yokogawa electric corporation 2-9-32 nakacho, musashino-shi tokyo, 180-8750 japan yokogawa electric...

Yokogawa Electric Corporation

2-9-32 Nakacho, Musashino-shiTokyo, 180-8750JAPAN

<ISD-MASP-S03048> Yokogawa Electric CorporationCopyright © by Yokogawa Electric Corporation<April 20, 2023>

DCS with long life

Yokogawa’s Migration Path

April 20, 2023

Proprietary info goes here…<ISD-MASP-S03048> Yokogawa Electric CorporationCopyright © by Yokogawa Electric Corporation<April 20, 2023>

Important issues for long life DCS.

Using DCS for a long time, the following items become more and more important.– System Deterioration Due to Aging.– Out-of-date Functions.– Increasing System Maintenance Cost.

You cannot avoid to renew your DCS to make your total cost lower.

HOWEVER ......


In case of “Scrap & Build”,

Advantages:– The latest technologies can be used.– System life becomes longer.

Disadvantages:– Full installation cost is necessary at once.– You need to consider your application assets.– How to use is changed suddenly, so particularly

operators may feel uncomfortable, at first.

Yokogawa’s MIGRATION solution is to minimize disadvantages without missing advantages.


Key points of Yokogawa's Migration

Step by step– Only the portion with shorter life parts can be renewed

with remaining other portion.– Divide renewing cost.

Reuse the existing assets.– Field cable wiring.– Field devices.– Application database.

Shorten stopping time for migration work.– Longer stopping time directly leads to larger loss of your

business chance.


Yokogawa’s Migration Path.

CENTUM CS

Micro-XL

CENTUM V

CENTUM-XL



CENTUM V, CENTUM-XL– Migrate to the latest CS3000 R3 system with 3

steps.• Step 1 : HMI migration• Step 2 : Controller migration• Step 3 : I/O portion migration


Solution with Migration step 1

Ethernet

Vnet

HISCOPSV, EOPS are no longer necessary.

It is not necessary to modify FCS and I/O.

HISs works instead of COPSV, EOPS

• All tag data of the existing FCSs can be operated from HIS. (Read/Write is OK.)

• Operators need not recognize whether the tag is the existing FCSs’ or CS3000 FCSs’.

• Operation keyboard and touch panel are available.

OPC server

All process data is handled as CS3000 data. • Operation improvement with AOA function. • Seamless connection with PIMS.• Audit trail • Remote operation

Bus converter


How to connect.

Ethernet

VnetHIS

FCSs do not be affected at all.

As HF bus is redundant, the communication does not stop when connecting Vnet -- HF bus.

Tags are registered in CS3000 builder.

Builder

Download tag information to each HIS.

Process operation is not stopped when connecting HISs.


What are benefit at Step 1 ?

Step 1: HMI Migration– Dramatically reduced the anxiety of parts supplement.

• HMI includes the shorter life parts, such as CRT, HDD.• As CS3000 HMI is based on generic PC, it is easy to supply

these parts. – You can utilize the latest Windows technologies.

• Because CS3000 R3 works on MS-Windows2000 and will be able to work on WindowsXP.

– Seamless connectivity with various kinds of the latest business domain systems.

• HIS (R3 HMI) has OPC interface.• Most of MES, PIMS, and CMMS have OPC interface.

– Operation improvement with AOA software in HIS.• AOA (Advanced Operation Assistance) can improve your

manual operation.



Ethernet

Vnet

HIS

It is not need to modify I/O nests, signal conditioners, and field wiring at all.

CS3000 FCU has the interface for the I/O bus of CENTUM-XL and V.

• You can connect the existing I/O nests to CS3000 FCU.

• Field wiring cables need not changed at all.• CS3000 control logics can be connected to XL, V I/O.

OPC server

FCU is used instead of SCN. • Control logics (Loop, sequence)works as CS3000 control function.

• Much more availablity with Pair&Spare technology.

• Connected on Vnet.


Solution with migration Step2

Existing CENTUM-XL

(Front) (Rear)

(Field)

Internal bus



(Field)

(Front) (Rear)CS3000

XL SCN

Internal bus



Same Interface connector

SI31 SI301

(Field)


Internal bus

XL SCN



(Field)


Internal bus

ESB bus

CS3000 FIO subsystem


How to connect.

Ethernet

VnetHIS

You can change FCUs one by one without affecting other FCSs at all.

Builder

Download control logics to each FCS.

Process operation by other FCUs is not stopped when replacing an FCU.

Control loops, Sequence, etc.

Control logics

Converted as CS3000 application.

Control Logics

Save



Step 2: Controller Migration– Much Larger application capacity.– Much quicker processing.

• Short turn around to improve control ability.• More control logics can be used.

– The batch system complied with ISA S88.– Much more reliability.

• Pair & Spare mechanism to detect not only the hardware abnormalities, but also software abnormalities, such as the error by transient noise.

– Much more number of I/O point.• FIO subsystems can be additionally connected.

– Much more visualized control logics.• Not only decision tables, but logic chart, SFC, are available.• The work status of these logics can be displayed on HIS.



Ethernet

Vnet

HIS

OPC server

Renew I/O portion to R3 FIO subsystem.

•Front connector of FIO modules is same as existing I/O cards.•Field wiring can be remain.


Hardware continuity

(Front) (Rear)

Same connector is available.

Field wiring is NO CHANGE

Field wiring

•Compatible modules with the existing.

•Same size as the existing.

Controller hardware can be renewed to R3 without changing field wiring.

In case of CENTUM V, CENTUM-XL



Step 3: I/O portion Migration– Much more reliability.

• All modules can be redundant.– Much more number of I/O point.– You can extend the functionality with new technologies.

• FOUNDATION Fieldbus solution.• Remote I/O installation.• Connectivity with various types of 3’rd party subsystems.

Even at Step 3, you need not rewire the field cables.– Yokogawa will continue supplying the signal conditioners.

Migration story completes !



CENTUM CS– Migrate to the latest CS3000 R3 system with 2

steps.• Step 1 : HMI migration• Step 2 : Controller migration

– Integrate with the latest CS3000 R3 system



Ethernet

Vnet

HISICSs are no longer necessary.


HISs works instead of ICS


• Operators need not recognize whether the tag is the existing FCSs’ or CS3000 FCSs’.


OPC server


CS FCS

EWS


How to connect.

Ethernet

Vnet

HIS

OPC server

CS FCS

EWS

Builder

FCSs are not affected at all. Process operation is not stopped when connecting HISs.

As Vnet is redundant, the communication does not stop when connecting replacing ICS to HIS.

•The ICS graphics can be imported into CS3000 HIS

•Tags are equalized in CS3000 builder.








• HIS (R3 HMI) has OPC interface without any gateways.• Most of MES, PIMS, and CMMS have OPC interface.


manual operation.



Ethernet

Vnet

HIS

As RIO can be used also in CS3000, it is not necessary to modify I/O portion, and field wiring at all.

CS3000 FCU has the interface for RIO.

• You can connect the existing I/O nests to CS3000 FCU.

• Field wiring cables need not changed at all.

OPC server

FCU is migrated to the latest one.• Control logics (Loop, sequence)works as CS3000 control function.


How to connect.

Ethernet

VnetHIS


Builder




Control logics


Control Logics

Save




• Short turn around to improve control ability.– Much more number of I/O point.– You can extend the functionality with new technologies.

• FOUNDATION Fieldbus solution.



MicroXL– Migrate to the latest CS3000 system with 2 steps.

• Step 1 : HMI migration• Step 2 : Controller migration



Ethernet

Vnet

HISMOPSs are no longer necessary.


HISs works instead of MOPS


• Operators need not recognize whether the tag is MicroXL’s or CS3000 FCSs’.


OPC server


Bus converter


How to connect.

Ethernet

VnetHIS

FCSs are not affected at all.

If RL bus is redundant, the communication does not stop when connecting Vnet -- RL bus.

Tags are registered in CS3000 builder.

Builder

Download tag information to each HIS.

Process operation is not stopped when connecting HISs.








• HIS (R3 HMI) has OPC interface.• Most of MES, PIMS, and CMMS have OPC interface.


manual operation.



Ethernet

Vnet

HIS

It is not need to modify most of signal conditioners, and field wiring at all.

OPC server

Migrate MicroXL FCS to FFCS• Control logics (Loop, sequence)works as CS3000 control function.

• Connected on Vnet. • Field wiring cables can be remain.

FFCS


How to connect.

Ethernet

VnetHIS


Builder




Control logics


Control Logics

Save


Hardware continuity

(Front) (Rear)

Same connector is available.

Field wiring is NO CHANGE

Field wiringController hardware can be renewed to R3 without changing field wiring.

•Compatible modules with the existing.

•Same size as the existing.




• Short turn around to improve control ability.• More control logics can be used.

– The batch system complied with ISA S88.– You can extend the functionality with new technologies.

• FOUNDATION Fieldbus solution.– Much more visualized control logics.

• Not only decision tables, but logic chart, SFC, are available.• The work status of these logics can be displayed on HIS.


Operation Continuity

CS3000 can provide quite similar operation environment to the existing operation.– Same kinds of screens, such as overview, trend, tuning, and

graphic, are available.– Console, touch-screen are available.– Operation keyboard is available.– Operator needs not recognize that each tag belongs

to CS3000 or to the existing systems.

Operators can smoothly start their work HIS instead of the existing HMI.


Conclusion

By Yokogawa’s Migration solution, your DCS will become a dramatically longer life system with much more capability.You can reduce your TCO (Total Cost Ownership).

yokogawa electric corporation 2-9-32 nakacho, musashino-shi tokyo, 180-8750 japan yokogawa electric...

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