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

Process Control Systems
 Process control systems are classified
into

 Analog Control Systems

 Digital Control Systems

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

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
 THE NINETIES BEYOND
THE SIXTIES THE SEVENTIES 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
 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
Digital Control System
 Digital Control Systems are further
classified into

 Centralized Control Systems

 Distributed Control Systems

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
PVn MVn
Field CPU Field

SV1 SV2 SV3 SVn

Set Points
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.
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
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

CENTUM VP 2008
CENTUM-XL
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.

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
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-Overview
Ethernet

V net

GSGW
Subsystem
Gateway

Ethernet

o oo
OPC
Server
PROFIBUS-DPV1

FFCS
DeviceNet Safety
FCJ/FCN
System
Photoelectric Other
Discrete I/O Drive
device System
PLC
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.
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.
Hardware Configuration- Local Node
V net

FFCS FFCS

EC401
CP401

EC401
CP401

CP401
CP401
PW48X
PW48X

PW48X
PW48X
Up to 6
Modules ESB bus
FIO: Max. 8

SB401
SB401
PW48X
PW48X
Minimum Configuration
Up to 8
Modules

SB401
SB401
PW48X
PW48X
Local node
Max. 3

SB401
SB401
PW48X
PW48X
Maximum Configuration
Hardware Configuration–Remote Node
V net

EB401

EB401

CP401
CP401
EB401
EB401

EB401
EB401

PW48X
PW48X
FFCS

Optical Repeater can be used

Remote node Remote node Remote node ER bus

EB501
EB501

EB501
EB501

EB501
EB501
PW48X
PW48X

PW48X
PW48X

PW48X
PW48X
Expanded Remote node up to 3
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

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

Input Output Modules
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)
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 Value
 SV Secondary Value
 TV Third Value
 FV(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-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
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)

Image of Redundant Card

ALF111

M Card
IO Card

PSU
IOM

IOM

PS
U
Com.
Com.
IO

IO

IO
External

M
Power
Supply
0x14 0x15

Field Devices
 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.

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 : 200-240VAC
 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

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)
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
 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
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
System Message Window

These buttons are provided for Type the TAGNAME to call the
calling various functional windows instrument faceplate window
on the HIS
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
Operation Keyboard

Oper at ion Keyboa

OPERATION
O pera tionKEYBOARD
Keyboa rd
rd

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 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
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 “= “ 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”.
Tuning Window
Control Drawing Display

Control Drawing Display

Select this icon to

call the Control
Drawing display

Control drawing display

Control Group Window

Select this icon to display

the Tool box

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 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

.
Control Group Window – 16 Instruments
Trend Window

Select this icon to display

the Tool box

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

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.
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.
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 Tool box

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.

Alarms can be acknowledged either as a

Group or as Individual alarm.
Navigator Window
Virtual test Function

TEST SYSTEM GENERATION

FUNCTION FUNCTION

OPERATION
&
MONITORING
FUNCTION

CONTROL FUNCTION

SFCS

HUMAN INTERFACE STATION

Thank you

Page 77