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Achieving the Autonomous Terminal
- 1. Akiko Shinozaki Manager, Logistics Coe, Digital Enterprise Solutions Center Yokogawa November 11, 2020 Achieving the Autonomous Terminal
- 2. Agenda 1. Introduction 2. Autonomous Terminal 3. Digitalized Terminal Operations 4. Dynamic Adaption 5. Value of Autonomous Operation
- 3. Introduction
- 4. Industrial Terminals LNG, LPG and Chemical Gases Terminals Chemical Terminals Oil Terminals Different Type of Terminal Energy Manufacturing Food and Agriculture End Markets
- 5. Field to Centralized Monitoring and Control
- 6. Autonomous Terminals Should Be Silent and Boring Operator intervention Optimize execution of customer orders without operator intervention, including coordination with other terminals with overlapping coverage to maximize distribution efficiency Information Exchange Automatically exchange information with business partners such as port authorities, transport agents, ship captain, customers, etc. Self Diagnostics Perform self-diagnostics of terminal assets by analyzing data provided by smart sensors and instruments in real-time, in coordination with digitized historical maintenance records Adaptive Adapt to and learn from terminal dynamics to provide operational advice for improving safety and efficiency
- 7. Digitalized Operations Master Contract Order Handling Movement Planning and Scheduling Inventory Book Stocks Invoice Consolidation Inventory Physical Stock Information Mgmt Order Mgmt Transport Preparation Blend Property Control (BPC) Scheduling Activity Equipment Reports Departure Handling Actcivity Mgmt Arrival Handling Transfer Blending HMI Master Database Role and Security Audit Trail Business Mgmt Workflow Mgmt Distributed Control System/Programable Logic Controller Ll LI SI SI SI SI SI MC SI FI SI SI SI
- 8. Integration with Business Domain Terminal B Inventory Invoice Terminal Orders and Movement Planning Terminal Orders and Movement Scheduling Invoice Calculations Book and Physiscal Stock Managementt BOLConsolidate BOL Orders Breakdown Orders into Jobs and Tasks Reesources Scheduling (Tank, Jetty, Pump and Line) Task Exexcution Consolidate BOL BOL Terminal A
- 9. Software Design Architecture for scalability and flexibility Core System Plug-in Component Plug-in Component Plug-in Component Plug-in Component Microservices with Event-Driven Architecture (EDA) design for scalability and flexible real-time deployment Event Producer Event Ingestion Event Consumer Event Consumer Event Consumer
- 10. Modularized, Expandable On-line TAS Core Truck Loading Truck Unloading Railcar Loading Ship Unloading Ship Loading New Functionalities bolted on-line, without stopping other services TAS Core Truck Loading Truck Unloading Railcar Loading Ship Unloading Ship Loading Pipeline Delivery
- 11. TAS Core Truck Loading Truck Unloading Railcar Loading Ship Unloading Ship Loading Pipeline Delivery Configurability ■ Workflow ■ Operation practices ■ Facilities ■ New path, ■ New bay, etc. Unified Configuration Center for All Modules
- 12. Truck Loading Gate In Gross Weigh Start Loading Pause Change Lane … Knowledge Management—Best Practices Library ■ Library to accumulate logistics best practices for sharing across enterprise ■ Configurable for each site conditions Activity Module
- 14. Current Material Compatible Material Material Group BGE BTG OG BULK BGE BTG BULK BTG EOA DEA BULK EOA DEA BULK OG DEA GLYCERINE GLYCERINE PU CPP HL 809 BULK OG PU CPP HL806 BULK Polyol Blend Contamination Check Path Optimizing Criterias Check Heel Contents Line Clearing ■ No line cleaning ■ Minimum of segment ■ Check line heel contents recorded by last previous activity ■ Check destination heel ■ Create line clearing sub-task to clear the line before line-up Compatibility Table
- 15. Jetty Scheduling Laycan 01 Ship A/Product A/Amt Demurrage Ship B/Product B/Amt Ship C/Product A/Amt Ship D/Poduct C/Amt 02 Maintenanc e Ship 1/Poduct C/Amt Ship 2/Product A/Amt Ship 3/Product B/Amt NOA NOR NOR ETA ETA ETA Shipping Schedule Jetty Schedule Optimizer Optimizing Criteria First come first serve Minimum waiting time Minimum operation time Minimum demurrage Jetty Constraint Product/Ullage Availability Harbor Information Shipping Agents
- 16. Customer Portal
- 17. Digitalized Maintenance Digital Maintenance System Terminal Assets Customer Operations and Maintenance (KPI) Dashboard Rule Based Engine and Auto Discovery (CMCDB) Ticket System and Run Books Third party “Plug-ins” “ComerComercial off the shelfs” Yokogawa “Plug-ins” Others “Plug-ins” Symantec McAfee What’sUpGold WSUS DELL CentrumVP ProSafeRS ControlValve Diagnostic HEXFouling Monitoring Pump Diagnostic Symantec McAfee WUG Network WSUS DELL Admin FCS SCS Control Valve Heat Exchanger Pump
- 18. Operator Actions Information from ICSS* Actions Through ICSS Process Plant Operator
- 19. Machine Learning to Reproduce Operator Actions Detect Deviation from SOP Capture Implicit Knowledge Detect Abnormal Conditions Machine Learning to Construct Operating Procedures Realtime and Historized Data
- 20. ■ Minimum site operation and maintenance crew as the Terminal is fully automated ■ Average terminal operator salary in U.S is c. $68k pa ■ No contamination; all heel and residues tracked and monitored ■ Minimum product losses; all movements monitored, and long-term data analyzed to detect small leaks ■ Minimum demurrages; close collaboration between the Logistics, Terminal Operation, Shipping Agent, Ship Captain, Port Authority, etc. ■ Demurrage bill is typically $ millions pa ■ Improve collaboration between Terminals with overlapping market coverage to improve the Level of services Value of Autonomous Operation
- 21. Many aspects of terminal operations are often directed by operators based on experience and judgment. This often results in inconsistent and non-optimal operations, with greater risk of incidents. Automating actions—and advising operators regarding their best course of action—by digitalized systems and making better use of data results in improved and consistent operator actions. These digitalized systems can also be used to shift maintenance from reactive to proactive, reducing downtime and maintenance costs. 1 2 Conclusions
- 22. Questions?
- 23. 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!