DCS Architecture &

Solution of CAN DCS/ESD

Channels Failure

By:
Zeeshan Maqsood
 Training Overview:
 Joined FFCL as GTE on October 10, 2011
 2 months in TTC
 Rotation on UREA, O&U, NP & finally PH&S
 Got exposure and hands on training on
1) Yokogawa DCS
2) Bentley Nevada 3500 MMS
3) CCC Anti Surge Controller
4) Siemens PLC (PCS7)
5) GE Mark VI
6) Field Instrumentation
 Contents:

What is DCS?

Yokogawa DCS
Solutions
Architecture

Presentation

DCS architecture
Problem of DCS
at Fatima
channel failure
Complex
 What is DCS?

A distributed control system (DCS) refers to a control system in which the controller
elements are not central in location (like the brain) but are distributed throughout the
system. The entire system of controllers is connected by networks for communication and
monitoring.
 What is DCS?
• DCS system consists minimum of following components
1. FCS
2. Operator Station
3. Engineering Station
 What is a DCS?

FIELD RACK ROOM CCR

4-20 mA
Vnet/IP
Transmitter

FCS

4-20 mA

Control Valve
 Comparison of Distributed Control Systems
Pneumatic Analog implementation Digital Implementation
implementation

1. Medium of 1. Air Pressure 1. Analog Signal 1. Binary Signal

transmission

2. Computation devices 2. Bellows, Spring 2. Same as pneumatic 2. Digital Computers

3. Signal Quality 3. Slow responding and 3. Interference and 3. Far less sensitive to
interference reliability decreases noise
4. Computation device 4. Computation device over long distance
limitation wear out quickly 4. Still limited 4. Virtually no limit on
calculation
5. Pros 5. High margin of 5. Complex calculations
safety possible
Typical DCS System Architecture
 Yokogawa DCS components:
• Operator Station
1. Referred as HIS (Human Interface Station)
2. Used for monitoring and controlling purpose

• Control Station
1. Referred to as FCS (Field Control Stations)
2. Core of the system and are necessary to control the plant 24 hours a day, 365
days a year
 Yokogawa DCS components:
• Engineering Station
1. Referred to as EWS (Engineering Work Station)
2. Used as supervisory station and for configuration of HIS, FCS

• Control Bus
1. Dual Redundant Vnet/IP
2. As important as FCS for controlling purpose
 What is Vnet/IP?
Vnet/IP is a new control network which maintains the reliability and real-time capability of
Vnet, while adding open performance for links with information systems.

Vnet/IP is Open, Reliable and Real-time.

Collaborating with various applications via Open
Standard Protocol

Open

Real-
Reliable
time

Securely transmitting information Transmitting information within a

with failure, definite period of time
load, and environmental factors
including noise taken into account
 What is Vnet/IP?

• “Vnet” part represents Vnet compatibility and the “IP” indicates an internet protocol for general
purpose communication.
• Vnet/IP is a 1-Gbps control network that is functionally compatible with Vnet and based on
Ethernet.
 Communication Classification
• Control Communication
1. Communications for exchanging control data
2. Real-time, highly reliable and stable protocol
3. UDP/IP based

• Open Communication
1. Communications with Ethernet-based standard protocols
(Rest of Control Communication)
2. Equivalent to Communications via Ethernet
a) Vnet/IP Station (VI701 Equipped)
• Equalization, Multi host-based engineering , Sequence
table/drawing/SEBOL/SFC status display, Other stations’ trends, Process
management server/client, OPC, etc.
b) General-purpose Ethernet-Based Device
• Exaopc client, Exapilot client, Exaquantum client, , PRM client/server,
Subsystem communications, Network printers, etc.
 Yokogawa’s
Exaquantum OPC HIS HIS dedicated hardware
Bus 2 Open Open Vnet Open Vnet Open Vnet

HIS-HIS communication
Open communication PLC communication

Control communication

Control communication

Vnet Open Vnet Open Vnet Open

Bus 1
FCS APCS GSGW PLC

Vnet/IP System
Design
 Bandwidth Bus1 Bus2
Normal
• Total Bandwidth: Open Comm.
Open Devices
• 1 Gbps (Reserved) 300Mbps
500Mbps

1Gbps
• Control Communication: Open Comm.
• Uses Bus1 under normal condition Vnet/IP Stations
650Mbps
Control & Diag.
• Open Communication: 500Mbps
Diagnosis
• Uses Bus2 50Mbps

• Open device comm bandwidth is limited Limits to 200Mbps

Bus1 Failure
within 300Mbps
Open Comm.
• Vnet/IP stations use 650Mbps Open Devices
300Mbps

• Bus 1 Faliure: Open Comm.

Vnet/IP Stations
• Control communication shifts to bus 2 200Mbps

• Vnet/IP stations bandwidth decrease to

200Mbps Control & Diag.
500Mbps
Network & System Configuration Specification

Page.16
 Network Switches
•Layer 2 Switch
A device to connect equipment within the Vnet/IP domain. The layer 2 switch, unlike a HUB,
incorporates bridge functions to send data to the destination terminal equipment only; it can,
therefore, reduce traffic within its domain.

•Layer 3 Switch
A switch is used to connect Vnet/IP domains. The layer 3 switch relays a communications frame to
another domain with IP address route control, or routing functions. Select layer 3 switch hardware
capable of relaying communications frames at high speeds.
Configuration of Yokogawa DCS

Page.18
 FFCL DCS Architecture

• Click here
 Problem

• Digital out (DO) channels of CAN DCS/ESD are damaged due to short circuit
• These channels are used for start/stop command for motors
• Instrument is providing wet contact to MCC
• DO channels used for solenoids are safe due to presence of relay
Current situation at CAN plant
Solution # 1
Solution # 2