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YOKOGAWA CS3000 FOUNDATION FIELDBUS

YOKOGAWA CS3000 FOUNDATION FIELDBUS

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  • This slide represents the evolution of control systems in terms of technology and application. Electronic computers were first introduced in the field of process control in 1960’s. Digital control technology has developed widely over the last few decades. The introduction of computers was done initially for data logging and set point control. With the introduction of computers in to the process control, advanced controller functions were superseded by computers, and DDC (Direct Digital Control) in which computers directly controlled processes were deployed. In the early stages, the control system was centralized where a central computer executed not only monitoring and operation but also process control. The most important reason was cost effectiveness. The advent of microprocessors greatly changed the scenario. The research moved on to how diversification could be implemented to achieve risk distribution, function distribution. The Distributed Control System (DCS) incorporated all these functionalities and with DCS, the control function could be functionally as well as geographically distributed. However the monitoring was still centralized for easy plant operation and control. At Yokogawa it will be our endeavor to develop newer technology systems and integrate them with existing systems - the best technology with most accurate results.
  • Digital Control Systems have evolved with developments in technology. Yokogawa’s Process Control system development history has also followed the technological innovation ranging from simple single loop controllers to highly complex solutions involving DCS and advanced process control techniques.
  • World has seen a lot of technological evolutions in the field of Plant Instrumentation and Control Automation since 1970’s... Instead of single loops, larger and more complicated loops such as cascade, ratio, feed-forward, multi-variable were used for achieving better control. For optimum, safe, and reliable control, effective control loops were developed using regulatory control, sequence control and inter-locks with the aid of computers. Systematic and reliable startup/shutdown procedures were incorporated in the control logic to ensure the safety of the plant. Yokogawa were the pioneers in introducing the first Distributed Control System to the world. Centum was the first Distributed Control System introduced by Yokogawa in the year 1975. Yokogawa continued its research in the DCS field and introduced many systems in line with the technological development. CENTUM VP is the latest DCS introduced by Yokogawa. VP is Vigilant Plant . CS3000 systems uses Windows platform for the GUI functions. The primary factors considered during the development of CS3000 are Easy connectivity of components The abnormality of one component does not affect the functionality of others Easy creation of regulatory and sequence control loops using computers Operators can easily monitor and handle multiple plant data’s from a Centralised Control Room
  • Centum CS 3000 equipments : 1. Human interface station (HIS) Used for operation & monitoring Incorporates open interfaces - supervisory computers and workstations can access data, messages and process data. Engineering and test functions. Desktop and console type 2. Field control station (FCS) Standard and compact type Regulatory and sequential process control User programming functions Plant control and communication with PLC, DAS etc. 3. Bus convertor (BCV) To link V-net system bus to another CS3000 domain or existing Centum or  XL. 4. Communication gateway Unit (CGW) Links V-net to Ethernet bus. 5. RIO bus (twisted pair) Communication between remote I/O to FCS CPU. 6. Nodes Remote I/O units 7. V-net (Co-axial multidrop) - Links FCS, HIS, BCV, CGW 8. Ethernet (Coaxial) - Links HIS, ENG and supervisory system (Also for HIS data equalisation). IEEE802.3, 10BASE5 (Thicklan), 10Mbps, 50ohm coaxial cable Base band modulation, 1 Physical port, CSMA/CD media access control method
  • This figure shows R3.04 New Hardware. FIO modules enhancement FIO Modules line up PROFIBUS-DPV1 and DeviceNet Interface. New Controller is FFCS FFCS is FIO based small size controller. GSGW (Global Subsystem GateWay) GSGW is Subsystem Gateway Interface.

DCS PRESENTATION DCS PRESENTATION Presentation Transcript

  • GULF LNG & SPONGE IRON CO LLC E & I DEPT
  • DISTRIBUTED CONTROL SYSTEM Yokogawa CS 3000 FF
  • Basic Loop Controller I/P Transmitter I/P Convertor PV MV SV 4-20 mA 4-20 mA Pneumatic Signal (0.2 to 1 Kg/cm2 or 3 to 15 psi) Final Control Element Basic Control Loop
  • Process Control Systems
    • Process control systems are classified into
      • Analog Control Systems
      • Digital Control Systems
  • Analog Control System Signal Conversion I/P 4-20 mA DC 1 to 5V DC Operational Amplifier Set Point Final Control Element Transmitter Analog Control System
  • Digital Control System Digital Control System I/P 4-20 mA DC A / D 1 to 5V DC D / A Digital Output Unit Input Unit Memory Unit Control Unit Arithmetic Unit Set Point Processor
  • * First control computers * First DDC * First mini computers * First distributed DDC using microprocessors * First one-loop DDC controllers * Integrated systems Ge.Tr Sl. Tr Rapid growth of process Industries DTL SSI TTL.SSI LSI uP Energy crisis (Transition to steady growth) Demand for conservation of resources Appearance of OA, LA and FA (Improved man- machine interface V LSI 32bit UP * Multi produce batch applications * Integrated FA system * CIM * multimedia * Pentium Processor * Revolution in info tech * Internet * windows NT gaining prominence * Object linking * ODBC * RDBMS EVOLUTION OF CONTROL SYSTEMS * Use of factory management computers THE EIGHTIES THE NINETIES THE SEVENTIES THE SIXTIES BEYOND 2000
  • EVOLUTION OF CONTROL SYSTEMS YEWCOM Factory Management Computer System HP9000 Computer Control System CCS YODIC 100 YODIC 1000 Manufacturing Line Control System YEWMAC Centralized DDC System YODIC 500 YODIC 600 Distributed Control System CENTUM II CENTUM V CENTUM-XL YEWPACK YEWPACK Mark II uXL YEWSERIES 80 YS 100 ECS EBS I SERIES Analog Control System CS1000 CS3000 CS THE EIGHTIES THE NINETIES THE SEVENTIES THE SIXTIES BEYOND 2000
  • Digital Control System
    • Digital Control Systems are further classified into
      • Centralized Control Systems
      • Distributed Control Systems
  • Centralized Processing Unit CPU Centralized Control System Input Signals from Field Set Points OutputSignals to Field Centralized Control , Centralized Monitoring PV1 PV2 PVn PV3 MV1 MV2 MVn MV3 SV1 SV2 SV3 SVn Centralized Control System
  • Centralized Control System
    • Drawbacks Of CCS:
    • If the CPU fails the entire plant gets affected.
    • Redundancy concept is not available.
    • Redundancy is having two controllers. One would be active and the other would be standby. If the active controller fails, the standby controller takes over.
  • Distributed Control System Input Signals from Field Distributed Control Centralized Monitoring Set Points Communication Bus Output Signals to Field MV1 MV8 FCS PV1 PV8 SV1 SV8 MV9 MV16 FCS PV9 PV16 SV9 SV16 MV17 MVn FCS PV17 PVn SV17 SVn OPS OPS Distributed Control System
  • Basic Components of DCS
    • FCS (Field Control Station):
    • Used to control the process. All the instruments and interlocks created by software reside in the memory of the FCS. All the field instruments like transmitters and control valves are wired to the FCS.
    • OPS (Operator Station):
    • Used to monitor the process and to operate various instruments.
    • Communication Bus:
    • Used to communicate between the FCS and the OPS
  • Advantages of DCS
    • Control function is distributed among multiple CPUs (Field Control Stations). Hence failure of one FCS does not affect the entire plant.
    • Redundancy is available at various levels.
    • Instruments and interlocks are created by software.
    • Generation and modifications of the interlocks are very flexible and simple.
    • Information regarding the process is presented to the user in various formats.
    • Field wiring is considerably less.
    • Maintenance and trouble shooting becomes very easy.
    • Cost effective in the long run.
  • CENTUM Series (DCS) Evolution 1st CENTUM 2nd CENTUM CENTUM V CENTUM-XL CENTUM CS CENTUM CS3000 1975 1981 1984 1988 1993 1998 CENTUM has developed as a true open system. World First DCS 2008 CENTUM VP
  • CS3000-System Configuration CS, CS 1000 CENTUM-XL, -V MXL BCV CGW Remote Domain System V net HIS ooo PFCS LFCS Ethernet HIS / ENG FFCS KFCS
  • CENTUM CS 3000 - Major Components
    • FCS (Field Control Station)
      • Reliable controller.
      • Cost-effective and capable I/O subsystem.
    • HIS (Human Interface Station)
      • The operator station based on Windows XP or Windows2000. (Both are selectable.)
      • HIS provides easy & flexible operation.
    • ENG (Engineering Station)
      • Engineering Station is used to do the engineering builder for all the stations like HIS, FCS, CGW, BCV etc. ENG is a PC loaded with Engineering software.
      • The HIS can be loaded with engineering software so that it can be used as HIS as well as ENG.
    • CGW: Communication Gateway Unit used to communicate with supervisory computers.
    • BCV: Bus Converter is used to link two domains.
  • CENTUM CS 3000 - Networks
    • V-Net (Communication Bus)
      • Real-time control bus.
      • V-NET is a used for communication between HIS, FCS, BCV & CGW.
      • Maximum 64 Stations can be connected on the V-net.
    • ETHERNET (Communication Bus)
      • Ethernet is a standard network in CS3000 to connect HIS, ENG and supervisory computers .
      • Transmission speed: 10 MBPS
  • CS3000 FIO System Configuration-Overview GSGW V net PLC FCJ/FCN Ethernet PROFIBUS-DPV1 Discrete I/O Drive DeviceNet Photoelectric device OPC Server FFCS Ethernet Safety System Other System ooo Subsystem Gateway
  • FIO
    • FIO means F ield network I / O .
    • FIO is Process I/O modules.
    • A kind of compact, cost-effective, reliable I/O devices, targeted as the industrial standard I/O of next-generation.
    • FIO includes the latest network technologies and field experience.
  • Power supply unit CP401 CPU module Eight FIO slots EC401 ESB bus coupler (Note) Note: Two I/O slots are to be used for NIU extension. AIP504 Vnet coupler (10BASE2 Vnet cable is used.) Detachable bottom unit FFCS Hardware View
  • Hardware Configuration- Local Node FIO: Max. 8 Local node Max. 3 ESB bus Up to 6 Modules Up to 8 Modules V net FFCS EC401 EC401 FFCS Minimum Configuration Maximum Configuration CP401 CP401 PW48X PW48X CP401 CP401 PW48X PW48X SB401 PW48X PW48X SB401 SB401 PW48X PW48X SB401 SB401 PW48X PW48X SB401
  • Hardware Configuration–Remote Node V net FFCS Remote node Expanded Remote node up to 3 ER bus EB401 EB401 EB401 EB401 EB401 EB401 EB401 CP401 CP401 PW48X PW48X Remote node Remote node Optical Repeater can be used EB501 PW48X PW48X EB501 EB501 PW48X PW48X EB501 EB501 PW48X PW48X EB501
  • FIO System Specification for FFCS
    • The bus among FFCS and local nodes. (ESB bus)
      • Dedicated Internal Bus
      • Speed : 128 Mbps
      • Distance in Total : Max. 10m
    • Remote I/O bus (ER bus)
      • Based on Ethernet
      • Speed : 10 Mbps
      • Distance in total : 10base2 -> max. 185m / 10base5 -> max. 500m max. 2 km with repeater (Standard of Ethernet)
      • Up to 3 remote nodes can be installed on a FFCS.
  • Pair & Spare CPU Concept
  • FFCS Specification 256 Realtime trend 2500 No. of function block (total with %ANN) 200 No. of control drawing sheet 200 %RQ 500 %OP 1000 %PR 1000 %ANN 4000 Common SW 256 Global SW 4000 words Communication data 1920 DI/DO 480 AI/AO AP capacity EB401/EB501 ER bus I/F Up to 3 Remote node for ER bus Up to 4 Local node for ESB bus EC401/SB401 ESB bus I/F total 4 including CPU node No. of I/O node 8 No. of I/O slot 100/220V AC, 24V DC Power supply 32MB Memory Size R5432 (RISC) CPU
  • Input Output Modules
  • Analog Modules
    • Analog Modules <Non-isolated type>
    • AAI141 16Ch Current input 4-20mA (Transmitter power supply)
    • AAV141 16Ch Voltage input 1-5V
    • AAV142 16Ch Voltage input -10V to +10V
    • AAI841 8Ch Current input/8Ch Current output 4-20mA (Transmitter power supply)
    • AAB841 8Ch Voltage input/8Ch Current output 1-5V input/4-20mA output
    • AAV542 16Ch Voltage output -10V to +10V
    • AAP149 16CH Pulse Count 0 to 6kHz (Pulse Input Module Pm1 Compatible)
    • <Isolated (between system and field)>
    • AAI143 16Ch Current input 4-20mA (Transmitter power supply)
    • AAI543 16Ch Current output 4-20mA
    • AAV144 16Ch Voltage Input -10V to +10V
    • AAV544 16Ch Voltage Output -10V to +10V
    • AAT141 16Ch mV,TC input JIS R,J,K,E,T,B,S,N / -100 to +150mV
    • AAR181 12Ch RTD JIS Pt100ohum
    • <Channel Isolated>
    • AAI135 8Ch Current input 4-20mA (Transmitter power supply)
    • AAI835 4Ch Current input/4Ch Current output 4-20mA (Transmitter power supply)
    • AAT145 16Ch mV,TC input JIS R,J,K,E,T,B,S,N / -100 to +150mV
    • AAR145 16Ch RTD/POT input RTD JIS Pt100ohum / POT 10kohum
    • AAP135 8Ch 0-10kHz Pulse input Transmitter power supply 12V/24VDC,
    • (Shunt resistance can be selected)
  • Analog Modules 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 data
    • Analog Data
      • 4 to 20 mA from Device
    • HART Variable Data
      • HART device supports Max 4 HART Variable
        • PV Primary Value
        • SV Secondary Value
        • TV Third Value
        • FV(4V) Fourth Value
      • HART Module supports Max 32 HART Variable data
  • Digital I/O Modules
    • <Generic type>
    • ADV151 32Ch24VDC input, Common minus side every 16-channel
    • ADV157 32Ch24VDC input, Common minus side every 16-channel, Single and Weidmueller only
    • ADV161 64Ch24VDC input, Common minus side every 16-channel, MIL type only
    • ADV551 32Ch24VDC,0.1A, Common minus side every 16-channel
    • ADV557 32Ch24VDC,0.1A, Common minus side every 16-channel, Single and Weidmueller only
    • ADV561 64Ch24VDC,0.1A, Common minus side every 16-channel, MIL type only
    • ADV851 16ch Input/16ch Output, 24VDC
    • <AC input modules>
    • ADV141 16Ch100VAC input, Common minus side every 8-channel
    • ADV142 16Ch220VAC input, Common minus side every 8-channel
    • <Relay output module>
    • ADR541 16Ch Relay output, Common minus side every 8-channel, 24-100VDC,100-200VAC, 2A/point, Maximum 8A is allowed per common, A type contact, exchange by a module.
    • <CENTUM-ST compatible type>
    • ADV859 ST2 compatible -16Ch input,16Ch output
    • ADV159 ST3 compatible - 32Ch input
    • ADV559 ST4 compatible - 32Ch output
    • ADV869 ST5 compatible - 32Ch input, 32Ch output
    • ADV169 ST6 compatible - 64Ch input
    • ADV569 ST7 compatible - 64Ch output
  • Communication Modules
    • Serial Communication Module
      • ALR111 RS232C
        • 2 ports, 1200bps to 115.2k bps
      • ALR121 RS422/RS485
        • 2 ports, 1200bps to 115.2k bps
    • Ethernet Communication Module
      • ALE111 Ethernet Communication
      • Installable both on Local and Remote Node
  • Subsystem Packages List
    • RS Communication (ALR111/ALR121)
      • YS Communication
      • YS Directly Communication
      • FA-M3
      • Modbus
      • SLC500/PLC5
      • MELSEC
    • Ethernet Communication (ALE111)
      • FA-M3
      • Modbus
      • SLC500/PLC5
      • Control Logix
      • MELSEC
  • Foundation Fieldbus Module (ALF111)
    • FF-H1 interface card
    • Redundancy
    • Installable both on Local and Remote nodes
    • VCR (Virtual Communications Relationship): 105 per port (one segment)
    • Both pressure clamp and terminal board are available.
    • Link Master
  • Redundant Fieldbus Module (ALF111) Field Devices ALF111 Image of Redundant Card 0x14 0x15 External Power Supply IOM IOM IOM IOM IOM IOM Com. Card Com. Card PSU PSU
    • The Station for Real time Plant Monitoring/Operation
    HIS (Human Interface Station) Easy Operation by a mouse, a keyboard etc. Real time display of Plant Abnormalities. Plant Operation by thousands of Graphics
  • Types of HIS
    • DESKTOP HIS:
    • A IBM PC/AT compatible machine is generally used. Apart from the general PC, the Yokogawa PC is also supported. Specifications of the PC HIS Desktop are as follows:
    • CPU : Pentium IV Processor
    • Main Memory : 256 MB (Minimum)
    • Hard Disk : 20 GB or more
    • Video Display : 1024 x 768 or more, 256 colours
    • CRT Monitor : Multi Scan 17” monitor or larger
    • Serial Port : RS232C one port or more
    • Parallel Port : One port or more
    • Extension Slot : PCI slot for V/VL net card, ISA slot for Ethernet card
    • Power Supply : 200-240V AC
    • Basic Software : Windows NT with Service Pack ,Windows 2000 or
    • Windows XP
    • CONSOLE HIS
    • The floor mounted console type HIS comes with 21” monitor which has a touch panel operation. It has an operation keyboard and an engineering keyboard.
  • Application Capacity of HIS
    • Maximum number of tags that can be monitored from HIS : One Million.
    • Maximum number of windows that can be created per HIS : 4000.
    • Maximum number of Trend Recording Points per HIS : 3328.
  • V net Communication Protocol : IEEE 802.4 Access Control : Token Passing Trans. Speed : 10 Mbps Trans. Distance : 500m to 20km Media : Coaxial/Optical Fibre Std. max. length : 185 m Max. length : 20 Km (with optical repeater) 1.6 Km (with coax. repeater) HIS V net
  • V net : Extension Details Optical Fibre Optical Fibre Max. 500m Max. 500m Max. 500m Max. 15 km Max. 15 km Overall Max. 20 km Co-axial Cable V net HIS HIS HIS R R R R T T R R R R T T
  • Bus Convertor Domains are group of stations connected on the V-net. Bus Convertor is used to link two domains. BCV is used to connect CS, CS 1000, CENTUM-XL,CENTUM-V AND MXL to CS3000 system HF BUS EFCD FCS HIS ooo BCV ooo ooo Domain connection EOPS V-NET ETHERNET
  • Operation Windows
    • Information regarding the process is gathered as well as monitored by the following Standard Operation windows on the HIS.
    • Tuning Window
    • Control Group Window
    • Trend Window
    • Process Alarm Window
    • Operator guide Message Window
    • Graphic Window
    • Overview Window
    • Process Report Window
    • Historical Report Window
  • System Message Window These buttons are provided for calling various functional windows on the HIS Type the TAGNAME to call the instrument faceplate window System Message Window
  • System Message Area Various windows can be accessed by selecting the respective icons in the System Message Area These windows can also be accessed by the keys on the Operator Keyboard SYSTEM MESSAGE AREA ICONS
  • Operation Keyboard Operation Keyboard OPERATION KEYBOARD All the operations can be performed with the help of the Operation Keyboard. The same operations can also be performed by touch functions available on the System Message Area Icons. Operation Keyboard
  • Operation Windows From this window, you can open the following windows. 1. Overview Window 2. Control Window 3. Tuning Window 4. Trend Window 5. Graphic Window 6. Alerm Window 7. Operator Guide message Window
  • Instrument Faceplate Window
  • Tuning Window Select this icon to display the Tool box Select this icon to display the Tuning Window
  • Tuning Window TUNING WINDOW displays all the Tuning parameters of the instrument. The Tuning Window is used to set up the alarm setting as well as the loop tuning parameters. Only the items indicated with a “= “ can be changed. Displaying a “Tuning Window” 1.Double click on a Tag’s name on a “ Control Window” and a faceplate window will appear. Select the “Tuning “ window icon from the toll box. 2. Select “NAME icon in the System Message Area” then enter the “TAGNAME”.
  • Tuning Window
  • Control Drawing Display Select this icon to call the Control Drawing display Control drawing display Control Drawing Display
  • Control Group Window Select this icon to display the Tool box Select this icon to display the Control Group Window
  • Control Group Window–8 Instruments Control group windows are used to display multiple instrument faceplates. Maximum 8 or 16 instrument faceplates can be displayed in one Control Group Window Normally the instruments are monitored and operated from this window. Double click on the instrument TAGNAME to display the Tuning Window of the instrument. Select the Upper Window Key to come back to Control Group Window .
  • Control Group Window – 16 Instruments
  • Trend Window Select this icon to display the Tool box Select this icon to display the Trend Window
  • Trend Window TREND WINDOW records the PV, SV and MV of various instruments. Trend can be displayed in Trend Group Format or in Trend Point Format. Maximum 8 pens can be assigned in one Trend Group Window
  • Trend Group Window
  • Trend Point Window Double click here to call the Trend Point Window Trend Point Window
  • Calling Instrument from Trend Window Double click here to call the Instrument faceplate Window Instrument Faceplate Window. Instrument can be operated from this window.
  • Process Alarm Window PROCESS ALARM WINDOW displays the latest 200 process alarms. Alarms can be acknowledged either as a Group or as Individual alarm. Select this icon to call the Process Alarm Window
  • Process Alarm Window PROCESS ALARM WINDOW displays the latest 200 process alarms. Alarms can be acknowledged either as a Group or as Individual alarm. This icon displays the current PV Values of the instruments that are in alarm This icon displays the important tags (High Priority Alarms) that are in alarm. This icon is used to acknowledge the process alarms.
  • Operator Guide Message Window Select this icon to call the Operator Guide Message Window OPERATOR GUIDE MESSAGE WINDOW displays the predefined messages to guide the operator regarding the current process status and /or the actions to be taken. OG messages can be acknowledged either as a Group or as Individual message.
  • Graphic Window
  • Overview Window Select this icon to display the Tool box Select this icon to display the Overview Window
  • Overview Window
    • Overview Window displays the overview of the current process status.
    • Information regarding the process is distributed among the various display blocks.
    • 32 Display Block s per Overview Window.
    • Each block gives dynamic information regarding the process.
    • Double click on the display block to more details.
    • 3 Types of Display Blocks
    • Single Tag Block
    • Window Display Block
    • Comment Block
  • Overview Window
  • Process Report Window
  • Historical Message Report Window
  • Sequence Tables
  • Sequence Tables
  • Logic Charts
  • Logic Charts
  • System Status Window
  • System Alarm Window SYSTEM ALARM WINDOW displays the latest 200 system alarms. Alarms can be acknowledged either as a Group or as Individual alarm.
  • Navigator Window
  • HUMAN INTERFACE STATION Virtual test Function SYSTEM GENERATION FUNCTION OPERATION & MONITORING FUNCTION CONTROL FUNCTION TEST FUNCTION SFCS
  • Page T h a n k y o u