Dcs presentation

3. Basic Control Loop
Basic Loop
SV
Transmitter PV MV
4-20 mA Controller
I/P 4-20 mA
I/P
Convertor
Pneumatic Signal
(0.2 to 1 Kg/cm2 or 3 to 15 psi)
Final Control Element

4. Process Control Systems
 Process control systems are classified
into
 Analog Control Systems
 Digital Control Systems

5. Analog Control System
Analog Control System
Operational Amplifier
Transmitter
1 to 5V DC
Signal
Conversion
4-20 mA DC
I/P
Set Point
Final Control Element

6. Digital Control
System
Digital Control System
Memory
Unit
1 to 5V DC Control
Unit Set
A/D Input Point
Unit
4-20 mA DC Digital
Output Arithmetic
D/A Unit Unit
I/P
Processor

7. THE SEVENTIES THE NINETIES BEYOND
THE SIXTIES THE EIGHTIES
2000
* First control * First DDC * First mini * First distributed * First one-loop * Integrated systems * multimedia
computers computers DDC using DDC controllers
microprocessors * windows NT gaining prominence
* Use of factory
Ge.Tr Sl. Tr management * Internet
DTL SSI
Rapid growth of computers
TTL.SSI LSI uP
process Industries * Pentium Processor
Demand for V LSI 32bit UP
Energy crisis
conservation Appearance of * Multi produce batch
(Transition to
of resources OA, LA and FA applications * Revolution in info tech
steady growth)
(Improved man- * Integrated FA system
machine interface * CIM * Object linking
* ODBC
* RDBMS

8. THE SIXTIES THE SEVENTIES THE NINETIES BEYOND
THE EIGHTIES
2000
Factory Management Computer System
YEWCOM 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
CS
YS 100
CS1000
CS3000
Analog Control System
ECS EBS I SERIES

9. Digital Control System
 Digital Control Systems are further
classified into
 Centralized Control Systems
 Distributed Control Systems

10. Centralized Control System
Centralized Control System
Centralized Control , Centralized Monitoring
PV1 MV1
Centralized
Input PV2 MV2 Output
Processing
Signals PV3 MV3 Signals
from Unit to
Field PVn
CPU MVn
Field
SV1 SV2 SV3 SVn
Set Points

11. 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.

12. Distributed Control System
Distributed Control System
Distributed Control Centralized Monitoring
PV1 MV1
FCS Output OPS
PV8 MV8
Input SV1 SV8 Signals
Signals PV9 MV9 to Field
from
FCS OPS
Field PV16 MV16
SV9 SV16
PV17 MV17
Communication
FCS Bus
PVn MVn
SV17 SVn
Set Points

13. 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

14. 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.

15. CENTUM Series (DCS) Evolution
CENTUM-XL CENTUM VP 2008
CENTUM CS3000
1998
2nd CENTUM 1993 CENTUM CS
1988
1981 1984 CENTUM V
World First DCS
1975
1st CENTUM
CENTUM has developed as a true open system.

16. CS3000-System Configuration
Ethernet
Remote Domain System
HIS / ENG
HI
S
CGW
V net
BCV
CS, CS 1000
PFCS CENTUM-XL, -V
ooo
MXL
LFCS
KFCS
FFCS

17. 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.

18. 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

19. CS3000 FIO System Configuration-Overview
Ethernet
V net
GSGW
Subsystem
Gateway
Ethernet
o oo
OPC
Server
PROFIBUS-DPV1
FFC
S
DeviceNet Safety
FCJ/FC
System
N
Photoelectric Other
Discrete I/O Drive
device System
PLC

20. FIO
 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.

21. FFCS Hardware View
Eight FIO slots
Detachable
bottom unit
EC401 ESB bus coupler Power supply unit
(Note)
CP401 CPU module
AIP504 Vnet coupler (10BASE2 Vnet cable is used.)
Note: Two I/O slots are to be used for NIU extension.

22. Hardware Configuration- Local Node
V net
FFC FFC
S S
EC40
EC40
CP40
CP40
CP40
CP40
PW48
PW48
PW48
PW48
1
1
1
1
1
1
X
X
X
X
Up to 6
Modules ESB bus
FIO: Max. 8
SB40
SB40
PW48
PW48
1
1
X
X
Minimum Configuration
Up to 8
Modules
SB40
SB40
PW48
PW48
Local node
1
1
X
X
Max. 3
SB40
SB40
PW48
PW48
Maximum Configuration
1
1
X
X

23. Hardware Configuration–Remote Node
V net
CP40
EB40
EB40
EB40
EB40
EB40
EB40
CP40
PW48
PW48
1
1
1
1
1
1
1
1
FFC
X
X
S
Optical Repeater can be used
Remote node Remote node Remote node ER bus
EB50
EB50
EB50
EB50
EB50
EB50
PW48
PW48
PW48
PW48
PW48
PW48
1
1
1
1
1
1
X
X
X
X
X
X
Expanded Remote node up to
3

24. 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.

25. Pair & Spare CPU Concept

26. FFCS Specification
CPU R5432 (RISC)
Memory Size 32MB
Power supply 100/220V AC, 24V DC
No. of I/O slot 8
total 4 including CPU
No. of I/O node
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
AI/AO 480
DI/DO 1920
Communication data 4000 words
Global SW 256
Common SW 4000
%ANN 1000
AP capacity %PR 1000
%OP 500
%RQ 200
No. of control drawing sheet 200
No. of function block (total with
2500
%ANN)
Realtime trend 256

27. Input Output Modules

28. 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)

29. 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

30. 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

31. 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

32. 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

33. 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

34. 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

35. Redundant Fieldbus Module (ALF111)
Image of Redundant Card
ALF111
Com. Card
Com. Card
PSU
PSU
IOM
IOM
IOM
IOM
IOM
IOM
External
Power
Supply
0x14 0x15
Field Devices

36. HIS (Human Interface Station)
 The Station for Real time Plant Monitoring/Operation
Plant Operation by thousands of Graphics
Real time display of Plant Abnormalities.
Easy Operation by a mouse, a keyboard etc.

37. 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.

38. 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.

39. V net Communication
HIS
V net
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)

40. V net : Extension Details
HIS HIS HIS
Optical Optical
V net Fibre Fibre Co-axial Cable
T R R R R T
T R R R R T
Max. Max.
Max. 500m 15 km Max. 500m 15 km Max. 500m
Overall Max. 20 km

41. Bus Convertor
ETHERNET
EOPS HIS
Domain
connection
HF BUS V-NET
BCV
EFCD FCS
ooo ooo ooo
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

42. 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

43. System Message Window
System Message Window
These buttons are provided for Type the TAGNAME to call
calling various functional the instrument faceplate
windows on the HIS window

44. System Message Area
SYSTEM MESSAGE AREA ICONS
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

45. Operation Keyboard
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.

46. 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

47. Instrument Faceplate Window

48. Tuning Window
Select this icon to display
the Tool box
Select this icon to display
the Tuning Window

49. 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”.

50. Tuning Window

51. Control Drawing Display
Control Drawing Display
Select this icon to
call the Control
Drawing display
Control drawing display

52. Control Group Window
Select this icon to display
the Tool box
Select this icon to display
the Control Group
Window

53. 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
.

54. Control Group Window – 16 Instruments

55. Trend Window
Select this icon to display
the Tool box
Select this icon to display
the Trend Window

56. 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

57. Trend Group Window

58. Trend Point Window
Double click here
to call the Trend
Point Window
Trend Point
Window

59. Calling Instrument from Trend Window
Double click here
to call the
Instrument
faceplate
Window
Instrument
Faceplate
Window.
Instrument can
be operated from
this window.

60. Process Alarm Window
Select this icon to call the
Process Alarm Window
PROCESS ALARM WINDOW displays the
latest 200 process alarms.
Alarms can be acknowledged either as a
Group or as Individual alarm.

61. Process Alarm Window
This icon displays the current
PV Values of the instruments
that are in alarm
This icon is used to acknowledge This icon displays the important
the process alarms. tags (High Priority Alarms) that
are in alarm.
PROCESS ALARM WINDOW displays the
latest 200 process alarms.
Alarms can be acknowledged either as a
Group or as Individual alarm.

62. 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.

63. Graphic Window

64. Overview Window
Select this icon to display
the Tool box
Select this icon to display
the Overview Window

65. 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

66. Overview Window

67. Process Report Window

68. Historical Message Report Window

69. Sequence Tables

70. Sequence Tables

71. Logic Charts

72. Logic Charts

73. System Status Window

74. System Alarm Window
SYSTEM ALARM WINDOW displays the
latest 200 system alarms.
Alarms can be acknowledged either as a
Group or as Individual alarm.

75. Navigator Window

76. Virtual test Function
TEST SYSTEM GENERATION
FUNCTION FUNCTION
OPERATION
&
MONITORING
FUNCTION
CONTROL FUNCTION
SFCS
HUMAN INTERFACE STATION

77. Thank you
Page 77