Integrated Operations Center

I’m Yukio Kasahara. For more than 30 years, I’ve been working at YOKOGAWA as a Manufacturing Execution System (MES) Consultant. Today, in an effort to prevent the spread of Covid-19, companies are actively pursuing “telework.” The business community is swiftly creating telework practices and utilizing Information and Communication Technology (ICT). Because of the global pandemic, I am also working from home.

Meanwhile, our major users have already been promoting remote technology for:

1.    Remote equipment diagnosis

2.    Process monitoring

3.    Event and/or alarm analysis

4.    Remote system maintenance

When plants operate in remote areas, their data is collected offsite. In these cases, various tools are employed to enhance the functionality and efficiency of plant operations. However, safe and stable operations have conventionally been realized by employees operating Distributed Control System (DCS) graphic panels from within plant control rooms. Thus, the aforementioned use case of remote technology is limited when put into the context of work in the overall plant operations. Also, its focus is limited to data acquisition, analysis, and monitoring operations.

Now, more than ever, the focus on achieving an “Integrated Operations Center” (IOC) has recently increased the number of users in the process industries. This is especially true for the oil and gas industry in the Middle East. They are significantly expanding and advancing the concept of remote operations. Here, only the maintenance personnel are left in the site’s control room, allowing for the execution of an operations mode that allows for the remote monitoring and control of all plants and related production facilities from a centralized location or the head office. The relevant service functions of production are also consolidated within the center.

With significant expansion and advancement in the concept of remote operations, IOC allows for the realization of the below points:

1.    Consolidate high efficiency plant monitoring and control work (an ergonomics-based command room)

2.    Cultivate an environment that supports decision-making processes under emergency conditions (dedicated room equipped with information distribution tools)

3.    Strengthen the technical support team (each expert as Center of Excellence (CoE) is available in the IOC)

4.    Reduce travel time to the work site, travel costs, risk of contagious diseases, accommodation facilities and expenses at the plant

5.    Improve the work environment to secure human resources (accommodations away from family and protection from the harsh natural environment)

A futuristic view, person watching the screens inside Integrated Operations Center (IOC)

Points 1, 2, and 3 demonstrate that a collaborative work environment is necessary for consolidated operations. Achievements, however, are not limited to plant operations, but encompass optimization of production in accordance to domestic and foreign demand, facility management, and troubleshooting capabilities. Ideally, it is vital to utilize a form of Smart Manufacturing that remarkably supports all individuals and work efforts related to production.

Yokogawa’s value propositions are:

-      More than 40 years of control room design capability

-      Human Machine Interfaces (HMI) design capability with ergonomics that led to the formulation of International Society of Automation (ISA) 101 (American National Standard of HMI for Process Automation System)

-      System integration capability for consolidated operation of DCS in all plants

-      Consultation experience in business operation design for an Integrated Operations Center

In addition to the above points, we envision the utilization of the latest digital technologies, such as Artificial Intelligence (AI) and Machine Learning, to realize an ideal Autonomous Operation.

Aiming to further enhance the remote operation of plants, we are driven to realize Smart Manufacturing together with our users. We are also dedicated to providing our renowned operational technology, information technology and consulting capabilities.

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