16183843 Yokogawa Centum CS3000 Overview

YOKOGAWA

DCS Introduction CS 3000 – Integrated Control System Overview Advanced , Flexible Operator Functions Powerful Control Station Features Flexibility in Engineering Integrated Solutions – Extended Applications Unique Advantages leading to Lower TCO

DCS Background C DD

System Cost

DDC

A

a ctu

log a An

cted e p Ex

No. of Loops Early1960s

l

Computer Compatible Controller 62H

Nest Type Controller (SPEC-200)

DCS (TDC-2000) 1975

Base: * Computer Compatible System * Process I/O with PID back up

*Position DDC as a Future System *Justify DDC cost by Automation Promotion

DCS (CENTUM) 1975

Base: * Enhancement of DDC from cost, failure problem, engineering point of view

First Generation DCS 1975: CENTUM was developed based on DDC Experience < CENTUM is the first Distributed Control System in the world.> – High Confidence on Reliability /Dependability • First Token Pass Highway in the world. ＊ Token Pass Data High Way -- No Electronic Parts at System Common. -- Redundant Highway alternately used for Complete Error Detection -- Became the Base of IEC Standard ”PROWAY”. then IEEE 802.4, MAP, and FieldBus.

• Duplex Control Station ＊ CPU redundancy -- Memory Update is a Key and Most Difficult -- Block by Block and Table by Table Memory Copy was applied. ＊ Internal Bus Redundancy -- Redundant Internal bus between CPU and I/Os with Alternate Use -- Power Supply for I/Os are also Redundant.

–

Easy Engineering for Automation and Advanced Control

–

User Friendly CAD (Fill-in Type) based Engineering

History of Yokogawa DCS 1965

1970

1975

1980

1985

1990

1995

2000

Supervisory Computer System YEWCOM, HP9000 Computer Systems for Control CCS

YODIC100 YODIC1000 Production Line Control System Concentrated Control System

YEWMAC

ASTMAC

YODIC500 YODIC600 CS1000

DCS

CENTUM

CENTUM-V CENTUM-XLCENTUM CS/CS3000

YEWPACK YS 80 Analog Control

ECS

EBS

I SERIES

μXL YS 100

Progress of Yokogawa DCS system ’75 ～’ 78

’79 ～’ 82

’82 ～’ 88

’84 ～’

’88 ～’

’98 ～’

’92 ～’

INTEGRATED SYSTEMOPEN SYSTEM EXCELLENT SYSTEM

NEW MODEL 1. High Speed Comunication THE FIRST DCS Bus 1. Unified Operator SYSTEM IN THE 2. WORLD Stations Adoption of 2. Redundant HDD 1. Distribution of Control Control Stations 3. CMOS Memory 2. FIF 4. One-Touch ＣＴＭ - ２ Operation

ＣＯＰＳ

2. Voice Output 3. Japanese Language Support 4. SequenceCE NTU M- V oriented Control Station

(Function Key Development)

ＣＳ３０００

Ｃ ENTU M ＣＳ

CENT UM- XL

XLAIS

Computer EOPS ENGS Station

ICS 10Mbps BCV

COPSV

　 V net

FCS

COPS2

7DF COPS 7DF

1. WINDOWS-NT OS 1. UNIX OS 2. Client / Server 1. Function Assignment 2. Advanced Control 3. Migration 3. Open Net Work 2. Separation of Engneering USER ORIENTED 4. High Reliability 3. High Peroformance 4. High Reliability OPERATION 4. Touch Operation 5. Utilisation of Users’ Assets 6. Easy Engineering 5. Window 1. Enhanced 6. Integration (Super Window) CENTUM Functions of OPS7. Expanded Control Capacity

7VP

EFCS 1Mbps HF-BUS

CFFS

256Kbps CFCS

CFSS

CFCS2 HF/F Converter Station

F-BUS 7FS

Control Loops Sequence Tables

32 20

32 20

40 40

40 200

80 200

4096 Blocks

HIS

Technology waves on Control Systems

Windows 2000 Internet IT

NT and Microsoft UNIX Micro processor

1st CENTUM

V

XL

CS

CS 3000

CS 3000 R3

June 1975

’82

’88

’93

’98

‘01

time

Enterprise Technology & Solution Business (Top Management) Domain

Business Domain

◆ Corporate Information systems ◆ Enterprise Resource Planning (ERP) ◆ Supply Chain Management (SCM)

Manufacturing Exec. System Domain ◆ Plant Information & Management System

MES Domain

(PIMS) ◆ Maintenance Management (MM)

Control Domain Control Domain

Advanced Application ◆Advanced Process Control (APC) ◆ Advance Operation Assistance (AOA) Plant Control Room/Factory Floor

DCS/PLC/PC/ESD/F&G

Field Domain

Field Domain Fieldbus and conventional Field Instrumentation.


Integrated Plant Control System (IPCS)

Hi-Tech Solutions Available in CS1000/3000 ◆Foundation Fieldbus ◆Profibus ◆ExaOPC - OPC Interface

OLE for Process Control

OPC Compliance Exaopc:

Domain wide “OPEN”Interface

PIMS / Maint.Mgt.

M E S

OPC Client

OPC Interface

APC/AOA

Process Data

OPC Client

C O N T R O L

Eng. Data

HIS/ ENG

HIS OPC Server

V-net ABC-H FCS

CENTUM-XL

HF-Bus

Positioning of CS 3000 R3 Well-balanced open architecture and reliability New migration path supplies open architecture with existing systems.

Migration

Business Systems ERP/SCM

PIMS

HMI CENTUM CS 3000 R3

APC AOA MM

FCS Rich interface by new I/O.

Existing Systems CENTUM-XL CENTUM V

Featuring cutting-edge “open” technologies

Field Network

FOUNDATION™ Fieldbus

Typical System Configuration Remote DCS Domain

Business Domain

Ethernet Closed-type HIS LCD-type HIS AOA

APC PIMS

HIS/ENG

MM ACG

Vnet APCS FCS With I/O

Mulcom

Incl. Fieldbus Engg.

Prosafe-ESD

RS-232/485/Ethernet

I/O in the Remote Field

(ExaCoast)

BCV Migration bus converter CS/CS 1000/3000 CENTUM-XL/V/ µXL

H1 Fieldbus

Field Devices PLC / Remote I/O / Subsystems

System Scalable Min. Configuration Single Domain Configuration

Expanded. System Configuration

Controller

Max. No. of Tags Max. No. of Stations

One Process Unit

Whole Complex

: 100,000 per HIS : 64 Expanded System Max. No. of Domains Max. No. of Stations

: 16 : 256

Security User Group Check user name

User in

User Permission Check operation and monitoring scope

•Function block operation and monitoring

Check operation and monitoring authority

•Windows operation and monitoring •Receipt of messages

Operation History

Tag Basis Important Tag

(Major Alarm)

Operation Mark Key Access

Ordinary Tag (Medium Alarm)

Auxiliary Tag1

(Minor Alarm)

Auxiliary Tag2

(Logging Alarm)

Windows user security

PV CONTROL 0007 PVPVPVPVPVPVPVPVPV SVSVSVSVSVSVSVSVSV FIC001


Monitoring & Operation Human Interface Station

Management Information Easy integration with higher level systems Historical database packages etc...

Off line engineering On line engineering Powerful engineering & testing tools One global database etc....

Engineering

Maintenance Extensive self diagnostics Maintenance & report functions On-line maintenance Remote maintenance etc....

100.000 tagnames 2,500 Display Panels Enhanced trending Intelligent alarm functions Reliable security functions Windowing operation etc....

Process Information

(HIS)

Web based Plant Monitoring General-purpose PC

HIS graphic/trend windows are converted into HTML files and Java Applets

Web Server

Ethernet

Plant LAN/WAN

HIS General-purpose PC

Dial-up Internet Connection

Graphic windows, trend windows, and ITV windows

V net FCS

Plant monitoring on a business trip, at home, at maintenance office, etc. using Web Browser

Browser ❚

Yokogawa FIELDEYE ITV system ❙

The Web camera server enables ITV images to be displayed via a Web browser at an incredible low cost.

FIELDEYE System HIS

Internet Explorer (free) Ethernet or dial-up connection

Web camera server ITV image signal

ITV camera control signal

ITV camera

Multiple Monitor ❚ Efficient monitoring/control of Advanced Process Control/Operation by a single operator with dual monitor

Single Monitor Windows overlap each other. Hard to see!

Dual Monitors Much easier to see!

Operation and Monitoring Standard Operation and Monitoring Windows

Operation and Monitoring Support Functions

Graphic,Tuning, Trends, Alarms, Operator guidance

Process & Historical message reports, Security ITV camera & CENTUM desktop customization

Control Status Display Window Control drawing, Sequence table Logic chart window SEBOL & SFC windows

Common Operation and Monitoring Functions Window call-up, Window” or “Full screen”, System message, Window sizing, Window hierarchy, Navigator window…

Trend Functions Real time, Historical trends Long term data archive, External recorder, Expert trend viewer &Tuning trend

System Maintenance Functions System status, System alarm, HIS setting, Time setting dialog & Help dialog

Lets have a look at some samples

Operation and Monitoring Windows Navigator Window

Overview Window

Control Group Window

Trend Window

Tuning Window

Sequence Table Window


Control Field Control Station Processor RISC processor Fixed scan times 4000 free configurable function blocks Powerful math. capacity etc...

Redundancy Redundant CPU, Power Supply and Communication Interface INPUT

BUFFER CPU

BUFFER

CPU

CPU

CPU

COMP

COMP

BUFFER

BUFFER

Unique Pair & Spare Design

OUTPUT

Easy integration subsystems e.g. PLC, SER.. Data exchange between FCS Support Fieldbus etc...

Integration

Large control block library Advanced control functions Calculation functions C-language Graphic Flowchart (SFC) etc...

Analog & Digital Control

Input Output Analog single card I/O Unit  Current/Voltage In  mV, Thermocouple, RTD Input  Pulse Input  Current/Voltage Out

I/OUnit 16 channels

Input/Output Modules I/OUnit 128 channels

Analog Multiplexer Unit (16 channels) ◆ ◆ ◆ ◆ ◆ ◆

RIO bus (max. 20 km) Node Interface Unit Max. 8 units per FCS

Input / Output Units Max. 5 units per NIU

Digital I/O unit connector type ◆ ◆ ◆ ◆

16 -pt. Input (isolated) 16 -pt Output (isolated) 32 -pt. Input 32 -pt. Output

Voltage Input mV Input Thermocouple Input RTD Input 2-wire transmitter input 4-20 mA Output

I/OUnit 32 channels

I/OUnit 2 ports

Communication unit

◆

RS-232C RS-422 RS-485 Fieldbus

◆

Profibus

◆

Ethernet

◆ ◆ ◆

Field Control Station and FIO feature .. Vnet

Direct Node Serial, Ethernet ・・・ FCS ・

PLC

New Remote I/O Bus (Ethernet)

To Field Device

FF-H1 4-20mA

(Subsystem)

Remote Node

FF-H1 To Field Devices

4-20mA (Conventional)

Fieldbus

FIO Features ❚ Small-sized (Compact) ❚ Two kinds of connection ❙ Direct Node ❙ Remote Node ❚ Dual redundant I/O Module are possible (for all type) ❚ Field Network ❙ RS:2 ports ❙ FF-H1 : 4 segments ❙ Profibus-DP

　 KFCS (Remote I/O type)

KFCS CP333 SB301

Local node

Generic cabinets Remote node

ESB bus 128 Mbps FIO

TB

FIO

TB

FIO

TB

FIO

TB

FIO

TB

Front

Rear

ER bus ( 10 Mbps )

FIO

TB

FIO

TB

Front ERbus ： Enhanced Remote BUS

Rear

FIO Node overview Up to 8 I/O modules

Remote I/O Interface (10Base2) Power supply

5 units (222.3mm) 写真挿入

19 inches

Node / FIO Features Environment ❚

Zone2 Compliant

❚

Temperature -20 -- 70 DEGC

❚

corrosion gas resistant G3

Node ❚ Direct Node : Max 10 Nodes/FCS ❚ Remote Node : - Max 9 Nodes/FCS - Max 4 Nodes/RIO - Max 4 RIO/FCS ❚ Field Communication - 2 ports : RS - 4 segments : FF-H1

ALF111 Advantage (FF-H1) No. of Segments ❙ 4 Segments / ALF111 No. of Points ❙ 48 Points / Segment No. of total Points ❙ 3072 Points / FIO LFCS 48 Points x 4 Segments x 16 ALF111

Low cost of construction with FIO FIO can be installed closely near field devices to reduce wiring cost

Open architecture

FIO is compact: Saves Space

Ethernet based ER Bus RS232/422/485

Cost-effective choice is available: Single/Dual Isolated/Non isolated/Channel isolation Hi-Density modules Built in interpose relays avoids relay cabinets

Rich Flexibility:

Field connections

Field wiring method according to the application & budget Pressure Clamp Terminal block (Direct wiring for field devices)

Yokogawa Terminal Board, Cable & I/O adapter (Wiring of field devices via Terminal Boards/marshaling)

I/O module Terminal Board & MIL Connector Cable (Popular for low cost installations-Wiring of field devices via Terminal Board/Marshaling)

Remote I/O installation Explosive sites

Corrosive sites FCU

ooo

CCR (Central Control Room)

Separated sites

FF Solution: Four-segments & Redundant High density of segments provides Cost Effective FF solutions Redundancy of modules adds high reliability for FF solutions

4 Segments FF-H1

Port

1

ALF111

ALF111 SB40 SB40 1 1 IOM IOM IOM IOM IOM IOM or or PSU EB50 EB50 1 1

2

PSU

Local Node or Remote Node

3 4

Redundant Configuration Available Field Devices

Redundancy ❚ Synchronous hot standby with fully redundant hardware and duplex functionality in design

Unique Pair & Spare Design


En gi neer in g Off line Engineering without Target Hardware by using Hardware Simulation Technology Off line Testing and Hardware Simulation

On line Engineering

CAE Computer Aided Engineering ENG Builder software

HIS

Concurrent Engineering

Order

Electronic Media Input

V net

FCS

Start-up

❚Engineering can start direct after ordering ❚Engineering up to Configuration Testing can be done Off Line

Concurrent Engineering Engineering done by multiple PCs DOWNLOAD the project

Engineering PC

Master Database HIS

Engineering PC FCS backup

Engineering PC

Virtual Test Function Virtual Testing HIS Function

Virtual Wiring

HIS

HIS

FCS Simulator

Off line Testing HIS Function

FCS Simulator

Exatif Communication Interface

Plant Simulator Plant Model

- Off Line Virtual Testing using only one PC - Connection with Plant Simulator using the FCS Simulator


AOA: Advanced Operation Assistance Yokogawa’s unique AOA Solutions for the Benefits of Customers

Exa plo g:

Event Analysis Package

-Detailed Analysis of Process and Operation events -Helps in decision making for further Automation/Monitoring/Operation

Exa pil ot:

Operation Efficiency Improvement Packag

-Automation of St-Up, S/D, Transition & Emergency Procedures -Reduction in Operating Time during Manual Operation -Higher Productivity -Maximization of Safe Operation -Availability of “EXPERT” knowledge for uniform operation every time

Partners in Advanced Process Control

Shell Global Solutions

The Alliance

The Alliance Yokogawa Shell customers customers Market a c e b Segmentation

f d ROW

EX: EXA-SMOC with CS3000 Optional Remote Operation/ Monitoring

Ethernet Card Exasmoc OPC Client Exaopc OS Server

WIN NT

VF701 Card

Etherne t Operation / Monitorin g/ Control

Standard Displays APC Displays

HIS

HIS/E NG

SMOC-PC (Builder)

Optional Ethernet

Exasmoc Station Download

V Net / VL Net

SFCS Process Data LFCS

Exasmoc Data

YOKOGAWA

Exa tas Ter minal TAS-MS poll to Host System Architec ture and searches for the following

Sys tem TAS-MS Client

Delivery data:

TAS-MS Management - BOLServer No. - Delivery Number - Host System Interface - Order Management- Order Number - Truck Number - Traffic Management - Product and Quantity - Ship Loading/Unloading Management - Data Gathering - Management Data Handling - Reporting - Master Data Management

TAS-CS Control Station TAS-CS Human Machine Interface

Loading Control, Pump Management, Bay Change, Additive Control, Spot Loading, Loading Monitoring

Ex ata s Main F unc tio ns : Inte gra tion Host System (e.g., SAP ) Exatas Terminal Automation System Refinery Onsite Systems

Refinery Offsite System

Ethernet

TAS-MS Human Machine Interface (HIS)

Control Station (FCS)

If the terminal is a part of refinery.

If the terminal is a part of refinery. Tank Gauging

Safety System

MOV System

Electronic Preset

Card Reader

Various Subsystems

TIM3000 : Tank Inventory Management Functionality Real-time module  Tank data collection  Tank data calculation  Tank status management  Monitoring of job control conditions  Monitoring of tank behavior Interface Module  Collection of tank snapshots into Database  Receipt of tank property

Features

Benefits

 Modularity of functions  Adoption of Oracle RDBMS  Easy interface to other systems  Easy development of reports  Easy development of user interface  Connectable to various TGS  Reliable TGS

 Safe tank operation  Provision of tank data for operation accounting & scheduling  Precise grasp of tank inventory

PIMS: Plant Information & Management System

DATA RECONCILIATION

PERFORMANCE MONITORING

MASS BALANCING

PROCESS PLANT PLANT UNIT TANK FACILITY STREAM

PRODUCTION ACCOUNTING

ECONOMIC CHARACTERISTICS

MATERIALS

FEED INTERMEDIATE FINISHED PRODUCT CHEMICALS UTILITIES

PLANT MODEL TECHNICAL CHARACTERISTICS

isa

PIMS

LIMS

ENVIRONMENTAL MONITORING

ERP CMMS EDMS

OPERATIONS ACTIVITY MANAGEMENT

DATA MANAGER

HISTORICAL DATABASE

REAL TIME DATABASE

REFERENCE DATABASE

OPC CLIENT

quantum OPC SERVER PCS

YOKOGAWA


Quick & High-quality configuration ❚ The time for newly plant construction or reconstruction should be minimum. ❙ The longer time links the larger financial disadvantage.

❚ R3 provides the following configuration environment. ❙ Total Project management. ❙ Advance Debugging. ❘ You need not wait the hardware delivery or field wiring construction.

❙ Reuse of configuration data ❘ This is available between several stations or between several plants.

❙ ❙ ❙ ❙

Unified configuration operation with LOOK&FEEL. Several engineers can work at the same time. On-line maintenance. Pinpoint help viewer.

Concurrent engineering ❚ Several engineers can work at the same time.

Only one database Back

Total Project management. All graphics, all control logic are in a database

❚ The application of all stations in a system is included in one database.

ooo

HIS No.1

HIS No.2

FCS No.1

ooo

FCS No.2 Back

Benefit of Project management. ❚ The application of all stations in a system is included in one database. ❙ At least 1 PC is required to generate whole over a system. ❘ You need not create same or similar graphics/sequences in front of each engineering PC.

❙ One PC (one configuration software) can handle several projects. ❙ You can reuse the application database of a plant to another plant by a project, by a station, by a graphic, by a control logic. ❘ This shortens the configuration time. ❘ This makes the configuration quality excellent because the copy source has been working well in an actual plant.

❙ Optimum management of application data is available.

Back

Advance Debugging. ❚ The delivery time of controller and construction time of field wiring is much longer than the delivery time of PC. ❙ If you can advance your configuration work only with PC, you can shorten your total configuration time. ❙ If you can advance your debugging work without actually connecting the controllers and field devices, you can shorten your total configuration time.

❚ Yokogawa provides the excellent debug functions. Virtual Test You can debug R3 configuration only with a PC.

Target Test You can debug R3 configuration without field wiring. Back

Advance Debugging Theory. ❚ Virtual test (only with PC) ❙ Check simple entry mistakes. ❙ Try new control logic. ❙ Check graphic work ❙ Operator training.

Normal operation is available.

Memory in PC FCS FCS Simulator

❚ Target test ( without wiring)

ooo ooo ooo

Virtual input is ❙ Check actual FCS CPU Virtual input is created from the created from the performance output from FCS output from FCS simulator. ❙ Check the actual relationship among each Only station. minimum check is needed

at start up !

HIS

For HIS, this pretends FCS

FCS memory Field Field devices devices Auto Auto wiring wiring

For FCS For FCS, this simulator, this pretends the pretends the actual plant. actual plant.

Start up Virtual !Target (Actual plant) test Actual plant

Reuse of configuration data. Tag 1 Tag 2 Tag 3

Export CSV file to use in MS-EXCEL. Import CSVthe file project to reuse. Reuse Reuse the graphic •Configuration tool is not needed Reuse logicwork in another project onlythe forcontrol simple entry

in another station Reuse the control logic in another project Reuse(Graphic the control logicavailable) is also in own station

Reuse the graphic in own station

ooo

Plant A (project A)

ooo

ooo

Plant B (project B)

Back

Unified configuration with LOOK&FEEL. Project Detail configuration (Each plant) for each

• Graphical configuration • FB in FCS and FF devices are handled in a same tool.

Each folder for each FCS

Drag&Drop enables Copy& paste

FB : Function Block

Each folder for each HIS

Example : Control logic

I/O specification ❚ Installation environment ❙ ❙ ❙ ❙

ISA G3 for corrosive environment Wide temperature range -20°C to 70°C Conformed to EMC, C-tick. Non-incendive for Explosion proof ❘ Class I, Div.2, Group A,B,C,D, T4

❚ Redundancy ❙ Available for all types (analog, digital, Fieldbus, Modbus)

❚ Replacement ability for the existing XL, V systems. ❙

Full compatible size, connection, and function.

Flexible Field Wiring. ❚ According to your plant, any I/O modules can be connected with direct connection or terminal board connection. ❚ Even in case of fieldbus, you can choose type.

Dedicated eithercable

Field wiring Terminal board

❚ Change the front blocks,

Field wiring

Flexible Field Wiring. For dual

For single Dedicated cable Terminal board

On-line maintenance. ❚ In your plant operation, sometimes you would like to modify or to add/remove your control logic or graphics. ❙ It is quite difficult (nearly impossible) to stop your controller frequently. ❙ You usually configured several control loops. While modifying one of loops, you do not want to effect the control of any other loops.

❚ R3 provides the “On-line maintenance” function to meet your above requirement. ❙ You need not stop your controller when you modify small parts of control logic, graphics, etc. ❙ Any other parts of control logic are effected by this modification, so the influence for your plant control is

Back

On-line maintenance. No effect No effect

Control logicNo effect

(1) R3 Controller is controlling the plant with its control logic.

No effect

(2) You modify one of control loops. (or sequence logic etc.) Only this loop is stopped. Others are going on working. (3) Modified item loop is retrieved online to actual control without any effect to other loops. (4) In this term, CPU of controller never stops. Controller CPU

is Non-stop !

No effect

ooo

Controlling

No effect

Life Cycle Benefits Efficient Engineering Function of CS 3000

Local Engineering Force

Short Engineering Period

Reasonable Engineering Pricing Maintenance Service

Hardware maintenance System upgrade Remote Maintenance

Reduce Customer’s Total Cost of Ownership in Life Cycle Additional Service

ETS capability

System Integration Service Network Engineering Service APC/AOA/PRM/PIMS

Software support Sub system support Tuning & Control Solutions

R3 Summary & Benefits (1) HIS Cost Effective LCD Displays, Win 2000: More Open to IT, Dual Monitor, Web monitoring, Low cost ITV Interfacing

FIO Very Cost Effective, High Density & Compact I/O Simple and low Engineering & Construction cost, Application and Budget based Flexibility in Selection, Cost cutting in field wiring on top of Fieldbus More immune towards Corrosion & Temperature Redundant modules even for Fieldbus Migration Friendly

R3: Fieldbus & PRM Hi density Module, Integrated Engineering, Maintenance Management

R3 Summary & Benefits (2) APCS - Station A Cost Effective station for Advanced Regulatory Control and Exacoast, Reduce load on FCSs, Compliments and Supplements Exasmoc and Exarqe based APC

AOA (Exaplog & Exapilot) & APC (Exasmoc & Exarqe) Seamlessly Integrated (Almost embedded like) in System

R3: Fully Loaded with IT Power PIMS, MES and Enterprise Integration

R3 Summary & Benefits (3) R3: Better than Hybrid Systems R3 is a Cost Effective Complete DCS solution against

V & XL Migration A special FCS (RFCS2) is available for V & XL migration, Field Wiring is not affected, Phase wise and/or Customer’s budget wise plan can be offered. Benefits of FIO, Win2000 HIS, FCS, APC & Fieldbus for Migrated system, Additional Benefits on MES & Enterprise Integration

Migration of Other Vendor DCS These Issues can be handled project by project. New Customer is benefited by R3 features.

16183843 Yokogawa Centum CS3000 Overview

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