Field Instrumentation Selection And Total Cost Of Ownership
FieldInstrumentationSelection and TotalCost of OwnershipWHITE PAPER
Field Instrumentation Selection and Total Cost of OwnershipTable ofContentsPart 1IntroductionPart 3Capital Expenditure (CAPEX)Considerations .Part 2Part 4Part 5.Quantifying Savings PotentialOperating Expenditure (OPEX)Considerations .Conclusion. 3. 5.6.12.22KEY TAKEAWAYSüü Understand theimportance of total cost ofownership when selectingfield instrumentation.üü Understand the two maincomponents that driveplant costs.üü Study the basic principlesthat inform and guidethe selection of fieldinstrumentation.www.yokogawa.com2
Part 1 IntroductionWithin a plant, field instrumentation and actuators are the sensorsof the process and the point at which the process automation systemdetects, measures, and responds to process conditions, includingpressure, temperature, flow, and level. Process manufacturingplants of any size and complexity typically need thousands of fieldinstruments, valves, actuators, and other devices. While critical toplant operations, field instrumentation is often purchased ad-hoc andbased on the lowest initial cost. This paper describes the importanceof considering the total cost of ownership across their lifecycle, frominitial purchase through their useful life.Two components of plant costs have been identified and will bediscussed in-depth in this paper:Capital Expenditures (CAPEX)Any investments associated with the design,.ongoing maintenance.can be a significant andoften unaccounted cost ofoperation.procurement, and construction of a major assetare referred to as CAPEX. These costs are taken intoaccount in the very early phases of a project, and areoften handled by an Engineering, Procurement, andConstruction (EPC) contractor or by an in-house staffof engineers.Operating Expenditures (OPEX)Once a plant is operational, the ongoing costsassociated with running the plant, includingoperating labor, maintenance, and engineering arereferred to as OPEX.All equipment utilized at a plant, including instruments, valves,and a Distributed Control System (DCS), require ongoing maintenance,which can be a significant and often unaccounted cost of operation.Having a clear record of the types of maintenance costs associatedwith each piece of equipment is essential.www.yokogawa.com3
Field Instrumentation Selection and Total Cost of OwnershipMany buyers select instrumentation based on initial purchaseprice only, which often leads to higher total cost of ownership thaninstrumentation that cost more initially. Inferior products can lead tomore maintenance work orders as a result of drifting orfailing instruments, even to the point of negativelyimpacting process quality or availability. Atremendous amount of engineering effortis invested in selecting the right controlsystem architecture; in contrast,the decision to purchase a singleinstrument or instrument package isfrequently undertaken with far lessrigor.Total cost of ownership shouldbe considered in any capitalinvestment, and field instrumentationis no exception. While total lifecyclecosts typically include the cost of theinitial purchase and the maintenance overthe estimated useful life of the instrument,instrument engineers should also take intoaccount stability and accuracy. Instrumentation thatFigure 1 - Sources of cost acrossthe lifecycle of a typical fieldinstrument.offers greater stability and accuracy is likely to requireless maintenance and improve process quality. Figure 1 depictsthe sources of cost over the lifecycle of a typical instrument, which canbe used as a guide when selecting field instruments.Plant maintenance is a massive business. Worldwide costs forprocess instrumentation and controls alone are estimated at 23billion, while costs strictly for plant maintenance are three times thatamount at 69 billion annually1. In light of these figures, the selectionof both a supplier and product can have a considerable impact ona plant’s CAPEX. Accurate comparisons between instrumentationand suppliers should take into account the full range of costs,1. "TDC - Real Examples of Downtime Cost," BusinessIndustrial Network, February 8, 2019, Accessed on May8, 2019, www.downtimecentral.com/examples.shtmlfrom implementation to the point at which the instrument isdecommissioned.www.yokogawa.com4
Part 2 Quantifying SavingsPotentialA simplified example of cost savings potential helps clarifyconcepts to be discussed in this paper. The table in Figure 2 lists thedrivers affecting both CAPEX and OPEX. A straightforward businesscase example based on 500 pressure transmitters shows a scenario ofCAPEX costs and OPEX costs when compared to traditional pressuretransmitters that are less reliable and require higher maintenanceover their useful life. While CAPEX costs are nearly equal, there is asubstantial savings in OPEX costs.Figure 2 – CAPEX and OPEXSavings for Hypothetical Refinery Project withsavings for a refinery projectwith 500 pressure transmitterdevices at an average unit priceof 1,000 for Yokogawa devicesand 800 for Traditionaldevices. Initial CAPEX costs areslightly higher for Yokogawa500 Pressure Transmitters in Instrumentation Package:Yokogawa Pressure Transmitters vs. Traditional Pressure Transmitters(1)CAPEX Drivers Inventory CostsApplication ComplexityCorrosive Environmentsdue to higher initial price butYokogawa CAPEX Costsincreased value for nearlyCAPEX SavingsYokogawa capabilities providethe same price as Traditional.Due to improved quality andperformance of Yokogawaover Traditional devices, OPEXsavings are 550,000 over a15-year life.OPEX DriversTraditional CAPEX Costs 1,187,500 1,183,750( 3,750) Ongoing Maintenance & CalibrationUnplanned DowntimeProof-TestingReplacement CostsYokogawa OPEX Costs 250,000OPEX Savings 550,000Traditional OPEX Costs 800,000Assumptions: Assumes average unit price ofAssumptions: 15-year transmitter life. Assumesdevice for Traditional. Assumes 1500 per deviceunplanned downtime, extended proof test intervals 1000 per device for Yokogawa and 800 perfor installation. Accounts for Yokogawa pressuretransmitter capabilities that significantly impact totalinstalled cost in the areas noted above, based on alonger time between calibrations, fewer chances ofand reduced replacement costs for Yokogawapressure transmitter.typical refinery’s application requirements.(1)A traditional pressure transmitter is defined as a lower quality, less reliable and poorer performing device.As evidenced by the table above, initial purchase price isnot the only factor when determining long-term costs associatedwith instrumentation purchases. From CAPEX to OPEX, this paperwill highlight and explore each of these cost drivers and otherconsiderations in more detail to better discern a more accurate totalcost of ownership for field instrumentation investments.www.yokogawa.com5
Part 3 Capital Expenditure(CAPEX) Considerations3.1 INSTRUMENT SELECTIONConsider the overall business impact of poor or even mediocrequality instrumentation, which may appear to be cheaper at theoutset, compared to instrumentation that offers greater stability andhas superior performance under all process conditions.The following three basic principles inform and guide the selectionof field instrumentation:AccuracyHigh accuracy allows control loops to be run at thedesired setpoint, regardless of process conditions.This produces greater quality and consistency of theproduct stream with less waste or scrap.ReliabilityHigh reliability means reduced cost of maintenanceand fewer work orders, thereby reducing spare partsinventory.StabilityHigh stability equates to increased time betweencalibrations, or allows calibration to be done duringscheduled plant turnarounds.If there is prior experience with the same class or type ofinstrumentation, lifecycle cost can be estimated and compared on astatistical basis using the following inputs to a financial model: Initial cost of the instrument Estimated useful life of the instrument Mean Time Between Failures (MTBF)Manufacturer’s recommended maintenance cyclewww.yokogawa.com6
Field Instrumentation Selection and Total Cost of Ownership3.2 APPLICATION EXPERTISEDemographic ChangesAs baby boomers retire in the coming years, plants will struggle tofind qualified, experienced workers to take their place. According toPew Research, Generation X contributes nearly 53 million workers tothe U.S. economy overall. Thisdemographic shift will leavea deficit of approximately 10million workers to replace thebaby boomers who will retire.This same gap will be seenin process facilities, resultingin a need for new engineersand technicians who may lackexperience and need supportwhen performing such functionsas selecting instrumentationfor the plant or determiningthe best solutions for pressure,temperature, flow, or levelapplications. These changingdemographics of the workplaceunderscore the importance and long-term impact of selecting the rightfield instrumentation at the outset.RecommendationsThis issue can largely be remedied through the use of instrument.changing demographics ofthe workplace underscore theimportance and long-termimpact of selecting the rightfield instrumentation at theoutset.consultants who work for suppliers, as well as their salespersons ortechnical specialists. Also, software tools provided by the suppliercan help identify optimal solutions for specific applications. AtYokogawa, for example, specialists can be involved in all phases ofthe process, including during Front End Engineering & Design (FEED),offering detailed site surveys, risk assessments, and performanceconsultations. This wealth of experiential and procedural knowledgecan be an asset when determining correct field instrumentation forspecific applications.www.yokogawa.com7
Field Instrumentation Selection and Total Cost of OwnershipProject DocumentationProject costs rise significantly when engineering drawings, suchas a piping and instrumentation diagrams (P&IDs), need to be createdto facilitate the layout of a plant for greenfield projects, and to ensureproper space requirements are met for instrumentation.RecommendationsWhen considering engineering documentation, identifying aninstrument supplier that can support 3D drawing requirements throughthe use of software can help keep this and related costs down. Automaticrendering tools can provide additional information about a supplier’sproducts, including 2D and 3D drawings/CAD models. Partnering with asupplier that has these critical capabilities can mitigate any applicationknowledge deficit that may exist at the outset of a project.3.3 INVENTORY COSTSProcess Control vs. Safety ApplicationsTraditionally, different transmitters are used for process controlversus safety applications, which may require plants to carry separateinstruments. Additionally, having too many different ranges of devicesto cover all applications of a plant is costly and may lead to more error.RecommendationsWith some manufacturers, the same transmitter can be used forTraditionally, differenttransmitters are used forprocess control versussafety applications, whichmay require plants to carryseparate instruments.both process control and safety applications. This allows the plantto significantly reduce the number of transmitters carried in sparesinventory for facilities with safety applications. Transmitters thatcome with safety capabilities as standard means no additional cost forthese measures and improved reliability. Moreover, instrumentationthat has a more condensed number of ranges should be sought.If one transmitter range can cover multiple applications withoutsacrificing performance, this will significantly reduce both the numberof additional devices that need to be kept in inventory, as well asmaintenance costs. All Yokogawa pressure transmitters are certified forsingle transmitter use in SIL 2 safety applications and dual transmitteruse in SIL 3 safety applications.www.yokogawa.com8
Field Instrumentation Selection and Total Cost of OwnershipMultiple SuppliersMany plants suffer from having too many suppliers for theirinstrumentation or several generations of product from a particularsupplier. This can lead to higher costs due to a multitude of factors,including a greater number of spares needed to be kept in stock andmore training required to ensure proper procedures are followed foreach device type.RecommendationsWhen possible, utilizing a single supplier for instrumentationallows for standardization of device design, procurement, installation,and commissioning. This streamlined approach avoids much of thelogistical complexity and costs associated with both inventory andtraining when implementing and maintaining instrumentation frommultiple suppliers.3.4 APPLICATION COMPLEXITYExcess InstrumentsDP Level applications typically require two instruments in closedtank applications: one to measure tank level, and one to measureblanket pressure. This essentially doubles the cost for the device’smechanical/electrical hardware, I/O point, engineering, procurement,and installation.RecommendationsThere are instruments available that can perform multiplemeasurements in a single device while withstanding a wide rangeof rigorous process conditions. Such instrumentation should beconsidered when selecting new or replacement instrumentation sinceits robustness can reduce the total cost of ownership. Additionally,instruments that make multiple measurements eliminate processpenetrations, and result in a reduction in potential leak points.www.yokogawa.com9
Field Instrumentation Selection and Total Cost of OwnershipThe multi-sensing feature of the DPharp sensor measures bothstatic and differential pressure in one device. This eliminates the needfor two transmitters to measure these process variables, saving the costof a gauge pressure transmitter and the manifold, piping, wiring, I/O,construction, and associated engineering hours. The DPharp sensor alsodecreases the number of devices that have to be managed, maintained,and calibrated, which ultimately reduces overall lifecycle costs.3.5 CORROSIVE ENVIRONMENTSMaterial QualityMost pressure transmitters on the market today use standard316-grade stainless steel by default. While often sufficient, theremay be many applicationswithin a facility that requirematerials above this standard.This inevitably requires thespecial order of materials at anadditional cost, driving up theinitial purchase price. Whensituations necessitate installationin salt water environments, asexist in offshore facilities, highwash-down areas, or in the dairy,food, and beverage industries,316 SST housings will often be required. These housings can addsignificant cost to the instrumentation package.At the beginning of a project,consider suppliers withmore robust materials ofconstruction that cover abroader range of applicationsas standard.RecommendationsAt the beginning of a project, consider suppliers with more robustmaterials of construction that cover a broader range of applicationsas standard. This can help mitigate any potentially unforeseen CAPEXelements. Also, alternatives to the 316 grade SS standard, includingcorrosion-resistant aluminum housings or other materials, will performwell under certain extreme conditions, and can potentially lower costs.www.yokogawa.com10
Field Instrumentation Selection and Total Cost of Ownership3.6 PRE-ASSEMBLED SOLUTIONSSite IntegrationWhen assembling instruments on-site, individual parts oftenship from different suppliers, leading to delays and difficulties in theprocess. Examples of such instruments include manifolds for pressuretransmitters or differential pressure transmitters for primary elements.There is often other hardware needed such as pipe runs, heat tracing,impulse piping, pipe stands, mounting brackets, and other auxiliaryequipment. These components require specific professionals to assistin the installation process, such as electricians, welders, pipe fitters,and other technical experts, and this can quickly drive up initial costs.RecommendationsWith these added expenses in mind, it is more cost effective to.it is more cost effectiveto find a supplier that canprovide pre-configured orpre-assembled solutions thatarrive on site ready to installwith little or no additionalhardware.find a supplier that can provide pre-configured or pre-assembledsolutions that arrive on site ready to install with little or no additionalhardware. Yokogawa’s VERIS Accelabar, which can be furnished as aready-to-install flow meter system, arrives complete with the primaryelement, configured transmitter, and RTD, along with other secondaryinstrumentation. The Accelabar is capable of measuring gases, liquids,and steam at previously unattainable flow rate turndowns and testedup to 65:1 with no straight pipe run requirements.www.yokogawa.com11
Part 4 Operating Expenditure(OPEX) Considerations4.1 ONGOING MAINTENANCE AND CALIBRATIONOverpressureInferior instrumentation or instrumentation that is not well-suited for its specific applications will need ongoing maintenanceand may have an adverse effect on the overall process. For instance,overpressure for pressure transmitters can occur during impropermanifold sequencing, startup or shutdown conditions, or processupsets. Many sensor technologies cannot handle overpressureconditions and, as a result, users often see a shift in the output of thedevice, forcing the instrument to be re-zeroed or recalibrated.An objective for safe and efficient boiler operation is to maintaina constant level in the boiler drum, as seen in Figure 3. This can beUltimately, inferiortransmitters can mean ahigher number of workorders to re-zero orrecalibrate devices.accomplished by maintaining a balance between the amount of steamleaving and water entering the boiler drum. Boiler drum level is one ofthe most challenging power plant pressure transmitter applicationsdue to high static pressures and low-level differential pressure. Achange in static pressure can cause significant output shifts in leveltransmitters. Static pressure changes occur when a boiler is startingup or shutting down, at which time accurate level measurement ismost critical. There is also a chance of over-pressuring the level deviceduring boiler blow down. In this type of application and many others,devices can drift to the point where they no longer make accuratemeasurements for the process loop in which they were installed,resulting in a potential safety risk, off-grade product quality or loweryields.Ultimately, inferior transmitters can mean a higher number of workorders to re-zero or recalibrate devices. Considering the number of pressuretransmitters throughout any given plant, costs can grow exponentially.www.yokogawa.com12
Field Instrumentation Selection and Total Cost of OwnershipRecommendationsYokogawa’s DPharp digital sensor measuresthe differential pressure (DP), static pressure(SP), and sensor temperature in a single device.Given these three pieces of process data, thedifferential pressure transmitter can compensatethe DP measurement for temperature effect andstatic pressure effect in real time. In addition,a protective system within the transmitterprovides overpressure protection by equalizingthe excessive pressure before it reaches thesensor. Once stable process conditions return,these features enable the transmitter to return tonormal operation within published specifications.In the case of DPharp technology, calibrationsFigure 3 – Example feedwatercan be extended by many years depending on the accuracy required forDPharp pressure transmitterterm. In the example below, the Yokogawa EJX A and EJA E Differentialflow control using a Yokogawathat measures differentialpressures up to 2,000 PSIDthe application, resulting in significant calibration cost savings in the longPressure Transmitters are compared to multiple suppliers on the markettoday. The graph shown in Figure 4 represents a
that inform and guide the selection of field instrumentation. KEY TAKEAWAYS. ü Understand the two main components that drive plant costs. www.yokogawa.com 3 Part 1. Introduction. Within a plant, field instrumentation and actuators are the sensors of the process and the point at which the process automation system . detects, measures, and .
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The Process & Instrumentation Diagram Process & Instrumentation Diagram (P&ID) show what is in the PFD –plus the instrumentation to monitor the process –plus how it is controlled. A P&ID shows the relationships between the all components in the system and shows details. Version - 1.0, January 2019 Process Flow / Instrumentation .
The Process & Instrumentation Diagram Process & Instrumentation Diagram (P&ID) show what is in the PFD -plus the instrumentation to monitor the process -plus how it is controlled. A P&ID shows the relationships between the all components in the system and shows details. Version - 1.0, January 2019 Process Flow / Instrumentation .
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Science and Reactor Fundamentals ΠInstrumentation & Control 7 CNSC Technical Training Group Revision 1 ΠJanuary 2003 INSTRUMENTATION EQUIPMENT 2.0 INTRODUCTION Instrumentation is the art of measuring the value of some plant parameter, pressure, flow, level or temperature to name a few and supplying a signal
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