YOKOGAWA CENTUM

CS3000
TRAINING
BEJING- CHINA
MARCH 2010
By:
KHALID SHAPO
GUMRY DCS&FPF FOREMAN
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 loop
Proportion
Integral
Derivative

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 advantage
PID 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)
Business
Domain
Manufacturing Exec. System Domain
 Plant Information & Management System
(PIMS)
MES Domain  Maintenance Management (MM)
Control Domain
Advanced Application
Advanced Process Control (APC)
Control Domain  Advance Operation Assistance (AOA)
Plant Control Room/Factory Floor
DCS/PLC/PC/ESD/F&G
Field Domain
Field Domain Fieldbus and conventional
Field Instrumentation.
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
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
CS 3000 – Integrated Control System Overview
Advanced , Flexible Operator Functions
Powerful Control Station Features
Flexibility in Engineering
Integrated Solutions – Extended Applications
Unique Advantages leading to Lower TCO
’75 ’79 ’82 ’8 ’8 ’9 
’9
INTEGRATED SYSTEM OPEN SYSTEM
 EXCELLENT SYSTEM

～’ 78
～’ 82～’ 884 ～’ 8 ～’ 2 ～’ 8 ～’ 1. UNIX OS 1. WINDOWS-NT OS
 
 1. Function Assignment  2. Advanced Control  2. Client / Server
 USER ORIENTED
 2. Separation of Engneering
 3. Open Net Work  3. Migration
 OPERATION  3. High Peroformance  4. High Reliability  4. High Reliability
 NEW MODEL
 1.  4. Touch Operation  5. Utilisation of Users’ Assets
Enhanced Functions
of OPS  5. Window  6. Easy Engineering
 CENTUM
 1. High
Speed  2. Voice  6. Integration (Super Window)  ＣＳ３０００
Comunication Bus
Output  Ｃ ENTUM
 3.
 7. Expanded Control Capacity
Japanese ＣＳ
 THE FIRST DCS  1. Unified Operator  2. Adoption Language Support


of HDD  CENTUM-XL HIS

 SYSTEM IN THE   4.  ICS

Stations
 3. CMOS Memory Sequence-oriented
 WORLD Control
 1. Distribution of Control
 2. Redundant  4. One-Touch
 Station
CENTUM-V
2. FIF Operation  10Mbps 　 V net
 Control Stations  EOPSENGSComputer
 ＣＴＭ - ２
 (Function Key
 XLAIS 
 Station
Development)  BCV
 ＣＯＰＳ  COPSV  FCS

 COPS2
 7DF
 EFCS
 COPS
 1Mbps
 CFSS
 7DF
 7VP  HF-BUS
 CFFS
 CFCS2
 256Kbps
 HF/F Converter
 CFCS 
Station
 F-BUS
 7FS

 Control  3  32  40  40  80
 40  200  200
 4096 Blocks
Loops  2
2
 2
0 0
 Sequen
ce
Tables
 Technology waves on Control
Systems
Windows 2000
Internet
NT
IT
and
Microsoft

UNIX

Micro processor

1st CENTUM V XL CS CS 3000 CS 3000 R3 time

June 1975 ’82 ’88 ’93 ’98 ‘01

Integrated Plant Control System
(IPCS)
 Typical System Configuration Remote
Business Domain DCS
Ethernet
Closed-type HIS LCD-typeDomain
HIS
HIS/EN
APC AOA G
PIMS MM
ACG

Vnet
APCS Incl. Fieldbus
BCV
Mulcom FCS Engg.
With I/O Migration
bus converter

I/O in the Remote Field CS/CS 1000/3000

(ExaCoast) CENTUM-XL/V/ µXL
RS-232/485/Ethernet

Prosafe-ESD H1 Fieldbus

Field Devices

PLC / Remote I/O /

 System Scalable

Min. Configuration Expanded. System

Single Domain Configuration
Configuration

Controller

Whole Complex
One Process Unit
Max. No. of Tags : 100,000 per HIS
Max. No. of Stations : 64
Expanded System
Max. No. of Domains : 16
Max. No. of Stations : 256
 Operation and Monitoring
Standard Operation and Operation and Monitoring Support
Monitoring Windows Functions
Graphic,Tuning, Trends, Alarms, Process & Historical message reports, Security
Operator guidance ITV camera & CENTUM desktop customization

Control Status Display Trend Functions

Window Real time, Historical trends Long term data
archive, External recorder, Expert trend
Control drawing, Sequence table viewer &Tuning trend
Logic chart window SEBOL & SFC
windows
System Maintenance Functions
Common Operation and System status, System alarm, HIS setting, Time
setting dialog & Help dialog
Monitoring Functions
Window call-up, Window” or “Full
screen”, System message, Window
Lets have a look
sizing, Window hierarchy, Navigator
window… at some
samples
Operation and Monitoring Windows
Navigator Window
Control Group Window
Tuning Window
Overview Window
Trend Window
 Control

Field Control Station

Processor Redundancy
RISC processor Redundant CPU, Power Supply
Fixed scan times and Communication Interface
INPUT
4000 free configurable function blocks
Powerful math. capacity BUFFER BUFFER Unique Pair & Spare
etc...
CPU CPU CPU CPU Design
COMP COMP
BUFFER BUFFER

OUTPUT

Easy integration Large control block library

subsystems e.g. PLC, SER.. Advanced control functions
Data exchange between FCS Calculation functions
Support Fieldbus C-language
etc... Graphic Flowchart (SFC)
etc...
Integration Analog &
Digital Control
 Input Output
Analog single card I/O Unit Analog Multiplexer Unit (16 channels)
 Current/Voltage In  Voltage Input
 mV, Thermocouple, RTD  mV Input
Input  Thermocouple Input
 Pulse Input  RTD Input
 Current/Voltage Out  2-wire transmitter input
 4-20 mA Output

RIO bus (max. 20 km)

I/OUnit I/OUnit
16 channels 32 channels
Node Interface Unit
Max. 8 units per FCS
Input/Output
Modules
I/OUnit Input / Output Units I/OUnit
128 channels Max. 5 units per NIU 2 ports

Digital I/O unit connector type Communication unit

 RS-232C
 16 -pt. Input (isolated)
 RS-422
 16 -pt Output (isolated)
 RS-485
 32 -pt. Input
 Fieldbus
 32 -pt. Output
 Profibus
 Ethernet
Field Control Station and FIO
feature
..
FIO Features
Vnet
Direct Node  Small-sized
To Field Device (Compact)
 Two kinds of
Serial, FF-H1 connection
Ethernet  Direct Node
4-20mA
・
・ ・ ・

 Remote Node
FCS  Dual redundant I/O
PLC(Subsystem)
Module are possible
(for all type)
New Remote I/O(Ethernet)
Remote Node
 Field Network
Bus
 RS:2 ports
 FF-H1 : 4
segments
FF-H1
 Profibus-DP

To Field Devices
4-20mA (Conventional) Fieldbus
 FIO Node overview
Remote I/O Interface
(10Base2)
Up to 8 I/O modules
Power supply

5 units (222.3mm)
写真挿入

19 inches
 Rich Flexibility: Field connections
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)

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

Explosive sites
Explosive sites

Corrosive sites
Corrosive sites
FCU

ooo

Separated sites
CCR (Central Control Room) Separated sites
Field Control Unit: Redundancy
Synchronous hot standby with fully redundant
hardware and duplex functionality in design
 Engineering
Off line Engineering without Target Hardware by using
Hardware Simulation Technology

Off line Testing CAE

and Hardware Computer Aided
Simulation Engineering
HIS ENG
Builder software

V net
Electronic
Concurrent Media
Engineering Input FCS

Order Start-up
Engineering can start direct after ordering
Engineering up to Configuration Testing can be done Off Line
Virtual Test Function

Virtual Testing Off line Testing

HIS
HIS HIS
HIS Function FCS
Function Simulator

Virtual
Wiring
FCS Exatif Communication Interface
Simulator

Plant Simulator

Plant Model

- Off Line Virtual Testing using only one PC

- Connection with Plant Simulator using the FCS
Simulator
 Unified configuration with LOOK&FEEL.

Project Detail configuration • Graphical configuration

(Each plant)
for each • FB in FCS and FF
devices are handled in a
same tool.

Each folder for each FCS

Drag&Drop enables
Copy& paste Each folder for each HIS

FB : Function Block Example : Control

logic
Flexible Field Wiring.

 Accordingto your plant,

any I/O modules can be
connected with
direct connection or
terminal board connection.
 Even in case of field bus,
Dedicated
you can choose either cable Field wiring
type.
Terminal
 Change board
the front blocks,
you can change how to
connect the field wiring. Field wiring
 Flexible Field Wiring.
For dual

For single

Dedicated
cable

Terminal
board
 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.
 R3provides 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.

No Control logicNo
Noeffect effect
effect

(1) R3 Controller is controlling

the plant with its control logic. No
effect
(2) You modify one of control loops.
(or sequence logic etc.)
Only this loop is stopped. No
Others are going on working. effect
(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. Controller CPU ooo

Controlling No
is Non-stop !
THANK YOU