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1 YOKOGAWATE33Q4T30-01E
Analog Control / Digital Control
PID unit
Controller
DeviationProcess variableMVSV +
–
PV
PIDPROCESS
(including control valve )
Sensor andTransmitter
Controller
MVSV +
–
PV
Numerical Data
CPU D/A &hold
A/D
PROCESS(including control
valve )
Sensor andTransmitter
Analog ControlIn analog control, PID computation is carried out with an electric current or voltage by a hardware. It is very hard to change the control algorithm.High accuracy computations used for the advanced control are also difficult.
Analog Control
Digital ControlIn digital control, PID computation is carried out by a software. It is easy to change the control algorithm.High accuracy computations used for the advanced control are also easy.
Digital Control
Process variableDeviation
2 YOKOGAWATE33Q4T30-01E
Centralized Control System
Operator Station(monitoring and logging)
A/D I/OBuffer
MPXINPUT UNIT
MV
PV
SV SV SV
CPU(Computer)
Alarm Report
D/AI/OBuffer
MPXOUTPUT UNIT
SPC (Setpoint Control)Then the computer was used for setting optimum setpoints on individual controllers.
DDC (Direct Digital Control)And then a single computer is used to executes control computations for controlling multiple control loops.
LoggerAt the initial stage, a computer was used as a logger only for the monitoring and logging.
SPC (Setpoint Control)
3 YOKOGAWATE33Q4T30-01E
Distributed Control System (1)
I/O Image
Communication module
Output moduleInput module
Analog outputAnalog input
Isolator
CPU Data/Communicationprocessing
V/Iconversion
D/A conversion
CPU Data/Communicationprocessing
A/D conversion
Signal conversion
Isolator
The concept of I/O processing of the distributed control system.
Each signal conversion module in the node (I/O processing unit) has a CPU.
I/O signal processing is distributed.
Node
4 YOKOGAWATE33Q4T30-01E
Distributed Control System (2)
Control Network
Plant A
Distributed control and centralized operation & monitoring
CPU
Field Control Station
I/O
CPU
Plant B Utility
I/O Image
I/O Image
Node
CPU
Field Control Station
I/O
CPU
I/O Image
I/O Image
Node
Field Control Station
CPU
I/O
FCU FCU
CPU
FCU
I/O Image
I/O Image
Node
The concept of computation processing of the distributed control system.
Independent control stations for each plant.
Control processing is distributed.
5 YOKOGAWATE33Q4T30-01E
CENTUM CS Lineup
• CENTUM CS 3000 R3CENTUM CS 3000 R3DCS based on Windows for large-scale factories DCS based on Windows for large-scale factories The new production control system of Yokogawa. The CENTUM CS 3000 R3 features The new production control system of Yokogawa. The CENTUM CS 3000 R3 features sophisticated functions and components to meet all production state requirements.sophisticated functions and components to meet all production state requirements.
• CENTUM CS 1000 R3CENTUM CS 1000 R3DCS based on Windows for small- and medium-scale factories DCS based on Windows for small- and medium-scale factories The CENTUM CS 1000 R3 has the same architecture as CS 3000. It is specifically The CENTUM CS 1000 R3 has the same architecture as CS 3000. It is specifically designed for the requirements for the middle and small scale plants. designed for the requirements for the middle and small scale plants.
• CENTUM CSCENTUM CSDCS based on UNIX for large-scale factories DCS based on UNIX for large-scale factories The CENTUM CS was put on market in 1993. Since then, the CENTUM CS proudly The CENTUM CS was put on market in 1993. Since then, the CENTUM CS proudly keeps its overwhelming high reliability. keeps its overwhelming high reliability.
6 YOKOGAWATE33Q4T30-01E
History of DCS
Development of digital control technology and Yokogawa’s DCS.
7 YOKOGAWATE33Q4T30-01E
Position of DCS
OrderProduction plan
Production management
Production Production systemsystem
Customer management
Process control management
Production equipment
Total information system in manufacturing.Total information system in manufacturing.
Order reception
Demand prediction
Business Business systemsystem
DCS(Production control system)
8 YOKOGAWATE33Q4T30-01E
Concepts of Modern DCS
Open information network
Operator/work station ( Open environment )
Real-time control network
Advanced control station
Field bus
9 YOKOGAWATE33Q4T30-01E
CENTUM CS Configuration
TIC101
PID
FIC101
PID
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FCS FCS (Control station)(Control station)
HIS HIS (Operator station)(Operator station)
I/O operations to and from the field, control computation and so on are executed by FCS.
The interface functions of operation and monitoring are executed by HIS.
V-netV-net (Communication bus)(Communication bus)
Real-time control network
10 YOKOGAWATE33Q4T30-01E
CS and Single Loop Controller
V net
YS100Single loopcontroller
Inpu
t con
vers
ion
Out
put c
onve
rsio
n
Computation
HIS
Input processing(A/D conversion)
Output processing(D/A conversion)
Control computationTI
C00
1
TIC
002
TIC
003
TIC
004
TIC
001
TIC
002
TIC
003
TIC
004
TIC
001
TIC
002
TIC
003
TIC
004
I/O modules
ESB or RIO bus I/O images
FCS
Node
FCU (Field Control Unit)
11 YOKOGAWATE33Q4T30-01E
Signal Flow in CS (Example)
TIC100
PID
Process variable PVEngineering data
Ex. 350 ºC
A/D
-5.9 – 48.8mVAnalog data
I/O images
Internal RIO/ESB bus communication
Field device connection(Hard-wiring)
FIC100
PID
-200 – 1200 ºCDigital data
Engineering dataEx. 6.5 M3/M SETOUT
Process variable PVEngineering data
Ex. 5.2 M3/M
Terminal connection(Soft-wiring)
OUT
IN
IN
A/D D/A
4 - 20mAAnalog data
4 - 20mAAnalog data
0 – 100 %Digital data
-200 – 1200 ºC Type K TC
0 - 10.0 M3/M
-200 – 1200 ºCDigital data
0 – 100 % Digital data
0 – 100%Digital data
0 – 100%Digital data
I/O (PIO) connection(Soft-wiring)
Measuring range is set by each function block.
12 YOKOGAWATE33Q4T30-01E
System Function Concept
SubsystemSubsystem(PLC, DARWIN etc)(PLC, DARWIN etc)
Production Management (MES*, PIM**)Production Management (MES*, PIM**)
Field Devices (Production Plant)Field Devices (Production Plant)
CENTUM CS1000/CS3000CENTUM CS1000/CS3000
*MES:Manufacturing Execution System
**PIM:Plant Information Management
Process I/O,Subsystem I/O,Fieldbus I/O etc.
Ethernet communication
*Can be executed by HIS.
Operation & MonitoringOperation & MonitoringFunction (HIS)Function (HIS)
V-net/VL-net communication
Control Function (FCS)Control Function (FCS)
Engineering Function* (ENG)Engineering Function* (ENG)
13 YOKOGAWATE33Q4T30-01E
System Configuration (CS1000)
VL-net
Desktop type HISEthernet(Optional)
Console type HIS
No. of monitoring tags: 8,000No. of stations: 24No. of domain: 1No. of HIS: Max. 8VL-net extension: 185 m*
Compact type PFCS
* Extension length is for 10Base2 cable.
14 YOKOGAWATE33Q4T30-01E
System Configuration (CS3000 small)
V-net
Ethernet
CGW
Communication gateway unit
BCV
Bus Converter
No. of monitoring tags: 8,000No. of stations: 256No. of domains: 16No. of stations per domain: 64No. of HIS: Max. 16V-net extension: 500m*
Desktop type HISConsole type HIS
Compact type FFCS-S(for FIO)
* Extension length is for 10Base5 cable.
Supervisory computer
CS3000 in another domain
or XL/μXL
The BCV connects the stations on the V/VL-net on another domain. Other non-V net systems manufactured by Yokogawa may be connected via BCV.
Out of the system
15 YOKOGAWATE33Q4T30-01E
System Configuration (CS3000)
V-net
Ethernet
BCV
Bus converter
(Sub-system)
ooo
ooo
CGW
Console type HIS Desktop type HIS
No. of monitoring tags: 100,000(Expandable up to 1,000,000)No. of stations: 256No. of domains: 16No. of stations per domain: 64No. of HIS per domain: Max. 16No. of HIS per network: Max. 64V-net extension: 500m*
Compact Type SFCS
Standard FCS (for RIO)
Standard FCS (for FIO)
* Extension length is for 10Base5 cable.
Supervisory computer
Communication gateway unit
CS3000 in another domain
or XL/μXL
Out of the system
16 YOKOGAWATE33Q4T30-01E
Engineering Environment in TC
VL net
FCS 0101(PFCS)
Ethernet
HIS 0124 HIS 0123
Left-hand side HIS is HIS0124, which has an engineering database. (Use Reactor A control system.)
Engineering data
HIS0124 should be activated before HIS0123.
Right-hand side HIS is HIS0123, which has no engineering database. HIS0123 shares the database with HIS0124. (Use Reactor B control system.)
17 YOKOGAWATE33Q4T30-01E
Sub-system Integration
The subsystem communication function enables CENTUM to use the data of PLC’s, recorders, measuring systems as the data from process I/O.
OPC* Server
Subsystem
Desktop type HIS Ethernet
Subsystem
Subsystem communication network
Subsystem communication network
Subsystem communication
module
Compact Type FCS
V-net
General-purpose PC
General-purpose subsystem gateway
GSGW(OPC client)
* OPC: OLE for Process Control
18 YOKOGAWATE33Q4T30-01E
Remote Desktop Function
V-net
HIS LAN
Operation and monitoring by remote PC
Internet / Internet / IntranetIntranet
LFCS KFCS
ooo The remote desktop function of Windows XP Professional enables to use the functions of CENTUM CS 3000 from the remote location. By logging on the host machine from a client machine, the client machine can execute operation and monitoring or builder functions. It is also possible to log on the host machine via internet.
PC
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