The Newsletter of Yokogawa in Australasia Second Quarter 2009

Testing the waters 2

7YAU Web GraphicsThe benefit of seven nines

3 Sakhalin - the big time

6First Foundation fieldbus hosts

Sleepless in Sydney

5 Growing our green credentials

1 Saving the world

4Product releases

Continued on page 2

its innovative second generation ‘Big Dish’

solar thermal concentrator. The device has

been built in the university grounds with

support from corporate partner Wizard

Power.

To work efficiently, the mirror-covered

dish needs to rotate and change angle dur-

ing the day as the sun changes

position, and for that, a small control

Researchers at the Australian National

University in Canberra have developed

breakthrough technology that makes large

scale solar thermal power generation com-

mercially viable. And a Yokogawa PLC is

playing a critical role.

The university has been involved in

solar thermal power research for decades

and is now conducting the final testing of

Saving the world,one FA-M3 at a time

8Wireless standard

Vacancy: Lead Safety System Engineer

News Tid Bits

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ityThe prototype ammonia dissociation receiver on the ANU 20m2 dish, shown with covers removed.

2

gases. These gases can

be stored indefinitely

at ambient tempera-

ture until required

for use. When power

is needed, the gases

are recombined in

an exothermic reac-

tion, which produc-

es enough heat to

generate electricity

through a steam

turbine.

Because the Big

Dish technology stores energy

before generating electricity, it is capable

of delivering multi-megawatt base load

electricity and meeting peak loads on

demand 24 hours a day in the same way

that coal, nuclear or gas fired power

stations do. It’s emission-free power

generation on a large scale.

Once the technology has been fully

tested, it will be utilised in a pilot base

load solar thermal power plant in Whyalla,

South Australia to be built by Australian

company Wizard Power.

The Whyalla plant will initially have

four dishes, each of which will have its

own control system and be capable of

producing up to 100kW of electricity. The

Federal Government has supported the

project with a $7m grant, as part of its

efforts to tackle climate change.

Wizard Power is already engaged in

negotiations to build more power plants

around the world that could see coal-fired

electricity generation eventually replaced

with zero emission solar thermal power.

There is also interest in the technology

because the high temperatures that the

Big Dish can achieve – up to 1200 degrees

Celsius – make an array of other

conversion opportunities possible. These

include solar gasification of coal and

biomass to produce distillates that can be

used as clean transport fuels.

“It’s very exciting for everyone at

Yokogawa that our equipment is

contributing to a technology that will

have such a positive impact on the

planet,” Yokogawa Australia’s Managing

Director, John Hewitt said.

“This could turn out to be an incredible

story to tell the grandkids one day.”

The steam receiver on the

ANU Big Dish.

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system is needed. Yokogawa successfully

presented the case for the FA-M3 pro-

grammable controller, and won the order

because of the reliability, value for money,

and world wide after sales support that

Yokogawa provides.

The dish concentrates the sun’s rays

onto a receiver mounted at its focal point,

providing sufficient heat to split

ammonia into hydrogen and nitrogen

Saving the world one FA-M3 at a time cont'd

Testing the watersThe challenge: to cool water from boilers

for testing and analysis when water is a

scarce commodity. The solution: sample

chillers from Yokogawa.

Yokogawa is working with Santos at its

oil and gas processing facility in Moomba

in central Australia, 770km north of

Adelaide. Management of boiler water

quality is important for the

efficient running of the plant. Yokogawa

has been commissioned to design, supply

and document eight free-standing

outdoor wet racks that will measure

conductivity, pH and dissolved oxygen in

the boiler water using Yokogawa’s

renowned process analysers. The analysis

results will be used by Santos operators to

control dosing of reagents to optimise

boiler water quality.

But the boiler water needs to be cooled

from temperatures up to several hundred

degrees Celsius before being analysed. In

most plants, this would be achieved using

a water cooled heat exchanger. But, in the

middle of a desert, with water in short

supply, an alternative approach is

needed.

Yokogawa’s solution is the installation

of seven industrial sample chillers. Not

only will the chillers minimise water use,

they will also provide samples for analysis

at a stable and uniform temperature,

making the results easier to interpret.

The project will be completed by late

July.

Above: Mike Wallis, Yokogawa Project Manager

and one of our resident analyser systems ‘gurus’,

examining the racks.

Right: Craig Smith of consulting engineering firm GPA Engineering (left) and

Fred Pinxteren, Santos Project Manager, attended

the Wet Rack Factory Acceptance Test at

Yokogawa’s Perth office.

3

The first LNG plant in Russia, built within

the world’s largest integrated oil and gas

project, Sakhalin II, was officially

inaugurated in a ceremony in February

this year. Sakhalin II is supported by a

range of Yokogawa measurement and

control systems installed in processes

from the extraction stage right through to

delivery.

The numbers associated with this

project are quite astounding:

recoverable reserves of the project

have been estimated at some 170

million metric tons of oil and

condensate, and over 600 billion cubic

metres of gas.

when full capacity is

reached next year, the

plant will produce 9.6

million tonnes of LNG

each year, with 98% of

this already sold in long

term contracts to customers in Japan,

Korea and the USA.

output from the project will represent

about 5% of the world’s total LNG.

the main project infrastructure includes

three offshore platforms, an onshore

processing facility, 300km of offshore

pipelines, 1600km of onshore

pipelines, an oil export terminal and

Russia’s first LNG plant, built in the

island’s south.

the first cargo of 145,000m3 was

delivered to Japan in March by LNG

carrier Energy Frontier.

Yokogawa is the Main Automation

Contractor for Sakhalin II, supplying

hardware, systems and services to the

LNG processing plant, the oil export

terminal, the tanker loading unit, the

pipeline online monitoring system, the

onshore processing facility, the offshore

platforms, and the booster station.

Sakhalin II has been built on Sakhalin

Island, only 7km off Russia’s far east coast

(at the closest point) and 40km north of

the Japanese island of Hokkaido. The

development is jointly owned by the

Sakhalin - the big time

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Photographed in February at the inauguration of the Sakhalin II LNG plant were (l to r): Prince Andrew, Duke of York; Maria van der Hoeven, Minister of Economic Affairs of The Netherlands; Taro Aso, Prime Minister of Japan; and Dmitry Medvedev, President of the Russian Federation.

Russia Sea of Okhotsk

China

Sakhalin Island

Japan

Sea of JapanNorth

Korea

South Korea

Russian state energy company Gazprom,

Shell, Mitsui and Mitsubishi. The project

has been described as one of the most

challenging engineering feats ever

achieved given the harsh operating

conditions it must contend with. The

region is prone to earthquakes, and

during winter, temperatures drop to

-45oC with a wind chill factor of -70oC.

The oil and gas is taken ashore through a

300km network of underwater pipes, as

the thick layer of ice that surrounds the

platforms in the Sea of Okhotsk prevents

tankers from reaching them.

The Sakhalin II development is a boost

to world supplies at a time when LNG is

growing in importance. By 2030, LNG is

expected to account for 60% of all inter-

national gas trade, up from 30% today.

The launch ceremony, held on a day

when the temperature was an almost

balmy -20oC, was attended by President

Dmitry Medvedev of Russia and Prime

Minister Taro Aso of Japan. Yokogawa was

represented by Teruyoshi Minaki,

President of Yokogawa Electric

International.

The Sakhalin II Onshore Processing

Facility in February 2009.

4

Product releases

Yokogawa releases wireless transmitters – EJX-B seriesTransmission of process measurements from field devices

has changed greatly over the years. Electronic signals

(4-20mA) followed pneumatic, which were in turn

followed by hybrid analog signals (4-20mA + HART) and

then digital signals (FOUNDATION Fieldbus). The latest in

field communication is wireless technology.

Wireless technology means that field devices no longer

require wires for power and transmission of process

measurements: instead they are sent wirelessly on a

2.4GHz signal. Yokogawa’s new EJX-B series wireless

pressure and differential pressure transmitters provide a

wireless HART output.

The EJX-B series operates using Yokogawa’s unique

digital silicon resonant sensor technology, just as its EJX-A

and EJA series transmitters employ, to deliver highly

accurate and stable process measurement.

The EJX-B series operate with an internal battery and

include a 1mW or 10mW radio transmitter. The units offer

a battery life of up to five years when utilised with a 30

second update rate.

Many industries are beginning to study the potential

use and cost savings of wireless transmitters. Initially,

most start with low-risk applications to allow them to

validate the technology within their operating

environment. Yokogawa’s EJX-B series is an excellent

choice for a first time introduction to field wireless

technology.

Increased density accuracy for Yokogawa Rota flowmeters RotaMASS flowmeters operate

on the coriolis principle,

allowing the flowmeter to

directly measure

the mass flow of a

process fluid. The

meter is also able

to measure the

density of the

fluid for liquid applications.

The Yokogawa RotaMASS

series has recently been

enhanced to provide increased

density measurement accuracy.

An increased accuracy in the

density measurement also means the RotaMASS can now

offer increased volumetric flow accuracy. By utilising high

accuracy instrumentation, processes can be more tightly

controlled, leading to increased profitability.

The new RotaMASS density options include special

thermal treatment of the sensor to provide long-term

temperature measurement stability as well as a special gas

filling and tightness check at the factory. The top end

model (Option/K6) also includes a factory density

calibration using three different process fluids, provided

with a calibration certificate, as well as individual

adjustment of the fluid temperature dependency.

There are now three models of RotaMASS to suit

different customer requirements and applications. The

standard RotaMASS offers an accuracy up to +/-1.5g/L.

The /K4 density option provides an accuracy of +/-1.0g/L,

while the /K6 option provides an accuracy of +/-0.5g/L.

SIL-compliant metal rotametersFunctional safety for field instrumentation and SIL

(Safety Integrity Level) compliance is a growing

requirement in a number of process industries, especially

oil & gas and chemicals. To meet this requirement,

Yokogawa is continuing to grow its range of field

instrumentation products that comply with SIL.

Yokogawa currently offers its EJX series of pressure

transmitters and YTA series of temperature transmitters

with SIL2 certification. We are now joining these

transmitters with the metal variable area flowmeter series.

The RAMC and RAKD series of metal rotameters can

now be used in various configurations to either SIL1 or

SIL2. Yokogawa is the only supplier to provide safety

excellence to all metal rotameter applications.

The RAMC with local indicator and limit switches is

suitable for application in safety functions up to and

including SIL2. Due to the unique Yokogawa patented float

blockage detection system, RAMC meters with 4-20mA

output are suitable for applications to SIL1.

The RAKD with local indicator and limit switches is

suitable for safety applications up to SIL2. RAKD meters

with local indicator, valve and flow controller reach SIL1.

Please contact

your local

Yokogawa office

if you require

further

information or a

copy of the Exida

FMEDA (Failure

Modes, Effects

and Diagnostic

Analysis) report

for RAMC/RAKD

metal rotameters.

Growing our green credentials

5

Yokogawa was the only

automation company to

exhibit at the Australian

Petroleum Production and

Exploration Association

(APPEA) Conference and

Exhibition this year.

Our booth, showcasing

our broad product range

and extensive experience

in the oil & gas industry,

and the LNG liquefaction,

transport and re-gasifica-

tion sectors in

particular, sat alongside

those of the current giants

of the industry in Australia

– Woodside Petroleum,

Chevron, Santos, Inpex,

Origin Energy, and

ConocoPhillips. As can be gleaned

from these names, LNG was the main

topic on everyone’s lips!

About 1400 delegates attended the

conference, which was held at the

new Darwin Convention Centre from

May 31 to June 3. The focus was on a

number of industry activities and

customer Delta Electricity, provided a

perspective of a large mainstream

electricity generator involved in the

sugar industry’s cogeneration efforts to

diversify.

325 delegates representing a broad

cross-section of the sugar industry

attended the conference and

exhibition. They also had the opportuni-

ty to see Yokogawa’s CENTUM 3000 dis-

tributed control system and ProSafe

safety instrumented system in action

during the tour of the Broadwater sugar

mill and cogeneration plant, which is

run as a joint venture between Delta

Electricity and the NSW Sugar Milling

Cooperative.

Yokogawa was also a participant in the

Industry Equipment Exhibition staged

at this year’s conference of the

Australian Society of Sugar Cane

Technologists (ASSCT) in Ballina, NSW

in May.

The theme of this year’s conference

was ‘Sugar cane as renewable energy

biomass – the way forward’ with a

focus on the practical application of

using renewable energy biomass as the

basis of future industry viability. In

particular, speakers considered the

harvesting and milling of whole of

crop cane for renewable electricity

generation. The keynote speaker, Greg

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Broadwater sugar mill and cogeneration plant.

plenary sessions of the

Conference to table their

respective views. Extensive

press coverage ensued for

the politicians and also for

many of the senior indus-

try representatives who

spoke at the Conference,

including Don Voelte,

Managing Director and

CEO of Woodside Energy,

and Roy Krzywosinski,

Managing Director of

Chevron Australia.

Yokogawa Australia’s

Director of Sales and

Marketing, Russell Palmer,

felt that the event was very

worthwhile. “Yokogawa has

a very strong commitment

to the oil & gas industry, and we have a

track record of providing outstanding

support around the globe. We are keen

to continue our involvement as the

industry moves its focus to LNG as a

cleaner, ‘greener’ fuel, so we welcomed

the opportunity to participate in this

prestigious event.”

Manning the Yokogawa booth at the APPEA Conference and Exhibition were Nick Sima, Systems Sales Manager for WA (left), and Russell Palmer, Director of Sales and Marketing.

. . . . and the sugar industry’s cogeneration initiatives

projects, and the debate about conten-

tious topics such as the Federal

Government’s proposed Carbon

Pollution Reduction Scheme.

The Hon Martin Ferguson, Minister

for Resources and Energy, and the Hon

Ian Macfarlane, Shadow Minister for

Energy and Resources, both addressed

Supporting LNG projects. . . .

6

Yokogawa’s STARDOM network-based

control system and CENTUM VP integrat-

ed production control system are among

the first Foundation fieldbus host systems

to pass the Fieldbus Foundation’s recent-

ly developed Host Profile Registration

Program. The registration process tests to

ensure robust interoperability and

integration between host systems and

devices from different vendors.

This newly-introduced Registration

Program replaces the Foundation’s

previous Host Interoperability Support

Test (HIST).

Under the Host Profile Registration

Program, the Foundation itself conducts

functional testing with a test device and

specialised Device Descriptions (DDs)

and Capabilities Files (CFs). Host

suppliers have access to standardised test

requirements and test cases for all hosts

within a profile tested to the same

requirements, and standardised test

devices for all basic I/O function blocks

and specialised test transducer blocks.

The Registration Program requires

mandatory testing of critical elements of

the technology. These tests verify

whether systems support the features

defined in FF-569 Revision 2 (host inter-

operability support test and procedures

revision 2.0), which set out how host

systems and field devices are to be linked

via a Foundation Fieldbus network.

A registered host system is formally

recognised to comply with the

Foundation’s interoperability require-

ments and is allowed to bear the

Foundation fieldbus product registration

symbol.

John Hewitt, Managing Director of

Yokogawa Australia said, “Yokogawa is

very pleased to be one of the first compa-

nies to complete the host profile registra-

tion process.

“Yokogawa continues its commitment

to support Foundation fieldbus

technology and promote the solution by

demonstrating interoperability and

compliance to the updated Foundation requirements. We will continue making

every effort to promote Foundation

fieldbus and reduce our customers' costs

over the entire plant lifecycle.”

Yokogawa systems named among the first Foundation fieldbus hosts

greater confidence that fieldbus systems incorporate the robust functionality of Foundation technology and are able to function as part of an open, interoperable control system

a higher level of consistency in multi-vendor environments. End users can select the best device for a specific measurement or control task, regardless of the manufacturer

the updated host profile specification is easier to understand than the previous specifications

the new process enables end users to evaluate solutions in a consistent way rather than trying to make sense of supported features and

functions from the HIST method

How users benefit from the new Host Profile Registration

Program

Left: John Hewitt offered to take his own sheet of Yokogawa cardboard packaging to the CEO Sleepout. Organisers thanked him but refused on the grounds that, like everything that Yokogawa makes, the quality was superb – and in this case, too good to enable him to experience what the genuinely homeless endure.

Yokogawa Australia’s Managing Director,

John Hewitt, participated in the

‘CEO Sleepout’ last month to raise funds

for services to support Australia’s

homeless.

The CEO Sleepout is run by the St

Vincent de Paul Society. CEOs from

industry, government and the non-profit

sector sleep overnight on a sheet of

cardboard in Sydney’s Luna Park to have

the kind of experience that thousands of

homeless men, women and children go

through every night. Colleagues and

customers sponsor their participation.

The money raised is used to provide

relief to the homeless through crisis

accommodation, domestic violence

support, access to budget counselling,

legal advice and education.

“In a society as affluent as ours, it’s a

tragedy that there are so many homeless,”

John said. “We’re going through a

challenging period in our industry right

now, but at least we’ve all got homes to

go to, food on the table, and friends and

family to support us.

“My objective in participating in the

CEO Sleepout was to provide a focus for

Yokogawa employees, customers and

suppliers to help those less fortunate.”

As a result of John’s efforts, almost

$6,000 was donated to the cause.

Sleepless in Sydney

7

YAU Web Graphics: a low cost, flexible solution

99.9999953%, and we’re working hard to

achieve availability of ‘eight nines’.

The difference between, say, a ‘four

nines’ system and a Yokogawa ‘seven

nines’ system – that is, the difference

between a system that has availability of

99.99% and one that has availability of

99.99999% – can be crucial over the

lifetime of the system. Imagine two

ethylene plants with 10 field control

stations, identical in all respects except

one is controlled by CENTUM and the

other by a system with only 99.99%

availability. Including all downstream

processes, the total value of the daily

production at each plant is valued at $2.7

million. As shown in the table below, the

difference in the total value of production

at the two plants over a 12 year period

could be $65 million.

It has been 34 years since the first

CENTUM series DCS was released. While

there have been many upgrades since

then, one thing remains constant:

Yokogawa’s commitment to achieving a

plant that never stops.

Yokogawa’s flagship DCS, CENTUM VP

boasts availability of ‘seven nines’ – that is,

99.99999%. This is an extraordinary level

of reliability.

What makes it even more remarkable is

that it’s not a calculated value like Mean

Time Between Failures (MBTF) but rather

an actual measurement based on data

from the global ‘fleet’ of CENTUM

systems installed in sites around the

world. Not test equipment – but the total

shutdown time of the installed base of

control systems running user plants in a

wide range of industries. The calculation

is simply:

The calculations are actually made to

seven decimal places. As of March 2009,

CENTUM had an availability of

The benefit of seven nines

dial-in or radio, making the package ideal

for remote applications.

Users who wish to develop their own

graphics can purchase a fully featured,

intuitive builder package. With it, quite

complex process displays can be built

using graphic shapes similar to those in

the CENTUM CS3000 graphics builder.

sum of downtime

total number of operation hours1- x

100

1

This makes the package very flexible, as it

can be customised to a wide range of

applications.

The YAU Web Graphics are currently

being used by Sydney-based adhesives

manufacturer National Starch and

Chemical on their glue bench automation

system.

List of graphics in project

Build your own parts library

Palette of draw objects

Properties ofselected object

List of variables in controller

Yokogawa Australia has developed a

feature-rich controller-based web

graphics and logging product that

provides an economical alternative to a

full SCADA package. The YAU Web

Graphics package is part of the web

server functionality of the STARDOM

controllers. It provides a simple

graphical interface through a web

browser, meaning that no new software is

needed on the PC to view the graphics.

Combined with the data logging func-

tionality of STARDOM, a complete user

HMI is available from the controller itself.

The package will be a boon to users

who have small systems – say 1-3

controllers – and need a low cost

interface to monitor and operate the

process using push buttons and touch

points. Typical applications include

mobile skids for water treatment,

filtration, and as a replacement for panel

controllers and recorders on a utility

boiler.

With the built-in communications

capability of the STARDOM controllers,

these graphics can be monitored

remotely through the internet, direct

Four 9(99.99%)

Seven 9(99.99999%) 31 Sec

0.6 hrs

Estimated YearlyDowntime

(10FCS)

$1K

$1M

Estimated CostDamage(10FCS)

450 years

0.4 years

MTBF(10FCS)

negligible

24

FailureCount12 yr

negligible

4 times

SystemShutdown Count

12 yr

negligible

more than$65M

CostDamage

12 yr

* Economic impact model comparison at an ethylene complex

A seven nines system means $65 million more sales*

Contributors to this issue: Megan Fisher, Paul Gillies, Martin Kolos, Yana Kuznetsova, Simon Lillie, Shige Uehara, David Walker, Mike Wallis

Editor: Lindsay Hadland

8

YOKOGAWA AUSTRALASIAN NETWORKNational toll free number across Australia: 1300 558 965

Sydney: 02 8870 1100, Adelaide: 08 8415 2600, Brisbane: 07 3902 6600, Melbourne: 03 8804 8800Mt Isa: 07 4743 8355, Newcastle: 02 4016 2100, Perth: 08 6465 6600, Gladstone: 07 4972 6044

Auckland: 09 255 0496, Christchurch: 03 348 0066, New Plymouth: 027 667 7226Internet: www.yokogawa.com/au Email inquiries: inquiries@au.yokogawa.com

Wireless standardYokogawa is promoting efforts to develop

the ISA100.11a wireless communication

standard for the process automation

industry. Based on this standard, Yokogawa

will develop a new field digital network

platform that will enhance productivity –

both by eliminating the difficulties users

currently face with incompatible wireless

communication protocols and by making

possible the systematic integration of

wired and wireless technologies.

Yokogawa believes that the ISA100.11a

standard provides a range of benefits: it

offers high reliability to ensures safe pro-

duction operations and information secu-

rity; it is based on IPv6 and can accommo-

date larger networks; it offers excellent

compatibility with existing instrumented

systems that use non-wireless protocols

such as FOUNDATION fieldbus, HART,

PROFIBUS, and Modbus; and it is suitable

for a wide range of applications, from

monitoring to control.

Vacancy Lead Safety System Engineer – Perth

Growth in our safety system business means that we wish to appoint a Lead Safety System Engineer in our Perth branch office.

The successful candidate will be responsible for:

• leading teams to implement emergency shutdown systems and fire and gas system projects;

• providing technical expertise and leadership on industrial safety applications;

• developing safety requirements specifications for projects;

• assisting customers in specifying and developing safety system applications;

• assisting our sales engineers in demonstrating the functions and capabilities of Yokogawa safety solutions.

It is anticipated that the successful candidate will have a tertiary engineering qualification; a globally-recognised functional safety engineering certification (eg TÜV); at least 5 years experience in the application/implementation of industrial safety systems in industrial processes; and demonstrated experience in project team leadership positions. Project management and practical experience in the oil and gas industries will be highly regarded.

Applications for this position should be emailed to Monika Drvenkar in the Human Resources department at Yokogawa Australia at monika.drvenkar@au.yokogawa.com

News Tid BitsYokogawa Canada has successfully completed a hot cutover from an ageing Toshiba TOSDIC system to Yokogawa’s CENTUM 3000 for BP at their Ricinus processing plant located 200km northwest of Calgary, Alberta. The cutover proceeded flawlessly and on schedule, delivering improved plant performance to BP and extending the life of the plant by at least 15 years. For more information, visit www.yokogawa.com/iab/suc/oilgas/iab-suc-bpcec-en.htm Yokogawa’s new European headquarters in Amersfoort,

the Netherlands, was officially opened in late May. The

environmentally-optimised building houses more than

500 employees and integrates operations previously

spread over separate sites in Amersfoort and nearby

Houten and Apeldoorn, as well as new departments,

including a gas chromatography application laboratory

and a test and measurement calibration centre.

Yokogawa Europe and SICK Maihak have signed a

mutual distribution agreement covering products in the

field of process analytical instrumentation. The

integration of SICK’s analysers will enhance Yokogawa’s

ability to provide turnkey automation solutions for key

process industries from a single supplier.

The Yokogawa America Technology Fair and

Users’ Conference was held in May in Houston. Almost

300 participants heard keynote speaker Terry Jones,

founder and former chief executive of online travel site

Travelocity.com challenge them on innovation, noting

that it will be the driver to get companies out of the

economic slump. Jones called innovation “fresh

thinking that creates value.”