DCS PRESENTATION

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/P4-20 mA DC

1 to 5V DC

Operational Amplifier

Set Point

Final Control Element

Transmitter


Digital Control System

I/P

4-20 mA DC

A / D

1 to 5V DC

D / A

DigitalOutput

Unit

Input Unit

Memory Unit

ControlUnit

ArithmeticUnit

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. TrRapid growth ofprocess Industries

DTL SSI TTL.SSI LSI uP

Energy crisis(Transition tosteady growth)

Demand forconservationof 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

THE EIGHTIES THE NINETIESTHE SEVENTIESTHE SIXTIESBEYOND2000

* Use of factory management computers

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 YEWPACKMark II uXL

YEWSERIES 80 YS 100

ECS EBS I SERIES


CS1000

CS3000

CS

THE EIGHTIES THE NINETIESTHE SEVENTIESTHE SIXTIES BEYOND2000


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



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.


Input Signals from Field

Distributed Control Centralized Monitoring

Set Points

Communication Bus

Output Signals to Field

MV1

MV8FCS

PV1

PV8

SV1 SV8

MV9

MV16FCS

PV9

PV16

SV9 SV16

MV17

MVnFCS

PV17

PVn

SV17 SVn

OPS

OPS


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 CENTUM1st CENTUM

2nd CENTUM 2nd CENTUM

CENTUM VCENTUM V

CENTUM-XLCENTUM-XL

CENTUM CSCENTUM CS

CENTUM CS3000CENTUM CS3000

19751975

19811981 19841984

1988198819931993

19981998

CENTUM has developed as a true open system.

World First DCSWorld First DCS

20082008CENTUM VPCENTUM VP

CS3000-System Configuration

CS, CS 1000CENTUM-XL, -V

MXL

BCV

CGW

Remote Domain System

V net

HIS

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PFCS

LFCS

Ethernet

HIS / ENG

FFCSKFCS

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-OverviewCS3000 FIO System Configuration-Overview

ooo

GSGWGSGW

V netV net

PLCPLC

FCJ/FCNFCJ/FCN

EthernetEthernet

PROFIBUS-DPV1PROFIBUS-DPV1

Discrete I/O Drive

DeviceNetDeviceNet

Photoelectricdevice

OPC OPC ServeServerr

FFCFFCSS

EthernetEthernet

Safety Safety SysteSystemm Other Other

SysteSystemm

SubsystemGateway

FIO

FIO means FField network II/OO. 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 slotsEight 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 busESB busUp to 6 Modules

Up to 8Modules

CP40

1C

P40

1PW

48

XPW

48

X

V netV net

FFCFFCSS

CP40

1C

P40

1PW

48

XPW

48

X

EC

40

1

EC

40

1SB

40

1

PW

48

XPW

48

X

SB

40

1

SB

40

1

PW

48

XPW

48

X

SB

40

1

SB

40

1

PW

48

XPW

48

X

SB

40

1

FFCFFCSS

Minimum Minimum

ConfigurationConfiguration

Maximum Maximum

ConfigurationConfiguration

Hardware Configuration–Remote NodeV netV net

FFCFFCSS

Remote nodeRemote node

Expanded Remote node up to 3

ER busER bus

EB

40

1EB

40

1EB

40

1EB

40

1EB

40

1EB

40

1EB

40

1C

P40

1C

P40

1PW

48

XPW

48

X

EB

50

1

PW

48

XPW

48

X

EB

50

1


EB

50

1

PW

48

XPW

48

X

EB

50

1

EB

50

1

PW

48

XPW

48

X

EB

50

1


Optical Repeater can be usedOptical Repeater can be used

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

CPU R5432 (RISC)

Memory Size 32MB

Power supply 100/220V AC, 24V DC

No. of I/O slot 8

No. of I/O nodetotal 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

Input Output Modules

Analog Modules

Analog Modules <Non-isolated type>AAI141 16Ch Current input 4-20mA (Transmitter power supply)AAV141 16Ch Voltage input 1-5VAAV142 16Ch Voltage input -10V to +10VAAI841 8Ch Current input/8Ch Current output 4-20mA (Transmitter power supply)AAB841 8Ch Voltage input/8Ch Current output 1-5V input/4-20mA outputAAV542 16Ch Voltage output -10V to +10VAAP149 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 4-20mAAAV144 16Ch Voltage Input -10V to +10VAAV544 16Ch Voltage Output -10V to +10VAAT141 16Ch mV,TC input JIS R,J,K,E,T,B,S,N / -100 to +150mVAAR181 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 +150mVAAR145 16Ch RTD/POT input RTD JIS Pt100ohum / POT 10kohumAAP135 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 ValueSV Secondary ValueTV Third ValueFV(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-channelADV157 32Ch24VDC input, Common minus side every 16-channel, Single and Weidmueller

onlyADV161 64Ch24VDC input, Common minus side every 16-channel, MIL type onlyADV551 32Ch24VDC,0.1A, Common minus side every 16-channel ADV557 32Ch24VDC,0.1A, Common minus side every 16-channel, Single and Weidmueller

onlyADV561 64Ch24VDC,0.1A, Common minus side every 16-channel, MIL type onlyADV851 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 outputADV159 ST3 compatible - 32Ch inputADV559 ST4 compatible - 32Ch outputADV869 ST5 compatible - 32Ch input, 32Ch outputADV169 ST6 compatible - 64Ch inputADV569 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)

IOM

IOM

IOM

IOM

IOM

IOM

Com

. C

ard

Com

. C

ard

PS

U

PS

U

Field Devices

ALF111Image of Redundant Card

0x14 0x15

ExternalPowerSupply

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 802.4Access Control : Token PassingTrans. Speed : 10 MbpsTrans. Distance : 500m to 20kmMedia : Coaxial/Optical FibreStd. max. length : 185 mMax. length : 20 Km (with optical repeater) 1.6 Km (with coax. repeater)

V net

HIS

V net : Extension Details

OpticalFibre

R

R R

RT

T

OpticalFibre

R

R R

R T

T

Max. 500m Max. 500mMax. 500mMax.

15 kmMax.

15 km

Overall Max. 20 km

Co-axial CableV net

HIS HISHIS

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 CS3000system

Bus Convertor

HF BUS

EFCD FCS

HIS

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BCV

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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

Various windows can be accessed by selecting

the respective icons in theSystem Message Area

These windows can also be accessed by the keys on the Operator Keyboard

SYSTEM MESSAGE AREA ICONS

System Message Area

Operation KeyboardOperation KeyboardOPERATION 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

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

Operation Windows

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 “= “ canbe changed.

Displaying a “Tuning Window”1.Double click on a Tag’s name on a “Control Window” and a faceplate windowwill 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 Control Group Window

Control Group Window–8 Instruments

Control group windows are used to display multiple instrument faceplates.

Maximum 8 or 16 instrument faceplatescan 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 toControl Group Window

.

Control Group Window – 16 Instruments

Trend Window


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.


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 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.


Navigator Window

HUMAN INTERFACE STATIONHUMAN INTERFACE STATION

Virtual test Function

SYSTEM GENERATION

FUNCTION

OPERATION

&

MONITORING

FUNCTION

CONTROL FUNCTION

TEST

FUNCTION

SFCS

Page 77

Thank you

Business

DCS PRESENTATION