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Control Loop

Heat Exchanger Process

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Recording Instrumentation
Circular Chart Recorder

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Controllers
DisplacerType Local Level Controller

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Control Valves

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Analog Instrumentation Loop

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The Digital Instrument Loop

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Smart Transmitters

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Functional Diagram of a Smart Transmitter

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Simple Proportional Control

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Moment Balance Pneumatic Proportional Controller

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Controller Output vs. Process Variable

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Proportional Plus Reset Controller

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Rate Contribution to Controller Output

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Proportional Plus Reset Plus Rate Controller

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Manual Feedforward Control

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Feedforward Model

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Feedforward Control with Feedback Trim

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Feedforward of a Level Process

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Temperature Control Loop

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Feedback Control Loop

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Typical Process Supply and Demand

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Simple Feedback Loop

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Response to Supply Upsets

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Simple Cascade Control Loop

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Relative Loop Performance to Supply Upsets

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Basic Ratio Process

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Typical Split-Range Control Loop

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Direct and Reverse Acting Valves

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Auto-Select Cut Back Control

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Multiple use of an End Device

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Interlocks

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Pneumatic Shutdown

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Local Control Loop

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Analog Field Panel

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DCS System Consoles

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Digital Control Screen

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Digital Controller Display

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Distributed and Logic Control


Analog Control System

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Distributed Control System with Data Highway

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DCS System

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Graphic Display

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Digital Controller Display

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Trend Display

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Inputs / Outputs of a Typical PLC

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Connection of a PLC Programmer to a PLC

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Electrical Schematic Symbols.

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Ladder Logic Diagram

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Simplified SCADA System

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Integrated Production Control System

~ A new system of CENTUM CS family ~

Control Execution
ERP (Enterprise Resource Planning)
Production Planning

Asset Management

BUSINESS DOMAIN

MES (Manufacturing Execution System)


Scheduling Maintenance Management Operation Assistance Modeling Simulation

CONTROL DOMAIN
Optimization Advanced Control

Safety Management

Control Execution

Field Communication Sensors, Actuators, Analyzers, ... Subsystems

Open System Architecture


To Internet Enterprise Resource Planning Training System & Simulation
ICS Computer FCS Simulation

Production Information Management Management System & Scheduling


WS/PC WS/PC

Process Model

APS

Ethernet Local Area Network and Wide Area Network


Optical Fiber

HIS

HIS

LIMS

V net
Analytical Instruments Optical Fiber

V net FCS
ENG HIS ENG PC

Controller

Controller

Laboratory

RIO

Engineering Environment Plant A Plant B

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Open Architecture

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Sub-systems Integration
Advanced Control

Major Features of CS3000

Easy Expansion & Scaling

High Reliability

User Friendly HMI

Single Window

Efficient Engineering

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Why NT ? 1 -Time requires NT

Computer technology waves on control systems


UNIX Micro processor

NT and Microsoft

Distributed object

Agent

V 1st CENTUM

XL

CS

CS 3000

time

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Functional superiority to UNIX


- NT is only one (diverse types of UNIX are present) -Low-price platform - Open technology - Diverse peripheral devices - De fact standard NT is demanded by times

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System Configuration

Basic System Configuration


HIS
HIS

V net

V net

SFCS
Discrete I/O Analog I/O NIU Subsystem NODE IOU

LFCS

Straight Forward Architecture Masterless V-Net Communication Limited no. of Spare Parts
LFCS = Standard Field Control Station SFCS = Compact Field Control Station HIS = Human Interface Station RIO = Remote I/O bus NIU = Node Interface Unit IOU = I/O Unit

RIO

Discrete I/O Analog I/O Subsystems Fieldbus

System Scale Details


Min. Configuration
Max. Domain Configuration

Tag Number : 16-character


Max. System Configuration

Max. No. of Tags : 100,000 per HIS Max. No. of Stations : 64 Total Length of V-net : 500 m or 20 km Max. Length of RIO bus : 20 km per Max. No. of Domains LFCS

: 100,000 per HIS : 256 : 500 m or 20 km : 20 km per LFCS

: 16

Networking
APC Router Printer HIS Console Type HIS HIS

Ethernet Ethernet
ENG for Builder

Redundant V net

LFCS

SFCS

V net: high performance process data transfer Ethernet (Internal System Bus): file server network Sharing of external devices Sharing of trend / graphic and OPC Server Ethernet: Standard Interface with Computer Systems

Domain Hierarchy
Frame mode Computer Gateway Unit ACG
ISDN

HIS
HIS

Domain 1 BCV BCV

Public Line ACG


HIS LFCS

LFCS HIS LFCS

SFCS

Domain 4

SFCS

Integration of Remote Locations Domain 3 Provides High Capacity Integration of existing DCS

Domain 2

Console Type HIS

System Buses
V net

V net: Protocol : IEEE 802.4 Access Control : Token Passing Trans. Speed : 10 Mbps

LFCS
RIO bus

Remote I/O bus: Communication Polling Trans. Speed Mbps

: :2

System Buses : Extension Details


T T

HIS

HIS

HIS

V net

Optical
R R R R

Optical
R R R T

Co-axial Cable
R T

500m

15 km

500m

15 km

500m

LFCS

750m RIO bus

15 km
R R R R

750m

15 km
R R R R

750m
Twisted Pair

Optical

Optical

Maximum length of V net = 20 Km Maximum length of RIO Bus= 20 Km

NIU

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Human Interface Station


Open Industry Standards Windows-NT Ethernet (TCP/IP) Etc. Single Window Concept Process Windows Half-sized Windows 100,000 Tags Management Information Functions Data gathering & Data processing Reporting, Logging, Long Term Trending Etc..

*ALARM 01
X

88.06.29 3
Time (min.)
PEN PLOT
PRINT NOTES ZOOM VIEW TREND OPTIONS CANCEL HELP
NEW

BATCH REACTOR

100

75

50

25

850

950

1050

1150

1250

1350

1450

CLS

FIT1001

FIT1002

FIT2001

FIT2002

FIT3001

FIT3002

FIT3003

FIT3004

TUNING

(VIEWTREN.WPG)

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Operator Identification
Operator Identification by Key and/or by User Name and Password Operation Log File (Time, User Name, Batch ID etc.): Audit Trail (Log in and out) Process Alarms Operator Actions Operator Authority and Station Authority can both be active

Operation and Monitoring Windows (1) Window calling up by mouse clicking


Control Group Window

Navigator Window

Overview Window

Operation and Monitoring Windows (2)


CS3000 inherited the operation of CENTUM CS
Custom Graphic Window Trend Window

Tuning Window

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Operator Guide Window

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Operation and Monitoring Windows (3)


Process Alarm Window

Operator Guide Window 40 Message / HIS Process Alarm Window 200 Alarm / HIS

Process Report Window

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Window Operation

Multi-Window operation Call up of window without erasing current displays Effective use of monitor by half-size window All Panels can be displayed in half-size windows

Security
Check user name

User User Group Check operation Permission operation Check


and monitoring scope and monitoring authority

Function block operation and monitoring Windows operation and monitoring Receipt of messages

User in

Operation History

Tag Basis Operation Mark


Important (Major Tag Alarm) Ordinary Tag
(Medium Alarm)
PV
CONTROL 0007 PV PV PVPVPV PVPV PVPV SV SV SVSVSV SVSV SVSV FIC001

Key Access Windows NT user security

Auxiliary (Minor Tag1 Alarm) Auxiliary (Logging Tag2 Alarm)

Operation and Monitoring Area


Example of operator A1 and A2
A1 HIS30 HIS31 HIS32 A2

Example of Operator A3, A4 and A5


A3 HIS30 A4 HIS31 A5 HIS32

Monitoring Only

FCS 1

FCS 2

FCS 3

FCS 4

FCS 5

FCS 1

FCS 2

FCS 3

FCS 4

FCS 5

Each operator has their own operation and monitoring area The operation level can be defined by the security function

Web Technology in CS3000

HIS Graphic browsed by Internet Explorer 4.0

Standard Alarm Generation and Indication


Process Alarm Occurs Indication ...
Any Panel

...

Alarm Window

Alarm Summary LED

Alarm Summary

Any Panel

Overview Key

#
PF-Key LED

Overview Display

Voice Output
Printer

Historical Message File

Alarm Buzzer

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Field Control Station

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Field Control Station


Two Sizes of Field Control Stations Standard FCS Compact FCS Standard Function Blocks (PID, SFC, etc.) High Reliability & Data Integrity Pair and Spare (for LFCS) ECC Direct Connection of Subsystems Hybrid Faceplate Blocks Complex Control Strategies

RISC

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Standard Field Control Station (LFCS)


High capacity because of RISC Processor (R3000) Reduced wiring costs through Remote I/O High Reliability and Data Integrity Pair and Spare redundancy ECC Standard Function Blocks (PID, SFC, etc.) User Definable Function Blocks Direct Connection of Subsystems

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V net

LFCS Architecture

LFCS

RIO bus

Remote I/O Dual Redundant Reduction of wiring costs through Remote I/O

NIU
Analog Input/Output Contact Input/Output

YS100 PLC Foundation FieldBus, etc.

Standard FCU Chassis


Power Supplies Node Communication Cards Processor Cards Duplex

Redundant V net Couplers

Power Supply Redundant RIO Bus Couplers

I/O Modules (1)


Analog I/O Module Analog I/O Unit

Current/Voltage In mV, Thermocouple, RTD Input Pulse Input Multiplexer Module (16 pt.) Voltage Input mV Input Current/Voltage Thermocouple Input Out
RTD Input 2-wire transmitter input 4-20 mA Output

Multiplexer Unit

I/O Module (2)


Terminal Type digital I/O Module
16 -pt. Input (isolated)

Terminal Type I/O Unit

16 -pt Output (isolated)


32 -pt. Input 32 -pt. Output

Relay I/O Module


16 -pt. Input 16 -pt. Output

Relay I/O Unit

I/O Module (3)


Connector Type digital I/O Module
16 -pt. Input (isolated)

Connector Type I/O Unit

16 -pt Output (isolated)


32 -pt. Input 32 -pt. Output

Communication Module
RS-232C RS-422 RS-485

Communication Unit

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INPUT

Pair and Spare Redundancy


Guaranteed Integrity of Calculated Data Bumpless Transfer

Standby Side

BUFFER

BUFFER

CPU SYNC CPU

CPU SYNC CPU

COMP

COMP BUFFER

Independent Memory and ECC

BUFFER

OUTPUT

Integration of Subsystems

Operation
HIS HIS HIS
V net LFCS LFCS RIO bus SFCS Discrete I/O Analog I/O PLC

Control, Sequence & Interlocking

PLC

YS 100

H1 Field bus

Discrete I/O Analog I/O

Plug-in Communication Cards Various types of Protocol Drivers available

Fieldbus Communication
CONTROL ROOM
F0123 MAINTENANCE REQUIRED AL 4/10 23:04 TRCA

TDA 37.5C

HIS

Engineering HIS

23: 04
Fieldbus Device Configuration MODEL # EJ110 TAG No INSTRUMENT ID FB ID DD ID LOC DESC CONFIG PAR ID CONFIGURATION RECORD LAST CONFIGURED: LAST CALIBRATED: NEXT SCHEDULED: YOKOGAWA DP HARP F0123 YEJ94012900384 N02 AA08 DA01 YEJ110-03 BOILER 02 INLET COOLANT FLOW 1 BOIL01_COOL_ FLOW 93/02/21 SCHEDULED 93/08/02 95/08/02

FCS with ACF11 Fieldbus Communication Card

51.7C LICA

FIC 25.4

Control Drawing 41.4

FIC

LICA 36.2

Field Maintenance

Distributed Control System Network V net

FIELDBUS
FBI FBI FBI

PS
FBI

FBI

PID

Loop based Control will migrate into the field


FBI: Fieldbus Interface 111

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Engineering Functions

Engineering
Off line Engineering without Target Hardware by using Hardware Simulation Technology Off line Testing and Hardware Simulation CAE
Computer Aided Engineering
HIS ENG with Builder

On line Engineering

Concurrent Engineering

Electronic Media Input

V net

LFCS

Order

Start-up

Engineering can start direct after ordering Engineering up to Configuration Testing can be

Control Drawing
Sequence
TIC 102

Control, Sequence and Interlocking Engineering Corresponding to P&ID

X 103

FIA 100

FIC 10

Sequence Logic Diagram

PID TIC102 IN 1 CALCU X103 SV

PV T1 IN

IN 2

F1 IN

F2 IN

IN 1 CALCU FIA100 IN 2 IN 3 T2 IN

PV

PID FIC103
MV

P IN

V OUT

Modular Engineering

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Configuration Testing
Classical Method
HIS
WS

Basic Method
HIS
WS

Off line Testing


WS

Off line Testing


WS

LFCS

LFCS

Simulated I./O

Virtual Wiring

LFCS Simulator Virtual Wiring

Virtual Test LFCS Simulator I/O List Plant Simulator Phase Plan

Exatif

Complete Off Line Testing of the Configuration

REMOTE MAINTENANCE SUPPORT (RMS)


Detailed Maintenance Information Acquisition & Analyzing by Service Center Specialists Hardware and Software Revision Management Initiation of Test Programs

Remote Analysis, Support and Advise Customer Local Service Engineer Etc.