Yokogawa Insightsuite-Ae Overview Rev1

YOKOGAWA - InsightSuite-AE Overview
Why it is important to have a proper asset management regime in place for reliable, efficient,
and profitable plant operations.
InsightSuiteAE (ISAE) has the capability to diagnose production equipment and field devices
around it together, it is easy to identify the cause of abnormalities, which leads to reduction in
production risk.ISAE helps customers to prioritize the right equipment for maintenance and the
plant will become more stable.
Asset Management and Integrity

Asset Management and Integrity practices are critical to ensure reliability and availability of
such assets while keeping maintenances costs to a minimum, and to capitalize on short-term
opportunities in the market. With domain knowledge and experience, Yokogawa and KBC
ensures its customers maximize their assets' value through asset management and integrity
products, services and solutions.
Key Operational Competencies in Asset Management and Integrity
 Maintenance and Integrity Strategy:

Determine the best asset maintenance and integrity strategy based on equipment
integrity objectives, as well as corporate and asset portfolio strategies
 Asset Care Planning:

Provide systems and methodologies to optimally define the activities needed to maintain
equipment in its designed operating conditions
 Reliability Assurance and Analytics:

Provide analysis of equipment health to determine the best maintenance approaches.
 Defect Elimination:
Identify activities that mitigate and eliminate sources of unreliability to assets or facility
systems
 Inspection:
Review inspections performed on equipment to identify specific maintenance activities.
This will be done in coordination with, or by, the inspection group.
Termos de Uso:
Os dados-informações contidos neste documento sobre os produtos Yokogawa foram obtidos na WEB e espelham o conteúdo publicado pela
mesma. Todas as marcas, nome de produtos mencionados, são de propriedade da YOKOGAWA e a sua utilização neste documento tem
exclusivamente o objetivo de referência técnica.
Por: Jorge Luiz-LOOPSERV Data: 26/10/2021 Página 1/8
 Contractor Management:
Manage contractors to utilize their services efficiently and effectively
 Minor Projects Delivery:

Screen options, engineer and deliver low- or no-capital projects to replace existing
equipment or achieve incremental improvements that are cost-effective, timely and fit for
purpose
 Turnaround Maintenance:
Perform special equipment maintenance to retain asset design and operational integrity.
This involves longer shutdowns or outages of the unit or the system.
 Routine Maintenance:
Perform normal equipment maintenance during operations to retain asset design and
operational integrity. This involves short-term or low-impact shutdown of the unit or the
system.
In addition, through Yokogawa’s reliability-based Asset Management portfolio, our

customers can:
 Contribute directly to corporate goals and objectives ;We help our customers assess and
design how they utilize their assets to achieve the following:
o Reduction in production cost per unit
o Reduction in unplanned breakdown of assets
o Increase in efficiency of maintenance operators
o Reduction in safety and environmental-related incidents
 Enable informed and operations-centric decision-making
We combine risk and reliability best practices with our customers’ actual plant
operations set up to identify and focus on critical assets that drive the largest
contributions in their company. By identifying critical assets – failure root causes and
recommended actions – resources and requirements are prioritized accordingly, in
consideration of associated risks and consequences.
Supply Chain Optimization

Optimize management of supply, whether oil in the ground or feedstocks for a refinery
or chemical asset, in light of product market demands. This provides operators with the
agility to take full advantage of market conditions.
Termos de Uso:
Asset Operations and Optimization
Optimize the potential of physical assets, by pushing throughput and maximizing the
production of the highest value products, whilst minimizing variable costs such as
energy.
Deliver small and large capex projects, on time and on budget, to deliver growth and
meet environmental requirements.
Operational Risk Management
Reliably control safety, health and environmental risk at a personal and process level.
This assures the robustness required to avoid catastrophic losses.
Field Asset Analytics (InsightSuiteAE)
Improve Plant Asset Productivity

With the increasing demand for energy that has accompanied the economic growth of newly
industrialized nations, companies need to find every possible way to add value and max out the
efficiency of their production processes. And they must find a way to do this without doing harm
to the environment and while complying with stringent HSE regulations.
Yokogawa has solutions for a sustainable future that solve the issues you face with your plant
assets. We can detect problems at an early stage and put forth proposals that show you the way
forward to achieving concrete improvements. We make it possible for you to slash your plant
asset operating and maintenance costs while reducing both energy consumption and carbon
emissions.
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Optimized Operations and Maintenance
Three steps have proven effective in optimizing the efficiency of plant assets. Choose any one of
these steps, depending on the condition of your plant assets, as your entry point for using our
state-of-the-art diagnostics and services. In this, Yokogawa will work with you in a collaborative
efort to get the maximum possible productivity out of your plant assets.
SEE CLEARLY with a birds-eye view, the condition of your plant assets by providing
diagnostic solutions
KNOW IN ADVANCE what must be done to optimize these plant assets by providing
information-intensive service solutions that precisely detect and analyze their conditions
ACT WITH AGILITY to implement proposals that resolve specific issues and acheive
improvements
Challenges for Management and Field Operators
 Increasing Availability
 Improving Efficiency
 Reducing Maintenance and Operating Costs
 Saving Energy
Field Digital Baseline Tuning

The Importance of Field Digital Solutions
One of the major advantages of field digital solutions is the ability to gather large amounts of
information on Foundation fieldbus & HART assets. Customers blieve they will have this
advantage and be able to reduce downtime and maintenance costs if they install an online and
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centralized automated asset management system such as PRM. However, if PRM is not
effectively managed and alarms and events are not handled correctly, it may be difficult to grasp
and diagnose actual asset conditions, negating some of the benefits of field digital solutions
As part of its InsightSuite services solutions, Yokogawa performs field digital baseline tuning of
Foundation fieldbus & HART devices to optimize PRM's alarm and event conditions, enabling a
condition-based maintenance (CBM) approach that paves the way for asset excellence.
Challenge to Customers
A flood of difficult to comprehend information from field devices
 Root causes of asset problems are difficult to identify and analyze

 Asset management is nearly impossible to plan
 Unable to make optimum use of PRM's solution-oriented functions that can reap the full benefits of
plant assets

Benefits and Solutions and Benefits to Customers - Data Analysis, Analysis Report,
Detailed Analysis, Countermeasures
Working together with the PRM data analysis functions, the InsightSuiteAE service tool
facilities the categorization of PRM data and the visualization of actual asset conditions
Yokogawa consulting services identify problematic assets and present solution
Termos de Uso:
InsightSuiteAE's reporting and consulting services enable customers to implement CBM and
facilaitate asset management decisions
Asset countermeasures are adapted not only in PRM but also in the device settings, one of the
most important and critical steps in advanced diagnostics that promotes asset excellence
throughout the plant lifecycle.
Control Valve Diagnostics

The Challenges for Customers
Control valve management plays a key role in optimizing the performance of plant assets and
achieving operational excellence.
 High maintenance costs as a result of the frequent need for complex adjustments
 The need to stop or slow down a production line in order to troubleshoot a control valve
 Inaccurate control valve and valve positioner diagnostics
 Insufficient resources for diagnosing and analyzing control valve data from valve positions
 The difficulty of setting up and configuring intelligent valve positioners
Key Features of InsightSuiteAE
 Makes it possible to quickly identify control valve problems

 No special skills or knowledge of terminology required to perform configuration
 Easy to use regarless of valve positioner model
 Like a radar, scans 24/7 for control valve problems
 No need to reconfigure or reset a value positioner to perform diagnostics
 No longer necessary to shut down a control valve and change its parameters to carry out diagnostics
 Employs algorithms that aid understanding by quantifying the impact of valve problems on loop
KPI's and automated systems
Benefits for Customers

Termos de Uso:
 Intuitive green (healthy) and red (unhealthy) valve status display quickly identifies
problems
 Provides the information needed to make timely valve maintenance decisions. Enables a
more proactive maintenance approach.
 User-friendly features eliminate the need for detailed knowlege about valves and field
digital protocols
 InsightSuitesAE non-invasive and read-only diagnostic techniques cause no trips or system
disturbances
Control Loop Diagnostics

"The ability to quickly and easily identify problems by monitoring all control loops provides a
strong foundation for stable plant control"
The Importance of Control Loop Diagnostics
High level plant control is the foundation for productivity improvements. An ideal plant is
achieved by optimized plant control, which increases productivity by ensuring that process units
and other plant assets operate stably.
While price competition has become increasingly fierce, the number of board operators and
maintenance peoples is markedly decreasing due to a shrinking workforce and the retirement of
experienced personnel. Our InsightSuiteAE control loop diagnostics service enables board
Termos de Uso:
operators and maintenance people to do real-time monitoring of all their control loops at a
glance and to quickly and easily identify which ones require maintenance. As a result, it reduces
their workload.
In addition, by combining our control loop and control valve diagnostics, major problems such
as inadequate tuning of control loops and/or control valves and incorrect configuration of control
loops can be better understood.
Benefits to Customers
With Yokogawas consulting and reporting services, customers can identisy and gain insight into
problems. It is possible, for example, to identify whether all control loops are operating properly
and are correctly automated. We provide the following solutions that make it possible for our
customers customers to minimize their maintenance costs:
Evaluation of control loops using simplified key performance indicators (KPIs). No special skills
or knowlege of terminology is required to grasp the loop conditions.
Decision support for operators and maintenance people concerning remedial actions that will
improve control loop controllability. This includes the generation of a list that will clarify
problematic loop behaviors.
A consulting service that identifies problem areas in control loops and analyzes their root
causes.
Yokogawa control loop diagnostics use engineering data from the CENTUM distributed control
system (DCS). The combined diagnostics for control valves and control loops use engineering
data that has been recorded by Plant Resource Manager (PRM). With these tools, it si possible to
quickly diagnose problems and change settings.
Termos de Uso:

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YOKOGAWA - InsightSuite-AE Overview

Asset Management and Integrity

Key Operational Competencies in Asset Management and Integrity

 Maintenance and Integrity Strategy:

 Asset Care Planning:

 Reliability Assurance and Analytics:

 Minor Projects Delivery:

In addition, through Yokogawa’s reliability-based Asset Management portfolio, our

Supply Chain Optimization

Operational Risk Management

Field Asset Analytics (InsightSuiteAE)

Improve Plant Asset Productivity

Challenges for Management and Field Operators

Field Digital Baseline Tuning

A flood of difficult to comprehend information from field devices

 Root causes of asset problems are difficult to identify and analyze

Yokogawa consulting services identify problematic assets and present solution

Control Valve Diagnostics

Key Features of InsightSuiteAE

 Makes it possible to quickly identify control valve problems

Benefits for Customers

Control Loop Diagnostics

The Importance of Control Loop Diagnostics

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