Basic LoopControllerI/PTransmitter I/P ConvertorPVMVSV4-20 mA4-20 mAPneumatic Signal(0.2 to 1 Kg/cm2 or 3 to 15 psi)Final Control ElementBasic Control Loop

Process Control SystemsProcess control systems are classified into

Analog Control Systems

Digital Control Systems

Analog Control SystemSignal ConversionI/P4-20 mA DC1 to 5V DCOperational AmplifierSet PointFinal Control ElementTransmitterAnalog Control System

Digital Control System

* 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 IndustriesDTL SSI TTL.SSILSI uPEnergy crisis(Transition tosteady growth)Demand forconservationof resourcesAppearance of OA, LA and FA(Improved man-machine interfaceV 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* Use of factory management computers

Digital Control SystemDigital Control Systems are further classified into

Centralized Control Systems

Distributed Control Systems

Centralized Processing Unit CPUCentralized Control SystemInput Signals from FieldSet PointsOutputSignals to FieldCentralized Control , Centralized MonitoringPV1PV2PVnPV3MV1MV2MVnMV3SV1SV2SV3SVnCentralized Control System

Centralized Control SystemDrawbacks 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 SystemInput Signals from Field Distributed Control Centralized MonitoringSet PointsCommunication BusOutput Signals to FieldMV1MV8

FCSPV1PV8SV1SV8MV9MV16

FCSPV9PV16SV9SV16MV17MVn

FCSPV17PVnSV17SVn

OPS

OPSDistributed Control System

Basic Components of DCSFCS (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 DCSControl 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) Evolution1st CENTUM2nd CENTUM CENTUM VCENTUM-XLCENTUM CSCENTUM CS3000197519811984198819931998CENTUM has developed as a true open system.World First DCS2008CENTUM VP

CS3000-System Configuration

CENTUM CS 3000 - Major ComponentsFCS (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 - NetworksV-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-OverviewGSGWV netPLCFCJ/FCNEthernetPROFIBUS-DPV1Discrete I/ODriveDeviceNetPhotoelectricdeviceOPC ServerFFCSEthernetSafety SystemOther System

FIOFIO 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.

Power supply unitCP401 CPU moduleEight FIO slotsEC401 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 unitFFCS Hardware View

Hardware Configuration- Local NodeFIO: Max. 8Local node Max. 3ESB busUp to 6 ModulesUp to 8ModulesV netFFCSEC401EC401FFCSMinimum Configuration Maximum Configuration

Hardware ConfigurationRemote NodeV netFFCSRemote nodeExpanded Remote node up to 3ER busEB401EB401EB401EB401EB401EB401EB401CP401CP401PW48XPW48XRemote nodeRemote nodeOptical Repeater can be used

FIO System Specification for FFCSThe bus among FFCS and local nodes. (ESB bus)Dedicated Internal BusSpeed : 128 MbpsDistance in Total : Max. 10mRemote I/O bus (ER bus)Based on EthernetSpeed : 10 MbpsDistance 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

CPUR5432 (RISC)Memory Size32MBPower supply100/220V AC, 24V DCNo. of I/O slot8No. of I/O nodetotal 4 including CPU nodeESB bus I/FEC401/SB401Local node for ESB busUp to 4Remote node for ER busUp to 3ER bus I/FEB401/EB501AP capacityAI/AO480DI/DO1920Communication data4000 wordsGlobal SW256Common SW4000%ANN1000%PR1000%OP500%RQ200No. of control drawing sheet 200No. of function block (total with %ANN)2500Realtime trend256

Input Output Modules

Analog ModulesAnalog Modules AAI14116Ch Current input4-20mA (Transmitter power supply)AAV14116Ch Voltage input1-5VAAV14216Ch Voltage input-10V to +10VAAI8418Ch Current input/8Ch Current output 4-20mA (Transmitter power supply)AAB8418Ch Voltage input/8Ch Current output 1-5V input/4-20mA outputAAV54216Ch Voltage output -10V to +10VAAP14916CH Pulse Count 0 to 6kHz (Pulse Input Module Pm1 Compatible)

AAI14316Ch Current input 4-20mA (Transmitter power supply)AAI54316Ch Current output 4-20mAAAV14416Ch Voltage Input -10V to +10VAAV54416Ch Voltage Output -10V to +10VAAT14116Ch mV,TC inputJIS R,J,K,E,T,B,S,N / -100 to +150mVAAR18112Ch RTDJIS Pt100ohum

AAI1358Ch Current input 4-20mA (Transmitter power supply)AAI8354Ch Current input/4Ch Current output 4-20mA (Transmitter power supply)AAT14516Ch mV,TC input JIS R,J,K,E,T,B,S,N / -100 to +150mVAAR14516Ch RTD/POT input RTD JIS Pt100ohum / POT 10kohumAAP1358Ch 0-10kHz Pulse input Transmitter power supply 12V/24VDC, (Shunt resistance can be selected)

Analog Modules with HARTFIO HART Module LineupsAAI135-H:8 input, channel isolatedAAI835-H:4 input/4 output, channel isolatedAAI141-H:16 input, non-isolatedAAI841-H:8 input / 8 output, non-isolatedAAI143-H:16 input, IsolatedAAI543-H:16 output, IsolatedASI133-H:8 input, IS moduleASI533-H:8 output, IS module

HART Module dataAnalog Data4 to 20 mA from Device

HART Variable DataHART device supports Max 4 HART VariablePVPrimary ValueSVSecondary ValueTVThird ValueFV(4V)Fourth ValueHART Module supports Max 32 HART Variable data

Digital I/O Modules

ADV15132Ch24VDC input, Common minus side every 16-channelADV15732Ch24VDC input, Common minus side every 16-channel, Single and Weidmueller onlyADV16164Ch24VDC input, Common minus side every 16-channel, MIL type onlyADV55132Ch24VDC,0.1A, Common minus side every 16-channel ADV55732Ch24VDC,0.1A, Common minus side every 16-channel, Single and Weidmueller onlyADV56164Ch24VDC,0.1A, Common minus side every 16-channel, MIL type onlyADV85116ch Input/16ch Output, 24VDC

ADV14116Ch100VAC input, Common minus side every 8-channel ADV14216Ch220VAC input, Common minus side every 8-channel

ADR54116Ch 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.

ADV859ST2 compatible -16Ch input,16Ch outputADV159ST3 compatible - 32Ch inputADV559ST4 compatible - 32Ch outputADV869ST5 compatible - 32Ch input, 32Ch outputADV169ST6 compatible - 64Ch inputADV569ST7 compatible - 64Ch output

Communication ModulesSerial Communication ModuleALR111RS232C2 ports, 1200bps to 115.2k bpsALR121RS422/RS4852 ports, 1200bps to 115.2k bps

Ethernet Communication ModuleALE111Ethernet CommunicationInstallable both on Local and Remote Node

Subsystem Packages ListRS Communication (ALR111/ALR121)YS CommunicationYS Directly CommunicationFA-M3ModbusSLC500/PLC5MELSEC

Ethernet Communication (ALE111)FA-M3ModbusSLC500/PLC5Control LogixMELSEC

Foundation Fieldbus Module (ALF111)FF-H1 interface cardRedundancyInstallable both on Local and Remote nodesVCR (Virtual Communications Relationship): 105 per port (one segment)Both pressure clamp and terminal board are available.Link Master

Redundant Fieldbus Module (ALF111)Field DevicesALF111Image of Redundant Card0x140x15ExternalPowerSupply

HIS (Human Interface Station) The Station for Real time Plant Monitoring/Operation

Types of HISDESKTOP 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 ProcessorMain Memory: 256 MB (Minimum)Hard Disk : 20 GB or moreVideo Display: 1024 x 768 or more, 256 coloursCRT Monitor: Multi Scan 17 monitor or largerSerial Port: RS232C one port or moreParallel Port : One port or moreExtension Slot: PCI slot for V/VL net card, ISA slot for Ethernet cardPower Supply: 200-240V ACBasic Software: Windows NT with Service Pack ,Windows 2000 or Windows XP

CONSOLE HISThe 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 HISMaximum 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 CommunicationProtocol: 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)

HIS

V net : Extension DetailsOpticalFibreOpticalFibreMax. 500mMax. 500mMax. 500mMax.15 kmMax.15 kmOverall Max. 20 kmCo-axial CableV netHISHISHIS

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 CS3000system

Operation Windows Information regarding the process is gathered as well as monitored by the following Standard Operation windows on the HIS.Tuning WindowControl Group WindowTrend WindowProcess Alarm WindowOperator guide Message WindowGraphic WindowOverview Window Process Report WindowHistorical Report Window

System Message WindowThese buttons are provided for calling various functional windows on the HISType the TAGNAME to call the instrument faceplate windowSystem Message Window

System Message AreaVarious windows can be accessed by selecting the respective icons in theSystem Message AreaThese windows can also be accessed by the keys on the Operator Keyboard

SYSTEM MESSAGE AREA ICONS

Operation KeyboardOperation KeyboardOPERATION KEYBOARDAll the operations can be performed with the help of the Operation Keyboard. The sameoperations can also be performed by touch functions available on the System Message Area Icons.Operation Keyboard

Operation Windows

Instrument Faceplate Window

Tuning Window

Tuning Window

Tuning Window

Control Drawing DisplaySelect this icon to call the Control Drawing displayControl drawing displayControl Drawing Display

Control Group Window

Control Group Window8 InstrumentsControl 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

Trend WindowTREND 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

Calling Instrument from Trend Window

Process Alarm Window

Process Alarm WindowPROCESS 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 alarmThis icon displays the important tags (High Priority Alarms) that are in alarm.This icon is used to acknowledge the process alarms.

Operator Guide Message WindowSelect this icon to call the Operator Guide Message WindowOPERATOR 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 WindowSelect this icon to display the Tool boxSelect this icon to display the Overview Window

Overview Window

Overview Window

Process Report Window

Historical Message Report Window

Sequence Tables

Sequence Tables

Logic Charts

Logic Charts

System Status Window

System Alarm WindowSYSTEM ALARM WINDOW displays the latest 200 system alarms.

Alarms can be acknowledged either as a Group or as Individual alarm.

Navigator Window

HUMAN INTERFACE STATIONVirtual test Function

Page *Thank you

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 1960s. 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. Yokogawas 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 1970s... 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 componentsThe abnormality of one component does not affect the functionality of othersEasy creation of regulatory and sequence control loops using computersOperators can easily monitor and handle multiple plant datas 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 type2. 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 units7. V-net (Co-axial multidrop) - Links FCS, HIS, BCV, CGW8. 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 enhancementFIO Modules line up PROFIBUS-DPV1 and DeviceNet Interface.New Controller is FFCSFFCS is FIO based small size controller.

GSGW (Global Subsystem GateWay)GSGW is Subsystem Gateway Interface.*