string
engr_dis p_unit string
engr_dis p_urv f loat
engr_dis p_value f loat
ext_sw_mode string
final_ass embly_number int
flange_m aterial string
Flange_size string
f lange_ t yp e string
gasket_material string
h2o_unit_s elect string
low_cut_mode string
low_cut_point f loat
Manufac turer_id string
Mes s ag e string
module_fill_fluid string
module_is olator_material string
number_of_rem ote_s eals string
Polling_address byte
pressure_damping_value f loat
pressure_lower_range_limit f loat
pressure_lower_range_value f loat
pressure_minimum_s pan f loat
pressure_output_transfer00001391 string
pressure_perc ent_range f loat
pressure_units string
pressure_upper_range_limit string
pressure_upper_range_value string
pressure_value f loat
private_label_distributor string
remote_s eal_fill_fluid string
remote_s eal_is olator_material string
remote_seal_type string
request_preamble byte
sensor_a_lower_s ens or_trim_point f loat
sensor_a_upper_sensor_trim_point f loat
software_revision byte
static_pressure_units string
static_pressure_value f loat
transmitter_revision byte
univers al_revision byte
write_protect string
xmtr_specific_status _0 string
xmtr_specific_status _1 string

130. ROFI Typical Architecture
7
PRM + ISAE
CI SERVERL3
L3.5
VNET
L4
IMHUB
USER
Field Devices
ROFI
•Provide visibility to field devices data from L4
IMHub
•Data repository for further consumption at L4
onwards
CI Server
•Access to non- diagnostic/parametric data
PRM + ISEA
•Main source of ROFI data
•Diagnostic/Advance diagnostic data

131. ROFI Dashboard
8

132. ROFI Dashboard
9

133. Data Source Manager
1
0

134. Data Source Manager
1
1

135. Import / Export
1
2

136. Key Performance Indicator
1
3

137. Key Performance Indicator
1
4

138. Report Viewer
1
5

139. Report Viewer
1
6

140. Workflow Definition
17

141. Workflow Definition Editor
18

142. Workflow Instances
19

143. ROFI Demo
20

144. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Workforce Enhancement
through Alarm Management
with Data Analysis
4,6/Feb.,2025
Hiroaki Tanaka, Ph.D
PCG/PCSB Engagement Session

145. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Contents
2
1. Outline of this presentation
2. Target Activities in Alarm Management Lifecycle
3. Detail of Alarm Evaluation
4. Demo of Data Analysis
5. The Project Achievement
6. Summary

146. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
1. Outline of this presentation
3

147. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Outline of this presentation
4
1) This presentation is based on Actual Project of Alarm Management
- Totally 12 plants (Fine/Chemical/Utility, Continuous/Batch)
- 5 years project
- Established whole of Alarm Management Lifecycle
Activity-1:
Philosophy
Creation
Activity-2:
Alarm design
Activity-4:
Alarm
Evaluation
Activity-5:
Change
Management
Activity-3:
Alarm
Operation
Activity-6:
Assessment
2) Original Objective
a) Reduction of operational risk due to missing
important alarms and mis-operation
b) Building a solid foundation for coming DX project
Ref. Alarm Management Lifecycle: ANSI/ISA- 18.2-2016
3) Additional Achievement
c) Changed mind- set of operational workforcewith,
- Motivation up from success
- Behavioral changes for more advanced challenges
- Organizational enhancement by sharing skill/knowledge
... mainly by Data Analysis

148. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
2. Target Activities
in Alarm Management Lifecycle
5

149. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Objective: Establish and Sustain Alarm Management Lifecycle
6
Ref. Alarm Management Lifecycle: ANSI/ISA- 18.2-2016
Activity-1:
Philosophy
Creation
Activity-2:
Alarm design
Activity-3:
Alarm Operation
Activity-4:
Alarm Evaluation
Activity-6:
Assessment
Activity-5:
Change Management
Today's main topic

150. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
3. Detail of Alarm Evaluation
7

151. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Typical Flow of Alarm Evaluation activity
8
1) Target setting and
progress monitoring
with Alarm KPI
2) Data analysis for root cause identification
a) Primary analysis for segregation
3) Workshop to identify actual
root cause and formulate countermeasures by team building
4) Implement the
countermeasures
Example of countermeasures:
- PID tuning
- Alarm re-configure
- DCS sequence adjustment
- Implement automation system
- Equipment repairment, etc.
Consolidated Data Analysis
b) Detail analysis for root cause identification
Key Pointto be achieved:
How to sustain this cycle more effectively and efficiently.

152. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
a. Introduced Alarm KPI
9

153. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Plant Stability Index as Evaluation of Operator Workload
10
Plant
Stability
Alarm
[day*100 Ai]
Intervention
[day*100 Ao]
Operator Capability
can be achieved
[Ao / operator]
Unstable > 20 > 144 200 (< 200)
Semi-stable < 20 < 144 250 (200 - 250)
Stable < 12 < 100 300 (250 - 380)
Super-stable < 6 < 24 500 (380 - 600)
Ai: Analogue input, Ao: Analogue output
Reason of introduction:
1) Operator Intervention can be evaluated as well
(Automation is also required for DX foundation)
2) Independent from count of board operator
3) Optimum coverage per board operator (no. of
analogue output) can be estimated

154. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
b. Root Cause Identification
(Approach)
11

155. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
0%10%20%30%40%50%60%70%
0
2,0004,0006,0008,000
10,00012,00014,000
1
6
11
16
21
26
31
36
41
46
51
56
61
66
71
76
81
86
91
96
Accumulate
Intervention Count
Tag Rank (No.1
-
100)
Intervention CountAccumulate
0%5%10%15%20%25%30%35%40%45%
0
500
1,0001,5002,0002,5003,000
1
6
11
16
21
26
31
36
41
46
51
56
61
66
71
76
81
86
91
96
Accumulate
Alarm Count
Tag Rank (No.1
-
100)
Alarm Count
Accumulate
Approach for Root Cause Identification
12
Need to consider difficulty
of root cause identification
Unit-AUnit-BUnit-C
Need to consider Process Unit base automation
Difficulty
(Criticality for
process operation)
More comprehensive and
Advanced Data Analysis is required.

156. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Utilization of Dedicated Tools for Data Analysis
13
Tools have been continuously enhanced during this Project
for practical and effective Data Analysis
for Event Data Analysis (Primary)
(eventCT)
for Event/Trend Data Analysis (Detail)
(trendVT)

157. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
c. Root Cause Identification
(Example)
14

158. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Example of Primary Analysis: Correlation Analysis
15
Can extract higher correlation of event trend
between,
- Alarm vs Alarm, - Alarm vs Intervention
so that effective reduction can be conducted.
Consecutive
Alarms
Alarm Handling
Operation
Ignored
Alarms
High
Probability No operation
after alarm
Alarm
Operation
P10101
HI
P10101
MAN
P10101
MV
P10101
AUT
P10101
SV
↓28.6%(↑58.4%)
↓22.5%(↑75.2%)
↓52.4%(↑51.2%)
↓49.4%(↑82.2%)
↓95.8%(↑78.8%)
↓88.3%(↑50.49)
More Advanced Correlation Analysis
(by separate Reporting Service)
Correlation Coefficient Matrix

159. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Example of Detail Analysis for Root Cause Identification
16
1) Feed cut &
Decoking (3days)
2) Shut down for
repair (3days)
3) Start up but
failed (1.5day)
4) Fix the trouble
(1day)
5) Re-start up
Background: 1) Selected higher rank of alarms (LC32001, TC32001)
2) There is cascade control loop for Drum Level: LC32001 -> FC32002
Identified root cause:
- Poor controllability on
LC32001/FC32002
Also found that this is resulting in,
- Equipment damage
- Production loss by fail to start up
: Alarm
: Intervention
From
Shift Log

160. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
d. Approach for
Determination of Countermeasures
(On-demand Training)
17

161. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
On-demand Execution of Associated Trainings for Operators
18
PID tuning DCS logic investigation Automation tool (Exapilot)
A) Basic Training with
Lecture and Hands- on
B) Discussion with actual
data for PID tuning
1. Drag and Drop icons
3. Parameter setting
after calling detail window
with double clicking the icon
2.Connecting icons
ExapilotBuilder Window
A) Basic Training
B) Validation by Trial Mode
(only read from DCS)
Using Actual Data base
Key point is to utilize actual case and data.

162. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
e. Determination of Countermeasures
(Example)
19

163. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Direct Process Model
Identification
PID tuning on Simulation tool
Countermeasure Example: PID tuning(Temperature)
20
Background: 1) Selected higher rank of alarms and interventions (TC13080)
2) This tag is controlling temperature of additives supplied to dryer
Before PID tuning After PID tuning
Many interventions (MH/ML) were required against ambient temperature fluctuation
- No intervention is required against
ambient temperature fluctuation.
- Temperature can be more stabilized.
Key Point:
- Knowledge of PID tuning
- Actual data usage
- Utilization of simulation tool
Implement into System

164. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Extract Start-up periods Analyze differences between operations with
visualization, then determine standard operation
Implement into Automation System (Exapilot)
Countermeasure Example: Automation of Manual Interventions
21
Background: 1) Selected higher rank of interventions (LIC2015)
2) Many interventions during start-up of vaporization equipment
Key Point:
- Understand each manual operation
- Determine Standard operation
- Visualize as flow chart

165. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Correlation Analysis to select data for creation of Estimation ModelCreate Estimation Model and Validate
Countermeasure Example: Estimation for Continuous Process
22
Background: 1) Quality alarms of product from distillation tower during feed changing
2) Quality is measured by analyzer, but causing measurement time delay (1h)
Implement into
System for
Prediction
Key Point:
- Obtain accurate Model for Estimation with
understanding from,
* Chemical Process perspectives * Statistic Knowledge
(i.e. should NOT be "Black Box")
Method:
Multiple Regression
Category:
Machine Learning
/ Supervised
/Regression

166. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
4. Demo of Data Analysis
23

167. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Demo of Data Analysis
24
Automation
Prediction (Continuous)
PID tuning
Prediction (Batch)
Early Detection

168. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
e. Determination of Countermeasures
(Example) (Continue)
25

169. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Extract data of target batchesCorrelation Analysis to select data for
creation of Estimation Model
Create Estimation Model
and Validate
Implement into System (Exapilot)
for Prediction
Countermeasure Example: Prediction for Batch Process
26
Background: 1) Many Interventions due to fluctuation of polymerization time for some product grades
2) Stabilization of Reaction time is also beneficial for efficient production
Key Point:
- Efficiently analyze complicated batch data
- Obtain accurate Estimation Model for Prediction with
understanding from,
* Chemical Process perspectives * Statistic Knowledge
(i.e. should NOT be "Black Box")
Method:
Multiple Regression
Category:
Machine Learning
/ Supervised
/Regression

170. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Correlation Analysis to select data for creation of
Detection Model
Create Detection Model (Mahalanobis Distance) and Validate
Countermeasure Example: Early Anomaly Detection
27
Background: 1) Reactor pressure need to be monitored carefully
2) Its anomaly detection requires skilled experiences
Key Point:
- Obtain accurate Model for Abnormal
Detection with understanding from,
* Chemical Process perspectives * Statistic Knowledge
(i.e. should NOT be "Black Box")
Implement into System for Detection
Utilized Statistic Method
Method:
Mahalanobis Distance (PCA)
Category:
Machine Learning
/ Un-Supervised
/ Demensionality Reduction

171. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
5. The Project Achievement
28

172. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
a. Alarm KPI
29

173. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Improvement of Plant Stability Index
30
Operator Intervention
[count / (day * 100 * Analogue output loops)]
Alarm Count
[count / (day * 100 * Analogue input loops)
Plant-I
Plant-A
Plant-DPlant
-F
Plant
-G
Plant
-C
Plant -J
Plant-E
Plant -H
500
200 500
Plant -B
Semi-Stable Area
Stable Area
(Target)
Unstable Area
■：Before 5 yeas Project
●：After the Project
Could realize more stable and safe operation
with necessary skills and knowledge,
so that they can continue after this project by
themselves.

174. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
b. Establishment of
Alarm Management Lifecycle
31

175. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Assessment: Alarm Management Lifecycle Completeness
32
- Developed with project experiences in Japan domestic and
overseas
- Metric to measure completeness of Alarm Management
Lifecycle along with ISA-18.2
- Evaluate establishment status of 10 items on a Band 0- 5
(5:best) basis.
(At least, Band4isrecommendedtobe achieved.)

176. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
c. Improvement of other Activities
than Alarm Evaluation
33

177. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Ref. Alarm Management Lifecycle: ANSI/ISA- 18.2-2016
Objective: Establish and Sustain Alarm Management Lifecycle
34
Activity-1:
Philosophy
Creation
Activity-2:
Alarm design
Activity-3:
Alarm Operation
Activity-4:
Alarm Evaluation
Activity-6:
Assessment
Activity-5:
Change Management
For all of alarms,- Basis of alarm setpoint, to
- Prioritization
(by collaboration between sections)
Implemented automatic deviation report system (see next page)
in addition to Approval System
Today's main topic

178. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Change Management: Deviation detection report system
35
HIS
Ethernet
Vnet/IP
PC
FCS
Alarm master
database
Compare
AOF Detection Report
Equipment
Name
Tag Name Tag Comment Alarm type HH LL HI LO DV+ DV- MHI MLO I OP I OP - Tag etc.
Equip-A LC002 comment Detaction > AOF_ H I AOF_ M H I AOF_ Tag
Equip-A FC010 comment Detaction > AOF_ L O
Equip-A AN001 comment Detaction >AOF_ H H AOF_ H I
Equip-C 02FC001 comment Detaction > AOF_ H IAOF_ L O
Equip-C 02TI003 comment Detaction >AOF_ H H AOF_ H I
Equip-E 04AIC0001 comment Detaction > AOF_ Tag
Equip-F 05FC090 comment Detaction > AOF_ Tag
Create Deviation Reports
Deviation Detection Report
Equipment
Nname
Tag
Alarm
type
Tag comment M aster DCS Unit
Equip-A LC001 HH comment 98 100%
Equip-A FC010 PL comment 20 10m 3/h
Equip-B AN002 LL comment 4 0pH
Equip-B LI010 DL comment 13 100%
Equip-B FI090 MH comment 99 100t/h
Equip-B TIC001 ML comment 5 0degC
Equip-B TIC002 PL comment 12 40degC
Equip-C 02FC001 LL comment 4 0t/h
Equip-C 02FI003 VL comment 12 100t/h
Equip-C 02LC002 DL comment 13 100%
Equip-C 02TIC010 I comment 20 80degC
Recommended to introduce system to detect deviation between master database and actual configuration in DCS.
In order to ensure sustainability of re-designed Alarm setpoints

179. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
6. Summary
36

180. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Workforce Enhancement with Data Analysis
37
<Various available Data>
- Trend data, Event data
- Setpoints (PID parameters,
Sequence, etc.)
- Task record (DCS operation, Field
operation, etc.)
- Production record (Load rate,
Quality index, etc.)
Others
<Knowledge / Experiences>
Operators
Maintenance
Instrument
Process
<Data Analysis Tools>
Clear understanding by,
- Quantitative Evaluation
- Visualization of Phenomena and Skill
Contributing to improve
Operation by countermeasures
Obtaining more skill / knowledge
Associated Trainings
Motivation Up
Contribution can
be measured
quantitatively
with Alarm KPI
with continuous enhancement
for practical and effective Data Analysis

181. The names of corporations, organizations, products and logos herein are either registered trademarks or
trademarks of Yokogawa Electric Corporation and their respective holders. 38
Thank you very much.

182. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Overview of introduced KPI representing Operator Workload
39
Overview:
1. Plant Stability Index is one of metric to measure stability of plant operation.
2. This index is developed by some Japanese plant and proposed by Japanese committee. (ref.1)
3. Currently, this index become one of common index especially in Japanese industry.
What it is ?:
1. This index is calculated by 2 parameters which are,
Y-axis: Count of board operator's manual intervention per day per (100 * count of analogue output loops)
Y-axis: Count of alarms notified to board operator per day per (100 * count of analogue input loops)
* Reason to divide by (100 * count of analogue loops) is for normalizing
based on plant size so that this index can be
compared regardless of plant size.
2. Stability Class are defined as area shown below upon plot of this index
Plant
Stability
Class
Alarm
[day*100 Ai]
Intervention
[day*100 Ao]
Unstable > 20 > 144
Semi-stable < 20 < 144
Stable < 12 < 100
Super-stable < 6 < 24
Ai: Analogue input
Ao: Analogue output

183. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Overview of introduced KPI representing Operator Workload
40
Feature:
1. This Plant Stability Index also provides appropriate analogue output count per one board operator based on
Plant Stability Class as shown in below table.
2. This appropriate means reasonable coverage of one board operator without any mis-operation and
overlooking of alarms.
3. For example, if current plant stability index is classified as Unstable area and meanwhile, actual count of
analogue output per board operator is calculated as 300, then it means that current board operation has risk of
mis-operation and overlooking of alarms which may result in load down or stoppage of production.
4. Therefore, this Plant Stability Index is also deemed as metric to measure workload of board operator.
Plant
Stability
Class
Alarm
[day*100 Ai]
Intervention
[day*100 Ao]
Reasonable analogue output
count per one board operator
[Ao / operator]
Unstable > 20 > 144 200 (< 200)
Semi-stable < 20 < 144 250 (200 - 250)
Stable < 12 < 100 300 (250 - 380)
Super-stable < 6 < 24 500 (380 - 600)

184. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Dynamic Alarming (State-base Alarming)
41
Equipment
Number
Trigger/
Alarm Tag
Alarm to be
suppressed
Delay
time
xx-P-0001
xx-XI-1709A
(Running Status)
(Trigger Signal)
xx-P-0001
xx-FIC-1004
(Discharge Flow)
Lo 20 sec
xx-P-0001
xx-PI-1213
(Discharge Pressure)
Lo 20 sec
xx-P-0001
xx-IZ-2001
(Pump Current)
Lo, LL 12 sec
xx-P-0001
xx-TI-1220
(Pump Temperature)
Lo 60 sec
Process value
Trigger signal
(Running Status)
Alarming Status
Delay time
Suppressed
Low threshold
Example of Data Analysis for Delay Time determination

185. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
Early Anomaly Detection
42
0
1
2
3
4
5
6
7
8
9
10
0 1 2 3 4 5 6 7 8 9 10
<Example in 2 dimensions>
Approach: Quantification of "Shift
of Balance" in target data (e.g.
abnormal state) from reference (e.g.
normal state) data set by
Mahalanobis distance.
Mahalanobis distance:
Distance of target data
from reference data set
considering correlation
among reference data set.
Utilized for multivariable
analysis.
Normal data set
Abnormal
Normal
Mahalanobis
distance
Normal
Abnormal
A
B
Small blue dot: reference data set
Red circle: target data to be tested
<Euclidean distance (common dist.)>
A → 1.0
B → 1.0
<Mahalanobis distance >
Distance by correlation (red ellipse)
A→ 1.3
B → 8.7

186. | GS2028 | April 1, 2024 |
© Yokogawa Electric Corporation
On MATLAB platform
(Free software to be installed)
Typical flow of Data Collection
43
OPC
Ethernet
Vnet/IP
PIMS
(PI/Exaquantum)
FCS
HIS
Even data
(CSV file)
HISHIST
files
(text file)
SystemData Analysis
Trend
data
(CSV file)
trendVT (Detail Analysis)
eventCT (Primary Analysis)
Extracted by Excel macro
with Excel Add-on
(PI DataLink/QDATA)
* YOKOGAWA developed
Long Term
HISHIST
files
(text file)
Extracted
(Copy)
Format
conversion tool
Import
Import
Import
CAMS
Export
CSV
Import to change
Alarm Priority

187. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
PRM Workshop:
Optimizing PRM Configuration
for Enhanced KPI Reporting and
Asset Management Efficiency
Siti Khadijah Binti Mohd Pauzi
LifeCycleServices Department
5
th
February 2025

188. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Objective
Thisworkshopaimtogainaclear,step-by-stepunderstandingofhow
toconfiguretheYokogawaPRMsystemeffectively,ensuringoptimized
functionality,andexplorehowaccurateconfigurationcandrivereliable
KPIreportingandenhanceassetmanagementefficiency.

189. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Agenda
1. PRM Housekeeping
a.Configuration of Device Information
b.Setup of device priority
2. Asset management using KPI report
a.Configuration of KPI report
b.Analysis on sample KPI report
3. Maintenance log creation for devices management (using investigation
report)
4. Parameter template & standardization

190. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
DevicereplacementmanagementonPRMExample(HART)
Performdevice
replacementat
CENTUMVP
PerformPlug&Play
Draganddrop
replaceddeviceto
OutofServicefolder
Draganddropnewly
registereddeviceto
thecorrectPlant
EquipmentModule
folder
UseParameter
Managertoupdate
thedevicevaluesof
thenewdevice
Importthelatest
exporteddevicedata
filefordevice
parameters
comparison
Downloadthe
requireddevice
parametervaluesto
thenewdevice
Savedevice
parameters
PerformPlug&Play
againandoverwrite
newdevicetag
Updatedevicestatus
andacknowledge
alarm
Deletethereplaced
deviceinOutof
Servicefolder.
Note:
•ThedeviceparametersmustbeexportedtothePRMServerwhendeviceisinnormaloperatingstatus
usingParameterManager
•DonotneedtoperformanyparameterschangeusingHARTcommunicator

191. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
RecommendedStepsforTroubleshootingHART/FFDevices
1
DeviceStatus
Check
•DeviceStatusIcon
•SignalView
2
Check
MaintenanceAlarm
•HistoryMaintenance
Tab
3
DeviceDiagnostic
•DeviceViewer
•DTMWorks
4
DeviceParameters
Comparison
•ParameterManager
5
RefertoDevice
InstructionManual
•DocumentLink
6
Acknowledge Alarm
•HistoryMaintenance
Tab

192. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
ViewingtheStatusofaDevice

193. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
DeviceStatusIcon
ThedevicestatusiconindicatesthecurrenthealthofadeviceinPRMbasedonthebasic
diagnosis.Eachdevicestatusiconcomesindifferentcolorsthatrepresentdifferentstatus.
Thestatusvaluesarenumbersthatindicatetheprioritylevelofeachstatus,withalargernumberindicating
ahigherpriority.

194. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
BasicDiagnosis
BasicDiagnosisperformsdiagnosiswheneveroneofthefollowingsituationsoccurs:
AnFF-H1,PROFIBUS(PAProfile),orISA100deviceraisesanalarmduetoaself-detectederroror
warning.
AHARTdeviceconnectedtoaCENTUMI/Omodule(withHARTcommunicationfunction)reportsan
error.Themodulethenraisesanalarmtoreporttheerror.
NOTE:Forerrorreportingmechanismtowork,HARTvariablesmustbedefinedfortheI/Omodule(withHARTcommunication
function)byusingI/OBuilderinCENTUM.
DevicePatrolrunsascheduledscan
AuserrunstheUpdateDeviceStatuscommandinthePRMClient toupdatethestatusofadevice.

195. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
BasicDiagnosis
BasicDiagnosisperformsdiagnosiswheneveroneofthefollowingsituationsoccurs:
AnFF-H1,PROFIBUS(PAProfile),orISA100deviceraisesanalarmduetoaself-detectederroror
warning.
AHARTdeviceconnectedtoaCENTUMI/Omodule(withHARTcommunicationfunction)reportsan
error.Themodulethenraisesanalarmtoreporttheerror.
NOTE:Forerrorreportingmechanismtowork,HARTvariablesmustbedefinedfortheI/Omodule(withHARTcommunication
function)byusingI/OBuilderinCENTUM.
DevicePatrolrunsascheduledscan
AuserrunstheUpdateDeviceStatuscommandinthePRMClient toupdatethestatusofadevice.

196. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
PerformingaReal-TimeUpdateofDeviceStatus

197. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
DeviceNavigator(SignalView)
IntheSignalview,devicesarelistedunderthecategories
calledstatussignals.NAMURNE107statusiconsare
displayed nexttoeachstatussignal.
Itprovidesclearunderstandingonfielddevicescondition.
Required Specification
Maintenance Outof CheckFunction Failure
Failure(Priority1):
Thedeviceis malfunctioningandmustbe
replaced.
CheckFunction(Priority2):
Thedevicehasincompletecalibrationortuning.
OutofSpecification(Priority3):
Thedeviceisnotoperatingwithinthespecified
measurementrange.
MaintenanceRequired(Priority4):
Thedevicerequiresshort-termormidterm
maintenancebecauseitisabouttostop
functioning.

198. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
BLOCK_ERR
Value
BLOCK_ALM
Value
Description
Device
Status
Value
Device
Status
Color
NAMUR
Status
Value
0x8000 0x0000 Other 40 Yellow
0x4000 0x0001 BlockConfigurationError 40 Yellow
0x2000 0x0002 LinkConfigurationError 40 Yellow
0x1000 0x0003 SimulateActive 40 Yellow
0x0800 0x0004 LocalOverride 40 Yellow
0x0400 0x0005 DeviceFaultStateSet 40 Yellow
0x0200 0x0006 DeviceNeedsMaintenanceSoon 40 Yellow
0x0100 0x0007 InputFailure/ProcessVariablehasBADStatus 50 Red
0x0080 0x0008 OutputFailure 50 Red
0x0040 0x0009 MemoryFailure 50 Red
0x0020 0x000A LostStaticData 50 Red
0x0010 0x000B LostNVData 50 Red
NAMUR Status Mapping for FF-H1 (BLOCK_ERR)

199. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
NAMURStatusMappingforFF-H1(XD_ERROR)
XD_ERR
Value
Error Description
Device
Status
Value
Device
Status
Color
NAMUR
Status
Value
16
Unspecified
error
Anunidentifiederroroccurred. 40 Yellow
17 GeneralError
Ageneralerrorthatcannotbespecifiedbelow
occurred.
40 Yellow
18
Calibration
Error
Anerroroccurredduringthecalibrationofthe
device,oracalibrationerrorwasdetected
duringnormaloperations
40 Yellow
19
Configuration
Error
Anerroroccurredduringtheconfigurationofthe
device,oraconfigurationerrorwas detected
duringnormaloperations.
40 Yellow
20
Electronics
Failure
Anelectricalcomponentfailed. 40 Yellow

200. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
XD_ERR
Value
Error Description
Device
Status
Value
Device
Status
Color
NAMUR
Status
Value
21
Mechanical
Failure
Amechanicalcomponentfailed. 40 Yellow
22 I/OFailureAnI/Ofailure occurred. 40 Yellow
23
DataIntegrity
Error
Datastoredinthedeviceisnolongervaliddue
toanon-volatilememorychecksumfailure,a
dataverifyafterwritefailure,etc.
40 Yellow
24
Software
Error
Thesoftwarehasdetectedanerrorduetoan
improperinterruptserviceroutine,anarithmetic
overflow, awatchdog time-out,etc.
40 Yellow
25
Algorithm
Error
Thealgorithmusedinthetransducerblock
producedanerrorduetooverflow,data
reasonablenessfailure,etc.
40 Yellow
NAMURStatusMappingforFF-H1(XD_ERROR) cont’d

201. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
NAMURStatusMappingforHART
StatusValue StatusDescription
Device
StatusValue
Device
StatusColor
NAMURStatus
Value
0x80 DeviceMalfunction 50 Red
0x40 ConfigurationChanged 20 Green
0x20 ColdStart 40 Yellow
0x10 MoreStatusAvailable 40 Yellow
0x08 LoopCurrentFixed 40 Yellow
0x04 LoopCurrentSaturated 40 Yellow
0x02
Non-PrimaryVariableOutof
Limits
40 Yellow
0x01 PrimaryVariableOutofLimits 40 Yellow

202. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
CheckingtheMaintenanceAlarm
History
Maintenance
Fore.g.:WhenSenor failsinYTAtransmitter.
<Problem>
InputFailure(YTA002_TB.BLOCK_ERR=0x100)
Sensor1Failure(YTA002_TB.XD_ERR=75)
<Cause>
Thiserroroccurswhensensorbecomes
malfunction,andthefieldbusdevicefailsto
providecorrectinformation.
<Action>
Resolvetheproblemorgetreadytoreplacethe
Device
SeethedescriptionregardingtheBLOCK_ERROR
intheinstructionmanualofthefieldbusdevice

203. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
DiagnosticInformationTab

204. CheckingtheMaintenanceAlarm
History
Maintenance
Fore.g.:WhenSenor failsinYTAtransmitter.
<Problem>
InputFailure(YTA002_TB.BLOCK_ERR=0x100)
Sensor1Failure(YTA002_TB.XD_ERR=75)
<Cause>
Thiserroroccurswhensensorbecomes
malfunction,andthefieldbusdevicefailsto
providecorrectinformation.
<Action>
Resolvetheproblemorgetreadytoreplacethe
Device
SeethedescriptionregardingtheBLOCK_ERROR
intheinstructionmanualofthefieldbusdevice
28

205. DiagnosingDevicesbyusingDeviceViewer
Displaysdiagnostic,specific,andtrendinformationabout
devices
Usescolorstodisplaythestatusofthedeviceandthe
statusofeachdeviceparameter
Showsthestatussignalsofadevice,whichcanhelpto
analyzedeviceproblems
Createsatrendgraphbasedontheparametervalues
Monitorsthestatusofthedevice
Retrievesthemostrecentparametervaluesorretrieve
parametervaluesperiodicallybasedonaspecifiedtime
duration
Identifiesthestandardparametersandcustom
parameters,addedbydevicevendorstoenhancedevice
features
ForFF-H1,HART,andISA100devicesonly.
29

206. DiagnosticInformationTab
30

207. SpecificTab
IntheSpecifictab,you canviewthedevicestatusandvendor-specificparameters.TheSpecifictabappearsonlywhena
configurationfilefromthedevicevendorisavailable.TheSpecifictabincludesthefollowingelements:
•DiagnosticParameterList
•ParameterList
Colorsareusedtoindicatethestatuslevelofadevice
parameter.Whenyouplaceyourpointerovera
parameter,aToolTipappears,displayingadetailed
descriptionoftheparameter.
NOTE
ThedevicestatusesthatappearontheSpecifictabmay
bedifferentfromthedevicestatusesthatappearonthe
DiagnosticInformationtab.Thisisbecausethe
parametersthataredefinedintheDeviceViewer
configurationfilecanbedifferentfromtheparameters
thatarecheckedduringDevicePatrol.
31

208. TrendInformationTab
IntheTrendInformationtab,onecanviewthetrendforspecificparameters
identifiedinthedeviceconfigurationfile.Atrendlineenablesyoutomonitor
diagnosticresultsandpredictchangestoadevicebeforetheyhappen. Youcan
thenmakeappropriateadjustmentstoadevice
32

209. DTM
ThedevicesupplierdevelopsaDeviceTypeManager(DTM)for
eachofitsdevicesorgroupofdevices.
TheDTMencapsulatesallthedevice- specificdata,functionsand
businessrulessuchasthedevicestructure,itscommunication
capabilities,internaldependencies,andtheHumanMachine
Interface(HMI)structure.
TheDTMsprovidefunctionsforaccessingdeviceparameters,
configuringandoperatingthedevices,anddiagnosingproblems.
DTMscanrangefromasimpleGraphicalUserInterface(GUI)for
settingdeviceparameterstoahighlysophisticatedapplication
capableofperformingcomplexreal-timecalculationsfordiagnosis
andmaintenancepurposes.
33

210. DTMWorksWindowElements
34

211. UseParameterManagertocomparingparameters
White
Parametervalues
match.
Yellow
Parametervaluesdo
notmatch,and
parameterisread-only.
Orange
Parametervaluesdo
notmatch,and
parameteriswritable.
Magenta
Parametervaluehas
beenmodifiedbuthas
notbeensavedyet.
Red
Valueofawritable
parameterisinvalid.
35

212. DocumentLink
36

213. AcknowledgingAlarm
Theunacknowledged
|LSBD/LCM&TSC|24May2024|
©YokogawaEngineeringAsiaPteLtd
37
alarm
adeviceindicatesthat
unacknowledgedmaintenance
Maintenance
icon
has
alarm
alarmmessages.
messagesareraisedwheneveran
abnormalityisdetectedinadevice,and
devicerecoversfromthewhenthe
abnormality.
Theunacknowledged alarmicon
disappearswhenallunacknowledged
maintenancealarmmessageshavebeen
acknowledged. Theunacknowledged
alarmiconfunctionsindependentlyofthe
devicestatusicon.

214. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
i. PRM Housekeeping

215. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
PRM housekeeping
Update device tag
name & necessary
parameters from
parameter manager
Assigning device to
respective plant
hierarchy
Configuration of
device detail from
Details tab in Plant
View
Run plug & play from
highest hierarchy &
update device status
as necessary
Check & Delete any
duplicate tag from
each channel
Archiving Historical
Messages Diagnosis
Historian, Parameter
Values & DTM Data
Performing database
cleanup
PRM System and Database Backup
Recommended to be done every twice a month from Network View by Instrument Team
Recommended to be done every twice a month from Plant View by Instrument Team
Recommended to be done every 3-6 month from PRM Server machine by Instrument Team
Note:

216. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Configuration of Device information from Details Tab
CATEGORY
You may select based on the following:
•Analytic
•Flow Meter
•Magnetic Flow Meter
•Others
•Positioner
•Pressure temperature
•Temperature Transmitter
•Valve
PLANT HIERARCHY Can drag and drop from out of service folder the respective hierarchy or assigned from here
PRIORITY Assign based on the criticality of the device

217. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Relationship between Alarm Priority & Device Priority
Alarm Priority
Definition:Refers to the importance or criticality of an alarm generated by the DCS when a process
variable deviates from its normal operating range.
Purpose: To alert operators to specific process conditions requiring attention or intervention.
Device Priority
Definition: Refers to the relative importance or role of a device (e.g., a pump, valve, or sensor) in
the overall process or safety hierarchy.
Purpose: To ensure that devices critical to process operation or safety are given precedence in
communication, control, and response.

218. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Importance of assigning device priority to device in PRM
 Focused attention on Critical Devices
 Efficient Alarm and Diagnostic Management
Maintenance Scheduling
Resource Optimization
Compliance with Industry standard such as ISA-18.2
(Asset management lifecycle), ISO 55000 (Asset
management) & IEC 61511 (Functional safety for SIS)

219. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Alarm Priority from DCS
CAMS for HIS Alarm Builder:
Use to locate the alarm priority for all
registered tag in DCS. The data from here
can be extracted in excel form.

220. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Archive/Retrieve
ArchiveGroups:
•HistoricalMessages
•DiagnosisHistorian
•ParameterValues
•DTMData
Filter:
•EnableFilter
ArchiveList:
•Status
•ArchiveID(uniquenumber)
•StartDate/Time
•EndDate/Time
•Size(KB)
•Description(entryinformation)
PeriodicArchive:
1to999days
Filterbydate:
•StartDate/Time
•EndDate/Time
ArchiveDestination:
Foldertostorearchivefiles
Contents:
Listof filessavedinarchive
destination
ArchiveOperations:
•Archive
•Retrieve
•Unretrieve
•Delete
Settings:
•EnableAuto DataProcessing
•AutoDataArchive
•AutoData Delete
•RetentionPeriod:1to999days

221. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Database Cleanup
EnableAuto Cleanup
Or
OnDemandCleanup
When a device is deleted from
PRM Client, its information no
longer appears in the PRM
client, but the data remains in
the database. The data case
cleanup function enables to
permanently delete this data
from database.

222. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
PRM Backup using PRM Backup Tool
YoucanusethePRMBackupTooltobackupthePRMsystemorPRMdatabases,orboth.
ThePRMBackupToolprovidesthefollowingbackupmodes:
SystemBackupMode
ThismodeenablesyoutobackupthePRMsystem,alongwithallPRMdatabases,and
anyfolders,orfilesonthecomputer.
DatabaseBackupMode
ThismodeenablesyoutobackupthePRMServer,PSTScheduler,andAdvancedDiagnosis
Serverdatabases,dependingonthepackagesthatareactivatedonyourcomputer.

223. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
ii- Asset Management Using KPI report
a. Configuration of KPI Report
b. Analysis on KPI Report sample

224. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Configuration of KPI Report

225. KPIReportContents
TheKPIReportanalysesthehealthoffielddevicesbasedonthefollowingkeyperformanceindicators
(KPI):
OverallDeviceEffectiveness(ODE)
Anindicatortomeasuretheaveragepercentageofoperatingtime*wherethestatuscolorofdevicesis
green.
TimeAvailability(TA)
Anindicatortomeasuretheaveragepercentageofoperatingtime*wherethestatuscolorofdevices
is green, red,oryellow.
PerformanceAvailability(PA)
Anindicatortomeasuretheaveragepercentageofuptime**wherethestatuscolorofdevicesisgreen.
Inaddition,thereportpresentsstatisticsaboutvariousdeviceproperties,suchasdevicestatus,device
priority,alarmsandeventsfrequency.
TheKPIReport canalsobe configuredto includetheSegment MonitorReport thatpresentsstatisticsabout
thenumberofcommunicationerrorsthatoccurredforthemonitoredfieldbussegments.
*Operatingtimereferstothetimewheredevicesarerunning.
**Uptimereferstothetimewheredevicescanbemonitoredwithoutcommunicationerrors.

226. KPILevels
KPIlevelsarevisualrepresentations ofdeviceavailability,basedontheKPIvalueofadeviceorthe
averageKPIvalueofalldevices.EachKPIlevelisrepresentedbyaweathersymbol.
ThefollowingtabledescribestheKPIlevelsusedintheKPIReport.

227. KPIReportConfiguration
Enablesyoutodefinethedatatobeincludedinthe"FieldAssetKPIReport"chapteroftheKPIreport,such
astheoverallsummary,deviceavailability,oralarmsandevents.
IMPORTANT:
Beforecustomizingreports,youmustinstallasupportedversionofMicrosoftExcelorMicrosoft
WordonthePRMServercomputer.
[PRMSetupTool]>
[PRMServer]>
[StartFieldAssetKPIReportTool]>
[Options]>[KPIReportConfiguration]

228. KPIReportConfiguration–OverallSummary(DeviceStatus)
TheDeviceStatustabenablesyoutocustomize
thecriteriaforfilteringdevicesbasedontheir
statusandpriority.

229. KPIReportConfiguration–OverallSummary(ODE)
TheODEtabenablesyoutocustomizethecriteria
forfilteringdevicesbasedontheirpriorityandODE
(OverallDeviceEffectiveness).Allcriteriaare
connectedwiththeANDoperator.

230. KPIReportConfiguration–OverallSummary(AlarmsandEvents)
TheAlarmsandEventstabenablesyouto
customizethecriteriaforfilteringdevicesbasedon
theirpriorityandthefrequencyofalarmsand
events.AllcriteriaareconnectedwiththeAND
operator.

231. KPIReportConfiguration–DeviceAvailability
TheDeviceAvailabilitytabdeterminesthedatatoincludeinthe
"WorstDeviceRankingofDeviceAvailability"subsectionofthe
"FieldAssetKPIReport"chapterintheKPIreport.Youcan
customizethecriteriaforfilteringdevicesbasedonODE(Overall
DeviceEffectiveness),TA(TimeAvailability),andPA
(PerformanceAvailability). AllcriteriaareconnectedwiththeAND
operator.

232. KPIReportConfiguration–AlarmsandEvents
TheAlarmsandEventstabdeterminesthedatato
includeinthe"WorstDeviceRankingofAlarmsand
Events"subsectionofthe"FieldAssetKPIReport"
chapterintheKPIreport.Youcancustomizethecriteria
forfilteringdevicesbasedonthefrequencyofalarmsand
eventsperday.AllcriteriaareconnectedwiththeAND
operator

233. WorstDeviceRankingMethodology
TheKPIreportranksdevicesfromworsttobestbasedonthedeviceavailabilityandthealarmsandevents
frequency.
Thefollowingtabledescribestherankingmethodology.

234. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Analysis on sample of KPI Report

235. KPIReport–Sheet1Sample
Sectionhead
Basicinformation
aboutthe analysis.
Listof devicesthatarefilteredaccordingtothe
threecriteria(devicestatusanddevicepriority).
Distributionof
devicesby
devicestatus

236. KPIReport–Sheet2Sample
DisplaystheaverageODElevelofalldevices,andafilteredlistofdeviceswithlowODElevel.
Althoughthereareredand
greystatusesforthe2
devices,thedurationisshort
ascomparedtogreenstatus.
ODElevelishigh,sono
deviceslisted

237. KPIReport–Sheet3Sample
Displays thefrequencyofalarmsandeventsintheanalysisperiod,andafilteredlist
ofdeviceswithhighalarmsandeventsfrequencyperday.
Thereare4devices.Sinceonly2
deviceshaveA&E,theratiois50%
•TT100inIOP,TT200disconnected
•Total2A&E;1A&Eforeachdevice
•Sinceeachdevicehasonly1A&E(frequency<1),nodevice
wasdisplayedintheabovetable

238. KPIReport–Sheet4Sample
Displaysthenumberofdevicesthatwereanalyzedforeachdevicemodel.
Breakdownofthe
4devicesby
communication
typeanddevice
model

239. KPIReport–Sheet5Sample
Displaysthe
distributionof
devicesbydevice
statusforall
devices,andfor
eachdevicegroup,
which isdefinedby
thecommunication
type,vendorand
model.
•4devices
•2devicesinA&E(50%)
•1deviceinred(25%)
•1deviceingrey(25%)
•2devicesingreen
(50%)
•1FF-H1EJA(25%)
•2FF-H1YTA320(50%)
•1HARTYTA (25%)
•Only1FF-H1EJAand
itisnormalso100%
•2FF-H1YTA320;1in
red(50%),1ingrey
(50%)
•Only1HARTYTA and
itisnormalso100%

240. KPIReport–Sheet6Sample
DisplaysalistofdeviceswhosedevicestatusisnotNormal.
OverallDeviceEffectiveness(ODE):Anindicatortomeasuretheaveragepercentageofoperatingtimewheredevicesarerunning

241. KPIReport–Sheet7Sample
Displaysthedistributionof
devicesbystatussignal
foralldevices,andfor
eachdevicegroup,which
isdefinedbythe
communicationtype,
vendorandmodel.
SimilartoSheet5butby
NE107standard
•4devices
•2devicesinA&E(50%)
•1deviceinred(25%)
•1deviceingrey(25%)
•2devicesingreen(50%)
•1FF-H1EJA(25%)
•2FF-H1YTA320(50%)
•1HARTYTA (25%)
•Only1FF-H1EJAandit
isnormalso100%
•2FF-H1YTA320;1inred
(50%),1ingrey(50%)
•Only1HARTYTA andit
isnormalso100%

242. KPIReport–Sheet8Sample
Displays alistofdeviceswhosestatussignalisnotNormal..
SimilartoSheet6butby
NE107standard
OverallDeviceEffectiveness(ODE):Anindicatortomeasuretheaveragepercentageofoperatingtimewheredevicesarerunning

243. KPIReport–Sheet9Sample
DisplaysasummaryoftheODE,TA,andPAlevelofalldevices.
OverallDeviceEffectiveness(ODE):
“Howlongthedevicecanoperatenormally”.Itcanbeimprovedbyreducingall
alarms.
ODE=
∑
Alldevices
n
Total
TimeofGreenStatusintheanalysisperiod
Timeofallanalysisperiod
TimeAvailability (TA):
“HowlongthedevicecanbemonitoredbyPRMwithoutcommunicationerror”.Itcan
beimprovedbyreducing“Grey”and“White”statustypealarms.
∑
n
TA=
Alldevices
Timeofallanalysisperiod−TotalTimeofGreyandWhiteStatusintheanalysisperiod
Timeofallanalysisperiod
PerformanceAvailability(PA):
“HowlongthedevicemonitoredbyPRMcanbeoperatednormally”.Itcanbe
improvedbyreducing“Red”statusand“Yellow”statustypealarms.
∑
n
PA=
Alldevices
TotalTimeofGreenStatusintheanalysisperiod
Timeofallanalysisperiod−TotalTimeofGreyandWhiteStatusintheanalysisperiod

244. KPIReport–Sheet10Sample
ODE:99.9%
TA:100%
PA:100%
DisplaysthedistributionofdevicesbasedonthevariousODE,TA,andPAlevels.

245. KPIReport–Sheet11Sample
ODE:99.9%
TA:100%
PA:100%
TherearenodevicelistedsinceODE,TAandPAareallabove80%
Displaysafilteredlistofdeviceswith lowODE,TA,andPAlevelsinascendingorder.

246. KPIReport–Sheet12Sample
Displays asummaryofthefrequencyofalarmsandeventsintheanalysisperiod.
AlltheA&EcamefromYTA320.
Theratiois100%.
2A&E.
1inputfailure(50%);
1communicationerror(50%)

247. KPIReport–Sheet13Sample
Displays afilteredlistofdeviceswithhighalarmsandeventsfrequencyperdayin
descendingorder.
Sincethereisonly1A&Eperdevice,this<1.Sotherearenodevicelisted.

248. KPIReport–Sheet14Sample
Displays theentirelistofdeviceswhosedevicestatusisnotNormal,sortedbythe
deviceavailabilityranking.

249. KPIReport–Sheet15Sample
Displays theentirelistofdeviceswhosedevicestatusisnotNormal,sortedbythe
alarmsandeventsranking.

250. KPIReport–Sheet16Sample(1)
Displaysinformationaboutthedevicemodelin
thesectionhead.
Displaysthedistributionofdevicesofthedevice
modelbydevicestatus,andalistofdevices
whosedevicestatusisnotNormal.

251. KPIReport–Sheet16Sample(2)
Displays thedistributionofdevicesofthedevicemodelby
statussignal,andalistofdeviceswhosestatussignalis
notNormal.

252. KPIReport–Sheet16Sample(3)
Displays thefrequencyofalarmsandeventsthataregeneratedforeacheventtype, anda
listofdeviceswith thehighestalarmsandeventsfrequencyperday.

253. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
iii. Maintenance Log Creation for Device
Management (using Investigation Report)

254. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Investigation Report Contents
TheInvestigationReportcontainsdetailedinformationabouterrors,andalarms
andeventsthatoccurredforfielddevices.
IfyouhaveconfiguredtheInvestigationReporttoincludetheSegmentMonitor
Reportchapter,thereportalsoprovidesdetailedinformationaboutthe
communicationerrorsthatoccurredforfieldbussegments.
ThisreportisusedfortroubleshootingbyYOKOGAWAserviceengineers.
However,youcanalsorefertoitfordetailsabouttheerrors.

255. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
FieldAssetInvestigationReport(DetailRedandYellowStatusAssetAnalysis)

256. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
iv. Device template standardization

257. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
Device Templates
Createandapplydevicetemplatesondevicestofacilitatethefollowingoperations:
Copyingofdevicedetails,documentlinks,andPLUG-INapplicationassociationstodevicesofthesame
deviceclass
Downloadingofparametervaluestodevicesofthesamedeviceclass
DevicetemplatesappearonlyintheDevice
NavigatoroftheClassview.Eachtemplate
appearsasaniconundertheTemplatefolderofa
deviceclass.

258. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
DeviceTemplateContents
Adevicetemplatecancontainthefollowinginformation:
Devicedetails
Referstothedevicemaster,block,andparameterinformationthatappearsintheCommonand
DetailtaboftheDeviceDetailswindow.IfatemplateiscreatedfromFF-H1devices,italso
includesinformationthatappearsintheBlocktab.
Template- specificinformation
Referstodocumentlinks,parametersets,andPLUG-INapplicationassociations.
Informationinadevicetemplateiscopiedfromaregistereddeviceduringthecreationofthe
templateandcanbemodifiedmanuallyaftercreation.

259. | Document Number 12345 | Month DD, YYYY |
© Yokogawa Electric Corporation
DeviceTemplate–DeviceDetails

260. The names of corporations, organizations, products and logos herein are either registered trademarks or
trademarks of Yokogawa Electric Corporation and their respective holders.
Thank you for your attention.