introduktion til dcs - insatech€¦ · “ as a result of yokogawa’s high r&d investment and...
TRANSCRIPT
Seminar TI-14 – Erik Fjordside/ Carsten Hounsgaard
Introduktion til DCS systemer
- 2 -
“ As a result of Yokogawa’s high R&D investment and the
consistent long term migration policy of the CENTUM DCS
family our investment are secure ”
Nearly 40 years History and the continuity
AVR
FFCS
HIS
CENTUM CS 3000 R3 HIS
CENTUM VP
Vnet/IP
2008
2001 2005
FFCS-L
1Gbps Dual
Redundant
2011 [Release 5]
FFCS-V
CFFS
HF-Bus
COPS
F-Bus
250 KBPS Dual
Redundant Token Pass
CENTUM
1MBPS Dual
Redundant Token Pass
CENTUM-XL
EOPS
EFCS EFCD
ENGS PFCS
KFCS LFCS COPS2 COPSV
CENTUM V
CFCS2 CFCD2
ABC
CENTUM CS ICS
EWS PICS
V net
10 MBPS Dual
Redundant Token Pass
HIS
1975
1983 1988
1998
1993
ENG
CENTUM CS 3000
CFCD CFCS
ENG
• Full Lifecycle Support for Customers’ Legacy Systems
The migration path for each legacy system is always taken into consideration before a new system is released
NORTH AMERICA
Africa
Asia
Oceania
Middle East
South America
North America
Europe
862
599
419
19407
366
580
2,144
EUROPE
As of Dec 2012
TOTAL
24,377 UNITS
AFRICA
MIDDLE EAST
OCEANIA AUSTRALIA (407)
NEW ZEALAND (2)
NEW CALEDONIA (1)
PAPUA NEW GUINEA (3)
FIJI (6)
ASIA SOUTH AMERICA
DCS Installation Map
AUSTRIA (30)
AZERBAIJAN (1)
BELGIUM (199)
BELARUS (8)
BULGARIA (5)
CROATIA (5)
DENMARK (6)
FINLAND (1)
FRANCE (232)
GERMANY (256)
GREECE (18)
HUNGARY (63)
IRELAND (3)
ITALY (149)
KAZAKHSTAN (7)
LITHUANIA (1)
NETHERLANDS (173)
NORWAY (5)
POLAND (17)
PORTUGAL (8)
ROMANIA (12)
RUSSIA (545)
SERBIA (10)
SLOVAKIA/CZECH (112)
SLOVENIA (2)
SPAIN (162)
SWEDEN (1)
SWITZERLAND (17)
TURKMENISTAN (5)
UK (83)
UKRAINE (8)
ALGERIA (35)
ANGOLA (15)
BOTSWANA (4)
CONGO (4)
EGYPT (60)
GABON (6)
GHANA (5)
KENYA (3)
LIBYA (4)
MOROCCO (22)
MOZAMBIQUE (1)
NAMBIA (1)
NIGERIA (38)
SENEGAL (2)
SOUTH AFRICA (153)
SUDAN (6)
SWAZILAND (2)
TUNISIA (1)
UGANDA (4)
BAHRAIN (34)
DUBAI (1)
IRAN (105)
IRAQ (9)
JORDAN (5)
KUWAIT (14)
OMAN (48)
QATAR (9)
SAUDI ARABIA (256)
SYRIA (6)
TURKEY (33)
U.A.E (52)
YEMEN (8)
BANGLADESH (1) INDIA (1,425) MYANMAR (5) PAKISTAN (6) CHINA (2,565) KOREA (1,101) TAIWAN (479) JAPAN (12,399) MALAYSIA (284) INDONESIA (284) PHILIPPINES (172) SINGAPORE (225) THAILAND (423) VIETNAM (35) BRUNEI (1) SRILANKA (2)
ARGENTINE (11)
BRAZIL (498)
CHILE (4)
COSTA RICA (1)
COLOMBIA (16)
CUBA (12)
EL SALVADOR (1)
MEXICO (41)
NICARAGUA (1)
PANAMA (2)
PERU (1)
TRINIDAD TOBAGO (2)
URUGUAY (1)
VENEZUELA (8)
CANADA (19)
USA (843)
Release Information
CENTUM VP Features
• Scalability and flexibility
– CENTUM VP meets the requirements for both simple small scale systems and huge scale 1,000,000 tag level systems
– CENTUM VP is suitable for different application types and system architectures
• Super-high plant operation availability
– Seven 9’s (99.9999959) hardware availability
– Pair & Spare technology to keep higher control loop availability
• Operators’ perspective design
– Real-time plant operation environment
– Intuitive look & feel HMI design
• Open Architecture
– The latest technologies can be applied in the control systems
– Easy integration with other subsystems
CENTUM VP System Configuration Overview
HIS (Operator Station)
Digital Field Network
Vnet/IP Real time Control Network
Open Style
Console Solid Style
Console
Client PC
Plant Asset
management
OPC
server
Engineering
Station
Desktop type
HIS
PR
M
SCS Safety Control Station
UGS Unified Gateway Station
Exaquantum Plant Information Management System
Subsystems
FCS
Field Control Station
TSE
serve
r
Operation and Monitoring
Operator Station (HIS)
HIS (Operator Station)
Vnet/IP Real time Control Network
Open Style
Console Solid Style
Console
Client PC
Plant Asset
management
OPC
server
Engineering
Station TSE
serve
r
Desktop type
HIS
PR
M
SCS Safety Control Station
UGS Unified Gateway Station
Exaquantum Plant Information Management System
Subsystems
FCS
Field Control Station
Digital Field Network
HIS (Operation Station) Features
• Various types of the operation views are prepared
– Graphic, Trend graph, Overview, Tuning etc.
• One-touch operation for related information
– Alarm dialog, trend graph, Graphics, and faceplates can be called up from each other based on the related tag without engineering
Ex.) Click alarm message, then the related faceplate is shown
• Performance and function for achieving real-time plant operation – 1 second graphic call up – 1 second screen refresh – Data gather mechanism for real-time trend
without the affection by the network delay – Frame display – Window History function
• Real-time Alarm Management View
• Large Capacity – Max. No. of Tags: 1,000,000 per system – Max. Graphic Displays: 4,000 per HIS – Real-time trend Points: 3,328 per HIS
• Various types of operation environment are available – Single, dual, quad monitor are available – Wide monitor is also available
– Mouse operation
– Operation keyboard and touch screen are also available
• Higher Compatibility with the former CENTUM systems
– Similar operation is also available
– Accessible to the FCSs of the former CENTUM systems with different control networks
HIS (Operation Station) Features
HIS Hardware
Solid Style
Console
• HIS works on the latest Microsoft Windows OS platform
– Windows 7, VISTA and 2008 server
• Three types of hardware can be chosen
– Desktop, Solid Style Console, and Open Style Console
• Various Operation Styles
– Mouse/Operation Keyboard/Touch panel
– Single, Dual and Quad-monitor are available
Open Style
Console
Desktop
Type
Operation Keyboard Features
• Calling up necessary information quickly – 64 function keys
– Alphanumeric buttons
– Tab switching
• Avoiding human mistakes – Highlighting the instrument plates
– Security key • Authorized Operator
• System Engineer
– IEC9241-11 Complied Key pitch
• Easing the installation – Power supply via USB (AC adapter is not needed)
– 2 built-in speakers for buzzer and for other sound
Operation Keyboard (OPKB) Description
USB Power Supply Control Keys
AIP831: Eight-Loop
AIP830：Single-Loop
64 Function
Keys
Buzzer Reset Key / Alarm
Acknowledgement Key
Numeric
keypad
Container Window
Key （for Frame Tab Switch）
Window Call
Keys
Operation
Confirmation Keys
Mode Selection
Switch
Built-in
Speakers
IEC 9241-11
Key Pitch
HIS Screen Overview System Message Banner
– Buttons to call-up the alarm & event dialogs quickly
– Latest 3 alarm messages are always displayed in real-time
Navigation
– Graphics & trend
views are arranged in
a hierarchy display
– Alarm status are
shown as the icon color
Favorite
– Frequently used views
can be registered by
operators’ drag & drop
Operation History
– Last 20 call-up
operations are listed
– Double-click the listed
operation to call up the
same view again Graphics, trend graphs and other views are displayed
The Latest Browser-like Operation Provided
Similar operation to the Internet Explorer
Tab operation Quick call up of up to five frequently used tabs
Less memory consumption to show multiple tabs
Each tab can be divided into 4 frames
4 frames can be shown at the same time to monitor overall
Tab Display
4 views on a sreen
Trend Data Acquisition
• Trend data is acquainted by each trend block on the HIS
– 34 trend blocks per HIS
– Up to 128 data points can be assigned in each trend block
– Other 16 trend blocks can be used for accessing the trend data acquainted in other HISs
• Data Acquisition period is specified for each trend block
– 1-sec, 10-sec, 1-min, 2-min, 5-min or 10-min
– The mechanism to achieve more accrued trend data acquisition
• For 1-second and 10-second trends, the trend data buffer is prepared in the FCS to eliminate the affection of network delay between FCS and HIS
• The capacity of the trend data buffer in an FCS is 8 trend data blocks
Trend Graph Display
• Up to 8 trend lines can be display in each trend graph
– Displaying/hiding of each trend line is by a single click
– Drag & Drop dynamic trend line assignment is available
– The trend lines with different acquisition periods can be displayed on a trend graph together
• Data export function for csv/bitmap format
– To ease to generate the report for analysis
• Drag & Drop zooming function
– For more quick and intuitive operation
• Index marks to show the data values on the trend graphs
– To refer and to compare the data easily
Trend Graph Display Example
Legend Area
– Assigned data points and the current data are shown
– Check/Uncheck to show/hide trend line
Trend line Assignment
– Drag & Drop to assign the data points
from any trend blocks on a trend view
Faceplate Display
– Click the Legend Area, then the Faceplate
is shown next to the trend graph view
Index
– Up to three indexes can be displayed
– Data values on the trend graphs can be checked
Trend Export Reporting Function
•Trend data export
– Right-click on the view, then the trend data can be exported
• Copied to the Clip Board
– It can be easily used for reporting or analysis
Real-time Alarm View (CAMS) Click blinking icons to open the CAMS View
The latest three alarms
are always shown
The Alarm list is shown here
Filter Pane – Based on the priority, consequence, tag, etc.
– Only the related alarm message for the operator can be
shown to reduce the workload
Shelving Pane
– Non-urgent alarms
can be shelved in temporary
– Operators can concentrate
to the alarms which requires
urgent actions
Real-time Alarm Management – Filtering
• To avoid overlooking important alarms in an alarm flooding situation, the displayed alarms can be filtered based on various conditions
– E.g. Alarm priority, Alarm purpose, Consequence, tag, etc.
Filter Pane
– Filters can be pre-configured
and can be configured by operators
during the operation
– Alarms from ProSafe-RS, System alarms,
and Process Alarm filters
are prepared in default
Only the filtered alarms are displayed
– Operators can concentrate to the related important
alarms which require urgent actions
– Less opportunities to overlook the important alarms
Real-time Alarm Management – Eclipsing
• To avoid overlooking important alarms in the alarm flooding situation, the displayed alarms can be grouped based on tag
– Only the highest priority alarm for each tag is displayed
– It can reduce the number of lines on the displayed list, so less opportunity to overlook important alarms
Click to open/close
the grouped alarm messages
Only a single line per tag
Support Quick Actions against the Alarms
• A single operation calls up related dialogs
Context menu on the alarm message
– Right-click on a alarm message to show the
context menu
– It calls up that alarm related faceplate,
tuning view, trend graph or graphic
by a single mouse click
Remote Operation
HIS (Operator Station)
Vnet/IP Real time Control Network
Open Style
Console Solid Style
Console
Client PC
Plant Asset
management
OPC
server
Engineering
Station TSE
server
Desktop type
HIS
PRM
SCS Safety Control Station
UGS Unified Gateway Station
Exaquantum Plant Information Management System
Subsystems
FCS
Field Control Station
Digital Field Network
Remote Operation and Monitoring
Terminal
Server
Office LAN
HIS
- Graphic
- Faceplate operation
- Trend view
- Alarm monitoring
Vnet/IP
Ethernet
Firewall
Controller
Field Control Station (FCS)
Field Control Station (FCS)
HIS (Operator Station)
Vnet/IP Real time Control Network
Open Style
Console Solid Style
Console
Client PC
Plant Asset
management
OPC
server
Engineering
Station
TSE
server
Desktop type
HIS
PR
M
SCS Safety Control Station
UGS Unified Gateway Station
Exaquantum Plant Information Management System
Subsystems
FCS
Field Control Station
Digital Field Network
FCS (Field Control Station)
• High availability process controller
– Seven 9’s (99.9999959) hardware availability
– Pair & Spare technology for higher control loop availability
• Large capacity Controller
– One controller handles 1,760 analog signals and 4,096 digital signals
– Various field digital protocols can be handled
• Foundation Fieldbus, ISA100, PROFIBUS, EtherNet/IP, HART, etc
– Up to 13 extra I/O racks
– Up to 50km distance remote I/O rack
• Various types of control functions are prepared
– Regulatory Control blocks, Sequence Control Blocks, Arithmetic blocks, etc
– 7,000 functions work on a controller
• Self-Independent controller
– All the control application runs in the highly reliable controller hardware
• CENTUM-VP Controller hardware Availability
– 0.999999959; Jun ’93 to May ’10
(Seven 9’s!)
• Benefit : Case of the users in a petrochemical Facility
– CENTUM Annual Failure Rate 0.29 loops for facility
• 26 CENTUM Systems, uptime for 33,000 loops
• From 1981 for first installation
– Other-vendor DCS Annual Failure Rate 2.86 loops for facility
• 2 Systems (one is 6-yrs old, one is 9-yrs old)
• Uptime of approximately 3,200 loops
“We’ve never had a processor fail and,
only once, replaced a couple of I/O cards
because we washed down the cabinets.” Jeff Bolhius, Flieshman’s Yeast
Highly Reliable Process Controller
Key Technologies for Highly Available FCS
• Extremely low failure rate design of each hardware
• Self-diagnosis function – Each portion is checked just before working
– If some abnormalities are detected, the module set its status flag to FALSE
• Dual hardware configuration – Each of dual hardware components is checking the status flags of the partner hardware
through backplane bus
• Real-time abnormality detecting
• Seamless switching – Immediately switching from the active module to the stand-by module without affecting
the input/output for process
• Hot swapping – Abnormal modules can be removed and spare modules can be inserted instead without
stopping any other input/output or any other hardware
Redundant Configuration of CENTUM VP
Dual Vnet/IP
Dual remote I/O network
Dual CPU module
Dual Vnet/IP
Dual Power
Dual ESB bus
All data are equalized in real time without
affecting the control communication
among all HISs
Dual Power
Dual ESB/ER bus
Dual I/O modules
Analog, Digital, Fieldbus, Serial
Pair & Spare CPU Architecture
• Both CPU modules are processing independently allowing CENTUM to achieve a real faultless switchover (For Redundancy purposes)
A pair of CPU chips is on
each CPU module
– Each CPU is processing
independently
•This is not
for redundancy purposes
Result checking
– Processed results of
CPUs are every time
compared each other
– If the results are not
congruous, control
switches to the stand-by
module
Vnet/IP I/F
Power card Power card
Coupler Coupler
Vnet/IP
I/O bus
Com
pa
rato
r IO bus
I/F
CPU module CPU module
IO bus
I/F
CPU 1
CPU 2
CPU 1
CPU 2
Com
pa
rato
r
PIO I/F
PIO I/F
PIO I/F
PIO I/F
Vnet/IP I/F
Main memory with ECC
Main memory with ECC
Control Function
• Basic Control functions are contained in a ‘Function Block’
– Almost 200 types of function blocks are available
– Regulatory Control blocks, Sequence Control Blocks, Arithmetic blocks, etc.
– Any function block type can work in a controller at the same time
– Control logics are generated by the combination of function blocks
• The processing of all the function blocks are executed periodically
– The processing period can be specified for each function block
• 1-sec, 500-msec, 250-msec, 100-msec and 50-msec can be selected
Control Function Capacity
PVI BLEND SI-1 BAND OPSBL SI-1E
PVI-DV FF-AI SI-2 BOR OPSFC SI-2E
PID FF-DI SO-1 BNOT OPSFCP1 SO-1E
PI-HLD FF-CS SO-2 CALCU OPSFCP2 SO-2E
PID-BSW FF-PID SIO-11 CALCU-C OPSFCP3 SIO-11E
ONOFF FF-RA SIO-12 SW-33 OPSFCP4 SIO-12E
ONOFF-G FF-AO SIO-21 SW-91 OPSFCP5 SIO-21E
ONOFF-E FF-DO SIO-22 DSW-16 ONOFF-E SIO-22E
ONOFF-GE FF-OS SIO-12P DSW-16C ONOFF-GE SIO-12PE
PID-TP FF-SC SIO-22P DSET MC-2E SIO-22PE
PD-MR FF-IT TM DSET-PVI MC-3E
PI-BLEND FF-IS CTS BDSET-1L SI-1E
PID-STC FF-MDI CTP BDSET-1C SI-2E
MLD FF-MDO CI BDSET-2L SO-1E
MLD-PVI FF-MAI CO BDSET-2C SO-2E
MLD-SW FF-MAO RL BDA-L SIO-11E
MC-2 FF-SUNV RS BDA-C SIO-12E
MC-3 SLCD VLVM INDST2 SIO-21E
RATIO SLPC LC64 INDST2S SIO-22E
PG-L13 SLMC ALM-R INDST3 SIO-12PE
BSETU-2 SMST-111 L_ST16E BSI SIO-22PE
BSETU-3 SMST-121 M_ST16E PBS5C VPM64
Signal SMRT ST16E PBS10C VPM128
SS-H/M/L SBSD L-ST16 Hybrid VPM256
AS-H/M/L SLCC M_ST16 _UTSW VPM512
SS-DUAL SLBC ST16 _UTPB VPM64A
FOUT STLD ADD _UTAS VPM128A
FFSUM _SFCSW MUL _UTSW-N VPM256A
XCPL _SFCPB DIV _UTPB-N VPM512A
SPLIT _SFCAS AVE _UTAS-N FSBSET
Function Block Types
Category Item Max.
Analog 1,760
Digital (On/Off) 4,096
Elements 18,000
Function blocks 7,000
Control drawings 500
Annunciator messages 2,000
Operator guide messages 2,000
Common switches 9,000
Global Switches 256Internal switches
Process IO
Tag Names
Message Outputs
Capacity of one Controller (FFCS-V)
35
I/O Nodes
Up to 13 I/O nodes can be connected per FCS
One I/O node has 8 I/O module slots
I/O nodes are connected by the remote I/O bus (ESB Bus)
– Up to 10 m from the FCS CPU node to the end of the I/O node if
electric cables are used as the ESB bus
– Up to 50 km in case of optical cables as the ESB bus
CPU node
I/O node
Max 9 I/O nodes/Line
Total Max 13 I/O nodes
36
ESB Bus for Remote I/O
Up to 50km per line by using optical fiber cables
13 nodes per FCS, 9 I/O nodes per line
Star configuration is available
8 Lines per FCS
Up to two-hop is available
SOE Recording from remote sites is available
FCS I/O node
I/O node
I/O node I/O node
Optical fiber cables
Optical fiber cables Optical fiber cables
Separated sites
Corrosive sites
(ISA G3)
Explosive sites
Remote I/O installation
FCS
ooo
CCR (Central Control Room)
Remote I/O network
•FM Class1, Div 2
•CSA Class 1, Div 2
•ATEX Zone 2
PROFIBUS-DP
ALP121 PROFIBUS-DP Module • Redundant Configuration is available
DeviceNet
Control Logix
PLC-5
SLC500
CIP
ALE111 Ethernet Communications
Module •EtherNet/IP (CIP)
•Modbus TCP
•PLC-5/SLC500
ALF111 Foundation Fieldbus Module • World’s First Dual-Redundant Fieldbus Ports • 4 Ports per ALF111 • 31 Devices per Port • 1,500 Fieldbus faceplate blocks per FCS
Foundation Fieldbus HART I/O
4-20mA
Linking Device
Various Field Digital Communication Protocols
Modbus/TCP
MW100
Analog Module with HART
• FIO HART Module Lineups
– AAI135-H: 8 input, channel isolated
– AAI835-H: 4 input / 4 output, channel isolated
– AAI141-H: 16 input, non-isolated
– AAI841-H: 8 input / 8 output, non-isolated
– AAI143-H: 16 input, Isolated
– AAI543-H: 16 output, Isolated
– ASI133-H: 8 input, IS module
– ASI533-H: 8 output, IS module
HART Module
HART Modem
Input Signal from HART Device
Analog Signal + HART Signal Analog Signal
(Current)
HART Variable
Real time Control network (Vnet/IP)
Control Network (Vnet/IP)
HIS (Operator Station)
Vnet/IP Real time Control Network
Open Style
Console Solid Style
Console
Client PC
Plant Asset
management
OPC
server
Engineering
Station
TSE
server
Desktop type
HIS
PR
M
SCS Safety Control Station
UGS Unified Gateway Station
Exaquantum Plant Information Management System
Subsystems
FCS
Field Control Station
Digital Field Network
Vnet/IP Specifications
• General specifications
– Topology: Star topology
– Transmission speed: 1 Gbps for Yokogawa hardware, 100 Mbps for general Ethernet equipment
– Access control: Full duplex
– Scale: 64 stations/domain
– Configuration: Redundant
– Control communication: Functionally compatible with Vnet
– Open communication: UDP/IP
– Network equipment: Commercially available switching hubs and routers (Layer 2 switches and Layer 3 switches)
– Cables: CAT5e or higher UTP cables or single-mode fiber optic cables
Vnet/IP Network Configuration
Field network
OPC Server Plant Asset
Management HMI
Controller
ENG
Vnet
Router ProSafe-RS
Vnet
System
Third party
system
Interface
Field network
OPC Server
Controller ProSafe-RS
ENG HMI Plant Asset
Management
Domain1
Domain2
OPC
Open Vnet
HIS/ENG
Open Vnet
HIS
Open Vnet
PIMS
Open
3rd Pty Appl.
Open
FCS
Vnet
PLC
Open
Field Eye
Server
Open
UGS
Vnet Open
Vnet/IP Unique Architecture -- Open Communication
Open Communication (UDP/IP)
Control Communication (Vnet Protocol)
Control Communication (Vnet Protocol)
LAN2 cable
LAN1 cable
- 45 -
WAC(Wide Area Communication) Router – Realize control and monitoring among remote Vnet/IP domains through WAN
lines • Available for long distance connection
• Available for using WAN lines (public network, satellite connections, etc.)
– High reliable and dedicated to Vnet/IP network • High reliable devices with redundant CPU, power, etc.
• Available for redundant wide area communication
• Availability of back up connection with different route
Local
domain
HIS FCS Wide area network line
Remote
domain
Satellite
WAC WAC
Fiber optic
Wide Area Communication with Vnet/IP
Engineering Function
Quick & High-quality Engineering
• The shutdown time for a new plant construction or reconstruction should be minimal
– A longer time results in larger financial disadvantage
• CENTUM VP provides the following configuration environment
– Total Project management
– Reuse of configuration data between several stations or plants
– Several engineers can work at the same time
– Online maintenance
– DCS Tag equalization for Historian
Total Project Management
• The application of all stations in a system is contained in one database
ooo
All graphics,
all control logic
are in a database
ooo HIS No.1 HIS No.2 FCS No.1 FCS No.2
Benefits of Project Management
• The application of all stations in a system is contained in one database
– At least 1 PC is required to generate whole over a system so there is no need to create the same or similar graphics for all the HMIs
– One PC (with configuration software) can handle several projects
– The application database of a plant can be reused on another plant by a project, by a station, by a graphic or by a control logic
• This shortens the configuration time
• This makes the configuration quality excellent because the copy source has been operational in an actual plant
– Optimum management of application data is available
ooo
Plant A
(project A)
Reuse of Configuration Asset (Application)
ooo
Plant B
(project B)
ooo
Graphics can be re-used for as a basis of other graphics,
on another HIS or on the HIS in different projects
Control application can be re-used for others in the controller,
in different controllers in the project or in another project
ooo
Plant A
(project A)
Reuse of Configuration Asset (Application)
ooo
Plant B
(project B)
ooo
Export CSV file to use within MS-EXCEL
Import CSV file to reuse data
•Configuration tool is not needed
for simple entry work
Tag 1 Tag 2 Tag 3
Concurrent Engineering
• Multiple engineers can work at the same time
Only one database
Advanced 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 excellent debug capability
Virtual Test
You can debug only with a PC
Target Test
You can debug without field wiring
Back
Virtual test (only with PC)
– Check simple entry mistakes
– Try new control logic
– Check graphic work
– Operator training
Advanced Debugging Theory
Advanced Debugging Theory
Virtual test (only with PC)
– Check simple entry mistakes
– Try new control logic
– Check graphic work
– Operator training
Target test (without wiring)
– Check actual FCS CPU performance
– Check the actual relationship among each station
Advanced Debugging Theory
Virtual test (only with PC)
– Check simple entry mistakes
– Try new control logic
– Check graphic work
– Operator training
Target test (without wiring)
– Check actual FCS CPU performance
– Check the actual relationship among each station
Only minimum check is needed at start up!
On-line maintenance
• For a more productive plant operation, online maintenance of the control application or HMI application is sometimes required
– Application modification without stopping the controller
– Application modification without affecting the rest of other application
• CENTUM VP provides the ‘On-line maintenance’ capability to meet the above needs
On-line Maintenance Example
Control logic
ooo
Controlling
No effect
No effect No effect
No effect
No effect
No effect
Controller CPU
is Non-stop !
• Modifying the configuration of one of control loops, and downloading to the controller under operation
– No impact for any other loops, graphics or processes
– Controller CPU is not stopped
Integration with other systems
Unified Gateway Station - UGS
Shadow Block with alarm information
Access by tag name + item name
FIC001 FIC002 FIC003
Vnet/IP
Redundant UGS Server
MODBUS/TCP,
MODBUS/RTU,
Ethernet/IP
STARDOM 3rd party
OPC
Server
• DCS and intelligent control Subsystem
are ’truly integrated’
– UGS enable to perform supervising data and alarms of various subsystems in the same manner as CENTUM series system tag based faceplate operation
– UGS can have the Shadow blocks inside to represent the data of the subsystem and the Shadow blocks can generate alarms
• High capacity monitoring
– UGS provide high capacity monitoring large amount of subsystems
– 1 UGS can treat 256 controllers and 750,000 data items
IED via
IEC61850
Subsystem data and alarms via faceplate for the Shadow Block
Unified Gateway Station – UGS Redundancy
• High availability of UGS Redundant system – The switch-over is achieved by the L2SWs connected on Vnet/IP
– Specific Hirschmann L2SWes are required separately from Vnet/IP L2SWes
– 10 to 20 seconds are required for switch-over.
– Subsystem data value would be shown on HIS within 10 sec – 3 min after switching over completed.
Note: Generally speaking, the server PC failure rate is less than 1% per year. Fail-over would hardly occur.
• Cause of switch-over of UGS Redundancy – No power on UGS PC
– OS stopped on UGS PC
– UGS service stopped on UGS PC
– Vnet/IP driver stopped on UGS PC
Trouble of each subsystem does not affect to switch-over of UGS redundancy to protect communication of other subsystems.
(Active) (Stand-by)
UGS redundancy system
L2SW
FCS is recommended for critical control and monitoring subsystem to avoid black out at HIS.
Safety Integration
• DCS and SIS are ’truly integrated’ – SIS and DCS data are within the same window
– SIS data can be used in the FCS
– Sequence of Event (SOE) data from the SIS and DCS are integrated
Integrated Monitoring - Faceplate - Trend - Graphic - System status - Alarm - SOE
CENTUM VP FCS ProSafe-RS SCS
CENTUM VP
Time shared
on the same
network
SIS data can be
used in FCS
FCS and SCS information integrated
SOE Viewer
SCS FCS
System status
Vnet/IP SCS FCS
SCS and FCS Faceplates
Plant Asset Data Integration
• Device information can be called-up
Device diagnostic
information
Device status
Help
Result of device Diagnosis