This PPT is based upon my training in Yokogawa Chennai.
Reference:
# Yokogawa Hand Book on CS 3000
# http://www.slideshare.net/bvent2005/dcs-presentation
2. Basics
Classification
Process Control Loops
Evolution
Hardware Configuration
Human Interface System
Communication Bus
Field Control Station
Projects
Overview
10. 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
f a i l s , t h e s t a n d b y c o n t r o l l e r t a k e s o v e r ) .
Centralized Control System
12. 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
Basic Components of DCS
13. Information regarding the
process is presented to the
user in various formats.
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.
Field wiring is considerably
less.
Maintenance and trouble
shooting becomes very
easy.
Cost effective in the long
run.
Advantages of DCS
14. 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
2008CENTUM VP
16. 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 - Major Components
17. 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
CENTUM CS 3000 - Networks
19. The Station for Real time Plant Monitoring/Operation
Human Interface System (HIS)
Easy Operation by a mouse, a keyboard etc.
Real time display of Plant Abnormalities.
Plant Operation by thousands of Graphics
20. 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 (Minimum)
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 : 200-240VAC
Basic Software : Windows NT with
Service Pack ,Windows
2000 or Windows XP
21. 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.
They are of types
• Enclosed Display Style
• Open Display Style
22. Engineering Station is used to do the engineering builder
for all the stations like HIS, FCS, CGW, BCV etc.
ENG station is a PC loaded with engineering software
(Standard builder function). It is mainly used to perform
CS3000 system generation and maintenance
management.
The HIS can be loaded with engineering software, so that it
can be used as HIS as well as ENG station.
Engineering Station (ENG)
23. 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.
Application Capacity of HIS
25. Optical
Fibre
R
R R
RT
T
Optical
Fibre
R
R R
R T
T
Max. 500m Max. 500mMax. 500m
Max.
15 km
Max.
15 km
Overall Max. 20 km
Co-axial CableV net
HIS
HISHIS
V net : Extension Details
Protocol : IEEE 802.4
Access Control : Token Passing
Trans. Speed : 10 Mbps
Trans. Distance : 500m to 20km
Media : Coaxial/Optical
Fiber
Std. max. length : 185 m
Max. length : 20 Km
26. The FCS controls the plant.
This is the component
where all the control
functions are executed
and hence it is a very
important and critical
component in the overall
system.
Field Control Station- Overview
28. FIO means Field 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.
FIO
29. FFCS is the Compact FIO type Field Control Station
supported by CS3000.
Components of FFCS:
a) Field Control Unit (FCU)
b) Nodes for FIO
c) Local / Remote Communication Bus
Compact Type FIO - Field Networked Field
Control Station (FFCS)
31. The FCU consists of
Two Power Supply Units
Two processor modules
Eight slots for Input Output cards
Out of these eight I/O slots, if I/O expansion is required, two
slots are used for ESB module and the rest six slots are used
for IO modules.
It has two V net coupler units for connecting V net Cables.
Field Control Unit of FFCS
32. 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
33. Node Unit of FIO
Node Unit
The node units (NU) for FIO are signal processing units which convert and
transmit analog or digital process I/O signals received from the field
devices to the FCU for FIO.
►Node Unit has two bus units
ESB Bus Node : For local nodes
ER Bus Node : For remote nodes
34. ESB bus Node or Local Node
Speed : 128 Mbps
Distance in Total : Max. 10m
ER bus Node or Remote Node
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.
35. FIO: Max. 8
Local node
Max. 3
ESB bus
Up to 6
Modules
Up to 8
Modules
CP401
CP401
PW48X
PW48X
V net
FFCS
CP401
CP401
PW48X
PW48X
EC401
EC401
SB401
PW48X
PW48X
SB401
SB401
PW48X
PW48X
SB401
SB401
PW48X
PW48X
SB401
FFCS
Minimum Configuration
Maximum Configuration
Hardware Configuration- Local Node
36. Hardware Configuration–Remote Node
V net
FFCS
Remote node
Expanded Remote node up to 3
ER bus
EB401
EB401EB401
EB401
EB401
EB401
EB401
CP401
CP401
PW48X
PW48X
EB501
PW48X
PW48X
EB501
Remote node
EB501
PW48X
PW48X
EB501
EB501
PW48X
PW48X
EB501
Remote node
Optical Repeater can be used
37. Domain is the group of stations connected on one V-net
cable. Maximum 64 stations can be connected per
domain. Bus Convertor (BCV) is used to link two domains.
Domain Concept
38. Addresses are used to identify the stations on the control
bus.
Address is composed of a domain number and a station
number.
The domain number is set in the range of 1 to 16. The
domain number is defined in project property setting
menu dialog box. The domain number cannot be
changed once it is set.
Station numbers are used to identify the equipments
connected in the same domain of the system. The station
numbers range from 1 to 64.
Network Address Configuration
40. Application Capacity Of FFCS
CPU R5432 (RISC)
Memory Size 32MB
Power supply 100/220V AC, 24V DC
No. of I/O slot 8
No. of I/O node total 4 including CPU node
ESB bus I/F EC401/SB401
Local node for ESB bus Up to 4
Remote node for ER bus Up to 3
ER bus I/F EB401/EB501
AP capacity
AI/AO 480
DI/DO 1920
Communication data 4000 words
Global SW 256
Common SW 4000
%ANN 1000
%PR 1000
%OP 500
%RQ 200
No. of control drawing sheet 200
No. of function block (total with %ANN) 2500
Realtime trend 256
41. The Field Network I/O (FIO) modules are used in the FCS for FIO.
Advantages of FIO series IOM
It supports Variety of Field connections.
I/O modules are available with different isolation types.
Supports wide range of Installation environment.
Redundancy is available.
Provides Replacement capability for the existing Centum V, Centum XL and
Micro-XL systems.
FIO Module
43. Pressure Clamp Terminal
A field signal cable, with its end uncovered, can be
connected directly to an analog or digital I/O module
equipped with the pressure clamp terminal block.
44. An analog or digital I/O module equipped with the KS
cable interface adapter can be connected with the
terminal board using the KS cable and field signal cables
are connected to the terminal board with M4 screws.
KS Cable Interface Adapter
45. Input modules convert process signals to the digital data format
used in the FCS. Output modules convert the digital data
format used in the FCS to analog or contact signals.
Types of I/O Module
Analog Input Module
Analog Output Module
Analog I/O Module
Digital Input Module
Digital Output Module
Digital I/O Module
Relay I/O Module
Multiplexers Module
Communication Module
Input Output Modules
51. 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
53. 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.
55. Tuning Window (PID)
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”.
61. 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
64. 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
65. 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.
Select this icon to call the Process
Alarm Window
66. SYSTEM ALARM WINDOW displays the
latest 200 system alarms.
Alarms can be acknowledged either as a
Group or as Individual alarm.
System Alarm Window
74. A Project is the basic unit of the engineering database
management. It is a unit which contains the database of the
FCS and the HIS created by the user. All builder files defined by
various builders are managed under the project.
There are three different types of projects in CS 3000:
1)Default Project
2) Current Project
3)User Defined Project
The project which runs inside the FFCS is called the current
project.
Projects in CS3000
75. A project is created under the System View. It is the
primary window for system generation to display the
builder files defined by the user and also to start the
builder for editing.
To open the system view we need to follow the shown
steps.
System View
76. When the system does not find any project definition, it
automatically prompts for the creation of a default
project. Click on Yes to create a new Project.
Creation Of Project
81. All types of analog input(Transmitters) and outputs(Valves)
labels are declared here.
It shows an analog i/o type.
IOM Builder
82. The download function transfers the FCS execution data
from the HIS to the FCS. The execution data is a database
containing the application logic to be copied on to the
processor card of the FCS.
There are three different types of download that can be
carried out on the FCS:
a) Offline download
b) Online download
Downloads
83. Offline downloading is performed when one of the following
changes is performed in the project:
• When adding • When the FCS properties
an FCS have been changed
Offline Download
85. CS3000 R3 system contains 200 control drawings per FCS.
To access control drawing, select FUNCTION_BLOCK
folder under FCS folder.
Control Drawing Builder
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