YOKOGAWA CENTUM

CS3000
TRAINING
BEJING- CHINA
MARCH 2010

By:
KHALID SHAPO
GUMRY DCS&FPF FOREMAN

Why we use control

system?
Control

system is reducing the

operation cost by reducing man
power.
Control system is improving the
product quality and reducing the
waste time by reducing the error
factor and high responding to the
errors.

Pressure control loop

Block diagram for control

loop

PID control loop

Proportion
Integral
Derivative

The

controller calculate the integral &

derivative of the errors between the
process variable and set point then
generate a control effort by adding
these two quantities to the error it self.

PID advantage
PID

is the most widely control

system in the projects.
Simple configuration.
High stability.
High reliability.
Simple operation.

PID controller with auto man

mode

PID controller response

CASCADE CONTROL

Simply

the Cascade control loop

consist of two control loops
interact together the output of
the first controller(master
controller) is the set point for the
control device, and the second
loop is slave loop.

CACADE CONTROLO LOOP

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.

Field Domain - for field instruments, control

valves, Field bus instruments in this domain etc..

Control domain

- DCS/PLC/PC/ESD etc as major

equipment in this domain. DCS is mainly carrying out
Basic Regulatory Control (BRC) and Enhanced
Regulatory Control (ERC) i.e. combination of calculation
and other blocks to provide final control. APC add value
on top of BRC/ERC to provide yield improvement,
precise product quality control, Economic optimization
of energy consumption (steam, power). Ultimately
APC provides economics benefits.
DCS and other systems, besides control and automation
function provides major plant operation. When plant in
a normal operating condition, Automatic control and
APC are in action. To further enhance the plant
operation and carry out automatic and guided operation
e.g. automatic startup/shutdown etc. AOA is our
solution which helps in faster and safe

MES Domain - Our MES and solutions practically

fulfills all needs of production & maintenance staffs
all process and equipment related historical and
real time information. Further it bridges the
information gap between Control domain and
Business domain. e.g. Material balance calculations
at MES level provides information on efficient
working of process to production management. At
the same time at Business domain material balance
information is used by Finance management for
understanding of production economics.

Business (Top Management) Domain

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

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

75 79 82

78 82 88 4

USER ORIENTED

OPERATION

1.

NEW MODEL

1.

High

2.

THE FIRST DCS

SYSTEM IN THE

WORLD

1. Distribution of Control
2. FIF

1. Unified Operator

Stations

7DF

7VP

F-BUS

CFCS

1. WINDOWS-NT OS

2. Advanced Control

2. Client / Server

3. Open Net Work

3. Migration

4. High Reliability

4. High Reliability

4. Touch Operation

5. Utilisation of Users Assets

5. Window

6. Easy Engineering

6. Integration (Super Window)

7. Expanded Control Capacity

ENTUM

-
(Function Key

EOPSENGSComputer
XLAIS

Station

COPSV

CENTUM

CENTUM-XL

ICS

Sequence-oriented
Control
Station
CENTUM-V

1. UNIX OS

3. High Peroformance

4.

Development)

OPEN SYSTEM

10Mbps

BCV

V net

FCS

COPS2
EFCS

1Mbps

CFFS

2. Separation of Engneering

256Kbps

EXCELLENT SYSTEM

1. Function Assignment

Operation

COPS

Japanese
Language Support

4. One-Touch

Control Stations

of HDD

7DF

3.

Adoption

3. CMOS Memory

2. Redundant

2.

Voice

Output

INTEGRATED SYSTEM

Enhanced Functions

of OPS

Speed
Comunication Bus

CFSS

40
200

HF-BUS

CFCS2

HF/F Converter
Station

7FS

Control
Loops
Sequen
ce
Tables

3
2
2
0

32

2
0

40
40

80
200

4096 Blocks

HIS

Technology waves on Control

Systems
Windows 2000
Internet
IT

NT
and
Microsoft
UNIX
Micro processor

1st CENTUM

XL

CS

CS 3000

CS 3000 R3

June 1975

82

88

93

98

01

time

Integrated Plant Control System

(IPCS)

Typical System Configuration

Remote
DCS
Ethernet
Closed-type HIS LCD-typeDomain
HIS

Business Domain

APC
PIMS

HIS/EN
G

AOA

MM
ACG

Vnet

Incl. Fieldbus
Engg.

APCS

FCS
With I/O

Mulcom

(ExaCoast)
Prosafe-ESD

RS-232/485/Ethernet

I/O in the Remote Field

BCV

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

H1 Fieldbus

Field Devices

PLC / Remote I/O /

System Scalable
Min. Configuration
Single Domain
Configuration

Expanded. System
Configuration

Controller

One Process Unit

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

: 100,000 per HIS

: 64

Whole Complex

Expanded System
Max. No. of Domains : 16
Max. No. of Stations : 256

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

Control Group Window

Tuning Window

Overview Window

Trend 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
New
Bus

Remote

To Field Device

FF-H1
4-20mA

PLC(Subsystem)
I/O(Ethernet)

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

FIO Node overview

Up to 8 I/O modules

Remote I/O Interface

(10Base2)
Power supply

5 units (222.3mm)

19 inches

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
Explosive sites

Corrosive sites
Corrosive sites

FCU

ooo

CCR (Central Control Room)

Separated sites
Separated sites

Field Control Unit: Redundancy

Synchronous

hot standby with fully redundant

hardware and duplex functionality in design

Engineering
Off line Engineering without Target Hardware by using
Hardware Simulation Technology
Off line Testing
and Hardware
Simulation

CAE
Computer Aided
Engineering

HIS

Concurrent
Engineering

Order
Engineering

Electronic
Media
Input

ENG
Builder software

V net

FCS

Start-up

can start direct after ordering

Engineering up to Configuration Testing can be done Off Line

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

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

Each folder for each HIS

FB : Function Block

Example : Control
logic

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 field bus,

you can choose either

type.
Change

the front blocks,

you can change how to
connect the field wiring.

Dedicated
cable

Field wiring

Terminal
board
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
minimum.

On-line maintenance.
No
Noeffect
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
on-line 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

THANK YOU