Yokogawa Distributed Control System

(1)

Yokogawa Distributed

Control System (CS3000 R3)

(2)

Yokogawa IA Field Proven Solutions

Corporate Management (ERP*)

Integrated business operation systems

Oracle EBS, SAP R/3, iRenaissance, etc

Integration

Yokogawa provides the best solutions

to support the foundation of manufacturing industries.

Production Management (MES*)

Systems for advanced control,

simulation, production

management, and scheduling

Advanced Process Control & Advance Operation Assistance

APC & AOA

Solution Based

Packages

PIMS

Process Data Acquisition & Management

Production Control System

Production control systems

Field Instruments

Field instruments, sensors, measuring

instruments, analyzers and other equipment

Safety Instrumented System

Prosafe

Integrated Production Control System

CENTUM

STARDOM

PCS

* ERP = Enterprise Resource Planning

Magnetic Flowmeter

Transmitter

Digital Vortex Flowmeter

Digital YEWFLO

Zirconia Oxygen Analyzer

ZR 402

DPharp EJA

(3)

AOK

:pneumatic

controllers

1951

1957

p d/p

:pneumatic

transmitters

1970

YODIC600

direct digital

control system

1971

I series

Electrical controllers

1975

CENTUM

world’s first

distributed

control system

UNI?

ultra-stable analog

transmitters.

1978

1990s

Solution Based Packages

software suite for advanced

control and advanced

production management.

DPharp EJA

fully-digital

noise-free sensing with

world’s first silicon

digital sensor.

1994

1998

Foundation

Fieldbus on EJA

field intelligence on

digital network.

2000

STARDOM

Network based

Control System

Autonomous controllers

WEB base Packages

IEC61131 lang.

System Products Evolution

Pneumatic

Analogue

Digital

Network Era

2000

Plant Resource

Manager (PRM)

field intelligence

integration to plant

management & operation.

2001

Non-stop evolution for never-ending improvement

in your plant management and operations.

2003

CS3000

R3.04

Most Powerful

DCS

(4)

FCN

(5)

SBP (Solution Based Package)

1. Define

5. Control

2. Measure

4. Improve

3. Analyze

Define

the target to be achieved

xxx alarms/100inputs-day

xxx actions/100loops-day

_Measure

DCS process data

DCS event message

Event message of field instruments

Improve

and solve the root cause of problem

1. Improve field related problems

2. Improve control related problems

3. Improve alarm related problems

4. Improve operators related problems

Value-added solutions on top of Process Control Systems

Realizes safer and more cost-effective operation

Improve plant operation through Six Sigma DMAIC approach

Supports continuous improvement process

Value-added solutions on top of Process Control Systems

Realizes safer and more cost-effective operation

Improve plant operation through Six Sigma DMAIC approach

Supports continuous improvement process

Six

Sigma

Six Sigma DMAIC

Control

and verify the improved condition

DCS process data

DCS event message

Event message of field instruments

Analyze

related data to identify the root cause

of problem

DCS process data

DCS event message

Event message of field instruments

AAA

(6)

CENTUM-XL

EOPS

CFCS EFCD

ENGS

CENTUM CS3000

HIS

PFCS

KFCS

LFCS

COPS2

CENTUM V

CFFS

CFCS2

COPSV

CFCD2

HF-Bus 1MBPS Dual Redundant Token Pass

CENTUM

CFCD

CFCS

COPS

F-Bus 250 KBPS Dual Redundant Token Pass

ABC

CENTUM CS

ICS

EWS

PICS

Vnet 10 MBPS Dual Redundant Token Pass

Evolution

and

Succession

CENTUM Evolution

1975

1983

1988

1993

1998

Long Term Suport for

Existing Systems

Long Term Suport for

Existing Systems

- Open & Reliable Architecture

- Genuine Foundation Fieldbus

- Full Upward Compatibility

- Evergreen & Growing Policy

- Open & Reliable Architecture

- Genuine Foundation Fieldbus

- Full Upward Compatibility

- Evergreen & Growing Policy

Yokogawa continues providing timely functional

upgrades to maintain CENTUM a leading-edge DCS.

Yokogawa continues providing timely

functional

upgrades

to maintain CENTUM a leading-edge DCS.

(7)

CENTUM-XL

EOPS

CFCS EFCD

ENGS

CENTUM CS3000

HIS

PFCS

KFCS

LFCS

COPS2

CENTUM V

CFFS

CFCS2

COPSV

CFCD2

HF-Bus 1MBPS Dual Redundant Token Pass

CENTUM

CFCD

CFCS

COPS

F-Bus 250 KBPS Dual Redundant Token Pass

ABC

CENTUM CS

ICS

EWS

PICS

Vnet 10 MBPS Dual Redundant Token Pass

Key Technology Trend

1975

1983

1988

1993

1998

UNIX

Technology

Micro Processor

Technology

Windows

Technology

Open Network

Technology

Evolution

and

Succession

Open and Flat Network Covers all over the Plant

Floor from Enterprise, Control, to Field Level.

Open and Flat Network Covers all over the Plant

Floor from Enterprise, Control, to Field Level.

(8)

State of the art technologies

Absolute performance guaranteed.

What’s unique about Yokogawa

Enterprise technology solutions

(9)

System Configuration Overview

Full digital network from plant floor to boardroom

Control LAN

4-20mA /

Smart

Intranet

Remote

IO

MIS

Browser

WEB

OPC

Fiber

Optic

Client

Safety

System

APC/ AOA

Advanced Solutions: Assets & Plant Information, APC/O and AOA

Fieldbus

FB

Seamless Integration of Fieldbus, Other digital

Communications & Conventional I/O with DCS

CS 3000R3 & Sub System Operation / Control / Engineering

ooo ooo

Enterprise Management

Advanced

Solutions

Ethernet, Modbus,

RS232/422/485…

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Basic CENTUM CS3000 Architecture

Dual Redundant V-net

HIS

ENG

Ethernet

HIS

CENTUM CS3000 Major Components:

HIS: Human Interface Station

ENG: Engineering Station

FCS: Field Control Station

FIO : Field Network I/O

Ethernet:

Information Bus

V-net: Real-time Control Bus

ooo

FCS

(FIO)

Discrete I/O

/ Analog I/O

Fieldbus

Subsystem

Control

In an FCS

•Up to 1280 analog I/O

•Up to 4096 digital I/O

•Up to 4000 sub-system I/O

•Up to 128 FF segments

•Up

to 48 I/O per segment

Control

Operation

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Operation and Monitoring Windows

Navigator

Overview

Trend

_{Sequence Table}

Tuning

Control Group

Alarm

Operator Guide

Process Report

Custom Graphic

(12)

True Redundant Technologies: Controllers

Duplex control bus (Vnet)

Ethernet

All data are equalized

real time among all HIS’s

Duplex CPU

Duplex Vnet

Dual Power

Duplex I/O bus

Duplex I/O modules

Analog, Digital, Fieldbus, Serial

Duplex node connection

Duplex I/O bus

Large Controller

(KFCS)

(13)

CPU Redundancy Pair&Spare

--Vnet I/F

CPU 1

CPU 2

Compa-rator

Main

memory

(with ECC)

PIO I/F

Vnet I/F

CPU 1

CPU 2

Coupler

Power card

Coupler

Vnet

I/O bus

Compa-rator

PIO I/F

Main

memory

(with ECC)

IO bus

I/F

IO bus

I/F

CPU module

Both CPU modules are processing independently, so

the switching is executed seamlessly.

Moreover ...

A Pair of CPU chips on

each module.

– Each CPU is processing

independently.

Result Checking

– Processed results of

CPUs are every time

compared each other.

– If the results are not

consident, switch to the

stand-by module.

(To avoid the effect

of transient error)

(14)

The feature of FCS

CENTUM-XL Availability

0. 999 999

897 ; Aug.’88 to Nov. ’01

(Six nines)

CENTUM CS/CS3000 Availability

0. 999 999 9

73 ; Jun.’93 to Nov. ’02

(Seven nines)

CENTUM-V Availability

Duplexed-CPU FCS total runtime, Apr.’82 to July 98

609,330,270 hrs (approx. 70,000 years)

(Note) Definition of “system failure” -- Simultaneous failure of two or more loops

(15)

Scalable System

•512 Stations (HISs & FCSs) and Long Distance Network Capability.

• 1,000,000 (1 Million) Tag Handling.

•Multi domain possibilities to avoid net work communication loads.

•Designed to cope up emerging needs of Fieldbus, Batch & Advanced/Complex Control

Yokogawa Tested and Guarantees Small~Medium~Large Scale Performance

Vnet

Large FCS

Ethernet

HIS

ooo

Ethernet

ooo ooo

Domain

Connection

Scalable from single I/O to Large Multi Project/Multi Complex Industry

Domain

Connection

Domain

Connection

One FCS

•Up to 1280 analog I/O

•Up to 4096 digital I/O

•Up to 4000 sub-system I/O

•Up to 128 FF segments

•Up to 48 I/O per segment

Compact FCS

One FFCS

•Up to 480 analog I/O

•Up to 1920 digital I/O

•Up to 4000 sub-system I/O

•Up to 64 FF segments

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Human Interface Station (HIS)

Web based Plant Monitoring

ITV Display via Web Browser

Remote Operation / Engineering

(17)

HIS (Human Interface Station)

Choice of Hardware.

Operation variety.

– Mouse/Operation Keyboard/Touch panel

– Dual monitor (Stack or Side by Side)

Hierarchy operation windows

– Graphic, Trend graph, Tuning, Alarm,

Historical message, Guidance, etc.

Client-Server Architecture HMI (optional)

– For remote Monitoring

Desktop

LCD Consoles (1)

LCD Consoles (2)

Customized

Yokogawa Standard:

(18)

Vnet technology

1 sec. data refresh for displays

20 operator screens

20 field control stations (FCS)

160 AI, 160 AO, 320 DI, 320 DO per FCS

System total :3,200 AI, 3,200 AO, 6,400 DI and 6,400 DO

FCS with

I/O

HIS

(19)

State of the art technologies

Absolute performance guaranteed.

What’s unique about Yokogawa

Enterprise technology solutions

(20)

OPC Compliance: Exaopc Server

FCS

V-net

HIS

OPC Interface

Process Data

Eng. Data

C

O

N

T

R

O

L

M

E

S

APC/AOA

OPC Client

HIS/

ENG

PIMS / Maint.Mgt.

OPC Client

Exaopc:

Domain wide

“OPEN”Interface

ABC-H

HF-Bus

CENTUM-XL

OPC Server

(21)

(22)

FFCS External View

Power supply unit

CP401 CPU module

Eight FIO slots

EC401 ESB bus coupler

(Note)

AIP504 Vnet coupler (10BASE2 Vnet cable is used.)

Detachable

bottom unit

(23)

What are the Features- System

With FFCS, CS3000 can cover from CS1000 scale to 1

million tags super large DCS system

CS3000 has full scalability by single architecture

Control intelligence can be distributed to each

process unit to fit the application

(24)

What are the Features - Hardware

Field proven reliability design is applied, such as: pair and

spare, micro sec. bumpless switch-over and ECC memory

Full range of FIO modules can be used

Compact form with modern look and feel

Flexible I/O expansion with up to three additional I/O

nodes to better fit smaller applications than a standard

large FCS system size

High performance utilizing the latest RISC processor

(25)

Hardware Configuration- Local Node

FIO: Max. 8

Local node

Max. 3

ESB bus

Up to 6

Modules

Up to 8

Modules

CP401

_PW48X

V net

FFCS

CP401

_PW48X

EC401

SB401

_PW48X

SB401

_PW48X

SB401

_PW48X

FFCS

Minimum Configuration

Maximum Configuration

(26)

Hardware Configuration – Remote Node

V net

FFCS

Remote node

Expanded Remote node up to 3

ER bus

EB401 EB401EB401

EB401 EB401 EB401 EB401 CP401

CP401

_PW48X

EB501

_PW48X

Remote node

EB501

_PW48X

EB501

_PW48X

Remote node

Optical Repeater can be used

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