By: KHALID SHAPOGUMRY DCS&FPF FOREMAN

YOKOGAWA CENTUM CS3000

TRAINING

BEJING- CHINA MARCH 2010

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 loopProportionIntegralDerivative

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

Control Domain Advanced Application Advanced Process Control (APC) Advance Operation Assistance (AOA) Plant Control Room/Factory Floor DCS/PLC/PC/ESD/F&G

Field DomainFieldbus and conventionalField Instrumentation.

Manufacturing Exec. System Domain Plant Information & Management System (PIMS) Maintenance Management (MM)

Field Domain

Control Domain

MES Domain

BusinessDomain

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 startup/shutdown. Ultimately AOA provides economic benefits as well as safe operation. .

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

Advanced , Flexible Operator FunctionsPowerful Control Station FeaturesFlexibility in EngineeringIntegrated Solutions – Extended Applications

CS 3000 – Integrated Control System Overview

Unique Advantages leading to Lower TCO

7DF 7VP

7FS

F-BUS

COPS

CFCS

HF-BUS

COPS2

CFCS2

COPSV

CFSS

XLAIS EOPS ENGS

EFCS

CENTUM-V

ＣＴＭ -２

ＣＯＰＳ

7DF

THE FIRST DCS

SYSTEM IN THE

WORLD 1. Distribution of Control

2. FIF

NEW MODEL

1.

High Speed Comunication Bus

2.

Adoption of HDD

3. CMOS Memory

4. One-Touch Operation

(Function Key Development)

1.

Enhanced Functions of OPS

2.

Voice Output

3.

Japanese Language Support

4.

Sequence-oriented Control Station

EXCELLENT SYSTEM

1. Function Assignment

2. Separation of Engneering

3. High Peroformance

4. Touch Operation

5. Window

6. Integration (Super Window)

7. Expanded Control Capacity

CFFS

HF/F Converter

Station

CENTUM-XL

Computer

Station

ICS

FCS BCV

Ｃ ENTUM ＣＳ

INTEGRATED SYSTEM

　 V net 10Mbps

1Mbps

256Kbps

Control Loops

Sequence Tables

32 20

32 2

0

40 40

40 200

80 200

4096 Blocks

’75 ～’ 78

1. Unified Operator

Stations

2. Redundant

Control Stations

USER ORIENTED

OPERATION

1. UNIX OS

2. Advanced Control

3. Open Net Work

4. High Reliability

5. Utilisation of Users’ Assets

6. Easy Engineering

HIS

CENTUM

ＣＳ３０００

OPEN SYSTEM

1. WINDOWS-NT OS

2. Client / Server

3. Migration

4. High Reliability

’79 ～’ 82’82 ～’ 88’84 ～’ ’98 ～’’92 ～’’88 ～’

Technology waves on Control Systems

Windows 2000InternetIT

time

UNIX

NTandMicrosoft

Micro processor

CS 3000CSXL1st CENTUM V

June 1975 ’82 ’88 ’93 ’98

CS 3000 R3

‘01

Integrated Plant Control System (IPCS)

Typical System Configuration

Vnet

HIS/ENG

Prosafe-ESD

FCSWith I/O

Ethernet

CS/CS 1000/3000CENTUM-XL/V/ µXL

BCV

ACG

Remote DCS Domain Closed-type HIS

H1 Fieldbus

Migration bus converter

LCD-type HIS

APCS

Mulcom

I/O in the Remote Field(ExaCoast)

Incl. FieldbusEngg.

PLC / Remote I/O / Subsystems

RS-

232/

485/

Eth

erne

t

Field Devices

Business Domain

PIMS

AOA

MMAPC

System Scalable

Min. ConfigurationSingle DomainConfiguration

Max. No. of Tags : 100,000 per HISMax. No. of Stations : 64

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

Expanded. SystemConfiguration

One Process UnitWhole Complex

Controller

Operation and Monitoring

Standard Operation and Monitoring WindowsGraphic,Tuning, Trends, Alarms, Operator guidance

Operation and Monitoring Support FunctionsProcess & Historical message reports, Security ITV camera & CENTUM desktop customization

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

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

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

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

Lets have a look at some samples

Operation and Monitoring WindowsNavigator Window

Control Group Window

Tuning Window

Overview Window

Trend Window

Field Control StationRedundancyProcessor

Analog &Digital Control

Integration

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

Redundant CPU, Power Supplyand Communication Interface

Unique Pair & Spare

DesignCOMP

CPU CPU

BUFFER

COMP

CPU CPU

BUFFER

INPUT

OUTPUT

BUFFER BUFFER

RISC processor Fixed scan times 4000 free configurable function blocks Powerful math. capacity etc...

Easy integration subsystems e.g. PLC, SER.. Data exchange between FCSSupport Fieldbusetc...

Control

Input Output

RS-232C

RS-422

RS-485

Communication unitDigital I/O unit connector type

16 -pt. Input (isolated)

16 -pt Output (isolated)

32 -pt. Input

32 -pt. Output

Current/Voltage InmV, Thermocouple, RTD

InputPulse InputCurrent/Voltage Out

Analog single card I/O Unit

Voltage Input

mV Input

Thermocouple Input

RTD Input

2-wire transmitter input

4-20 mA Output

Analog Multiplexer Unit (16 channels)

RIO bus (max. 20 km)

Node Interface UnitMax. 8 units per FCS

Input / Output UnitsMax. 5 units per NIU

I/OUnit32 channels

I/OUnit2 ports

I/OUnit16 channels

I/OUnit128 channels

Input/OutputModules

Fieldbus

Profibus

Ethernet

Field Control Station and FIO feature

......

・・・・

To Field Device

To Field Devices

Fieldbus

Vnet

New Remote I/O Bus

Direct Node

(Ethernet)

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

PLC(Subsystem)

FF-H1

Serial,Ethernet

4-20mA (Conventional)

FF-H1

4-20mA

Remote Node

FCS

FIO Node overview

写真挿入

Power supply

(10Base2)Remote I/O Interface

Up to 8 I/O modules

5 units (222.3mm)

19 inches

Rich Flexibility: Field connections

I/O module

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)

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

Remote I/O installation

Separated sites

Corrosive sites

Explosive sites

FCU

ooo

CCR (Central Control Room) Separated sites

Corrosive sites

Explosive sites

Field Control Unit: RedundancySynchronous hot standby with fully redundant

hardware and duplex functionality in design

EngineeringOff line Engineering without Target Hardware by using Hardware Simulation Technology

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

Off line Testingand HardwareSimulation

CAEComputer Aided Engineering

ConcurrentEngineering

ElectronicMediaInput

Order Start-up

HIS

V net

FCS

ENGBuilder software

Virtual Test Function

Off line Testing

FCSSimulator

HISFunction

Virtual Testing

Vir

tual

Wir

ing FCS

Simulator

HIS Function

Plant Model

Plant Simulator

HIS

Exatif Communication Interface

HIS

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

Unified configuration with LOOK&FEEL.

Project(Each plant)

Each folder for each FCS

Each folder for each HIS

Drag&Drop enables Copy& paste

Detail configuration for each

Example : Control logic

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

FB : Function Block

Flexible Field Wiring.

Terminal board

Field wiring

Field wiring

Dedicated cable

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.

Flexible Field Wiring.

Terminal board

Dedicated cable

For single

For dual

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.

Control logic

ooo

Controlling

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

(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.

No effect

No effect

No effect

No effect

No effect

No effect

Controller CPU is Non-stop !