Professional Documents
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YOKOGAWA
Yokogawa Electric Corporation 2-9-32 Nakacho, Musashino-shi Tokyo, 180-8750 JAPAN
TRAINING CENTRE
Basic Loop
Transmitter
SV PV MV
4-20 mA
Controller
4-20 mA
Pneumatic Signal
(0.2 to 1 Kg/cm2 or 3 to 15 psi)
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4-20 mA DC
I/P
Set Point
Set Point
I/P
Arithmetic Unit
Processor
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PV2 PV3
MV2 MV3
PVn
CPU
MVn
SVn
Set Points
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Centralized Control System Drawbacks Of CCS: If the CPU fails the entire plant gets affected. Redundancy concept was 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.
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Centralized Monitoring
FCS
MV8 SV 8 MV9
OPS
FCS
MV16 SV16 MV17
OPS
PVn SV17
FCS
MVn SVn
Communication Bus
Set Points
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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
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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.
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DCS Evolution
CENTUM was released in 1975 as the world-first DCS (Distributed Control System), and has been progressed. CENTUM CS 3000 is the latest Yokogawa DCS.
From 98 (1458 Systems) CENTUM CS From 93 (2113 Systems) CENTUM-XL From 88 to 00 (1703 Systems) CENTUM/CENTUM V From 75 to 93 (1983 Systems)
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As of March 03
CGW V net
BCV
PFCS
ooo
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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.
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FFCS
EC401 EC401 CP401 CP401 PW48X PW48X
Up to 6 Modules
SB401 SB401 PW48X PW48X PW48X PW48X
ESB bus
Up to 8 Modules
SB401 SB401 PW48X
SB401 SB401
Maximum Configuration
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PW48X
Remote node
ER bus
EB501 EB501 PW48X PW48X
HIS (Human Interface Station) The Station for Real time Plant Monitoring/Operation
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.
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Application Capacity of HIS Maximum number of tags that can be monitored from HIS : 1000000 Maximum number of windows that can be created per HIS : 4000 Maximum number of Trend Recording Points per HIS : 2304
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V net Communication
HIS
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)
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HIS
HIS
HIS
V net
T T
Optical Fibre
R R R R
Optical Fibre
R R R R
Co-axial Cable
T T
Max. 500m
Max. 15 km
Max. 500m
Max. 15 km
Max. 500m
Overall Max. 20 km
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Bus Convertor
EOPS ETHERNET HIS
HF BUS
V-NET
Domain connection
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
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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
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These buttons are provided for calling various functional windows on the HIS
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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
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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.
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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
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Tuning Window
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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 Tags 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.
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Tuning Window
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Mode Status
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Manual Mode
MANUAL MODE: In manual mode, the MV pointer appears in red colour and the SV pointer appears in yellow colour. MV of the instrument can be changed by increment/decrement keys or through data entry box. The SV of the instrument can be changed either by set point change key or using ITEM and DATA in the data entry box.
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Auto Mode
AUTO MODE: In auto mode, the SV pointer appears in red colour and the MV pointer appears in yellow colour. SV of the instrument c a n b e c h a n g e d b y increment/decrement keys or through data entry box. The MV of the instrument cannot be changed by any method.
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Cascade Mode
CASCADE MODE: In a cascade loop the output of the primary controller (MV1) goes as set point of the secondary controller (SV2). The output of the secondary controller (MV2) goes to the final control element. For a cascade loop, the primary controller can be in AUT or MAN mode, but the secondary controller has to be in CAS mode. In cascade mode both the SV and MV pointers appear in yellow colour. The SV and MV of the instrument cannot be changed.
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PRD: PRIMARY DIRECT MODE In a normal cascade loop the output of the primary controller (MV1) goes as set point of the secondary controller (SV2). The output of the secondary controller (MV2) goes to the final control element. In PRD mode the output of the primary controller (MV1) directly goes to the final control element. The secondary controller is bypassed and cannot be operated.
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To select PRD mode: Go to the tuning window of the Secondary controller. Select PRD Icon. Confirm. To select CASCADE mode: Change the mode status of the secondary controller to CAS.
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IMAN (INITIALIZATION MANUAL MODE) In a cascade loop, if the cascade is broken by taking the secondary controller from CAS to either AUT or MAN mode, IMAN appears as the mode sub status of the primary controller. IMAN indicates that
Cascade loop is broken Primary controller is bypassed Primary controller cannot be operated due to SV tracking.
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SV Tracking
SV tracking: The output of the primary controller (MV1) automatically tracks the set point of the secondary controller (SV2) to have bumpless transfer to CAS mode. To bring the primary controller out of IMAN mode Change the mode status of the secondary controller to CAS. The primary controller will automatically c o m e o u t o f I M A N mode.
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Clamped Positive
CLP+ (CLAMPED POSITIVE) In auto mode, if MV of the instrument is increased beyond MH value, MV gets clamped at the MH value and C appears on the instrument faceplate . MHI alarm also appears on the instrument as well as in the Process Alarm Window.
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Clamped Negative
CLP- (CLAMPED NEGATIVE) In auto mode, if MV of the instrument is decreased below ML value, MV gets clamped at the ML value and C appears on the instrument faceplate. MLO alarm also appears on the instrument as well as in the Process Alarm Window.
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HH
PV > HH
HH
RED
RED
----------
HI
PV > PH
PH
RED
RED
----------
LL
PV < LL
LL
RED
RED
----------
LO
PV < PL
PL
RED
RED
----------
DV+ / -
YELLOW
YELLOW
VEL + / -
YELLOW
YELLOW
IOP + / -
RED
RED
OOP
OUTPUT OPEN
RED
RED
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MLO
MV LOW
MV < ML
ML
YELLOW
YELLOW
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To put the instrument to AOF mode: Go to the tuning window of the instrument. Select AOF icon. Confirm. To bring the instrument back to normal mode: Go to the tuning window of the instrument. Select AOF icon once again. Confirm.
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CAL (Calibration)
When an instrument is put in CAL mode CAL appears on the instrument faceplate. The PV bar changes to cyan colour. The Instrument automatically comes to MAN mode. The actual transmitter input is bypassed. PV of the instrument can be changed. All the alarms checking on the instrument are bypassed.
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To put an instrument in to CAL mode: Go to the tuning window of the instrument. Select CAL icon. Confirm. To bring the instrument back to normal mode: Go to the tuning window of the instrument. Select CAL icon once again. Confirm.
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Importance Level
Importance level is assigned to an instrument when it is created in the engineering builder. There are 8 importance levels. 1 Important tag with confirmation 5 Important tag without confirmation 2 - General tag without confirmation 6 - General tag with confirmation 3 - Auxillary tag I without Confirmation 7 - Auxillary tag I with Confirmation 4 - Auxillary tag II without Confirmation 8 - Auxillary tag II with Confirmation
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Security Level
Security level is assigned to an instrument when it is created in the engineering builder. There are 8 security levels. Tuning Parameters are displayed with = or : depending on the security level. Parameters displayed with = can be changed in the current key position. Parameters displayed with : cannot be changed in the current key position.
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Security Level
KEY POSITION/ MONITORING OPERATION
ACCESS LEVEL
FACEPLATE DISPLAY
OPERATIONS
OFF
ON
ENG
OFF
ON
ENG
1 2 3 4 5 6 7 8
O O O O O X X X
O O O O O O X X
O O O O O O O X
O *1 *2 X X X X X
O O O O X X X X
O O O O X O X X
O : Can be executed X : Cannot be executed *1 : Only the PV alarm settings, SV, MV and block mode can be changed * 2 : Only the SV, MV and block mode can be changed
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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
.
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Trend Window
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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
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PROCESS ALARM WINDOW displays the latest 200 process alarms. Alarms can be acknowledged either as a Group or as Individual alarm.
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This icon displays the current PV Values of the instruments that are in alarm
This icon displays the important 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.
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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.
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Graphic Window
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Overview Window
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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
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Overview Window
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Sequence Tables
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Sequence Tables
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Logic Charts
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Logic Charts
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SYSTEM ALARM WINDOW displays the latest 100 system alarms. Alarms can be acknowledged either as a Group or as Individual alarm.
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Navigator Window
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Digital Inputs
System Code : %ZnnusccSddss %Z - Process Input/Output nn - node number u s - I/O unit number - Slot number S - Station dd - Domain number ss - Station number
cc - Channel number Digital Inputs are contact inputs from field to CS3000. Digital Inputs are used to indicate the i) ON / OFF status of pumps, motors, heaters, etc. ii) OPEN / CLOSE status of on-off valves. Digital Inputs are used only as a condition signal in the Sequence Table. They cannot be used as an action signal in Sequence Table.
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PV = 0 DI = 0
CLOSE Contact is open in field
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Digital Outputs
System Code : %ZnnusccSddss %Z - Process Input/Output nn - node number u s - I/O unit number - Slot number S - Station dd - Domain number ss - Station number
cc - Channel number Digital Outputs are contact outputs from CS3000 to field. Digital Outputs are used to i) Switch ON / OFF pumps, motors, heaters etc ii) OPEN / CLOSE on-off Valves. Digital Outputs can be used as condition signals or as action signals in sequence table. If Digital Output is specified as Latched i.e. H, it has to be made ON on a particular condition and has to be made OFF on another condition
Proprietary info goes here
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PV=1 DO=1
Output relay is energised
ON
Condition
OFF PV = 0
TAGNO.PV.ON CO1
N Y
Y Y Y N
ON PV = 1
TAGNO.PV.L
Action
Y Y Y N
TAGNO.PV.H TAGNO.PV.P
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R-1
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Switches
Switches are classified into Global switches and Common Switches.
Global Switches are common to all FCS. The status of global switches are transmitted to other FCS through link transmission. Hence they can be set and referred in any FCS. Common Switches are used to within the FCS. They are specific to each FCS.
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Global Switches Max.256 GS/FCS System Code: %GSxxxxSddss %GSxxxx - Switch number (0001 - 0256)
dd ss - Domain number - Station number
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Common Switches Max.4000 SW/FCS System Code: %SWxxxxSddss %SWxxxx - Switch number (0001 - 4000)
dd ss - Domain number - Station number
Switches are used to store intermediate variables in the interlocks. Switches are internal flags that can be set and reset whenever required. Switches are used for auto / man selection, pump selection, speed selection, bypass selection etc.. Switches No. 1 - 200 are used by the system. Hence the user can use switches from 201 - 4000.
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Switches Syntax
TAGNO.PV.ON CO1 Action TAGNO.PV. L TAGNO.PV.H TAGNO.PV.P
Y
Condition
Y Y Y
BYPASSSW
N- PV=0 PV=1
BYPASS PV=1, SW=ON
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Timer
Timer Operation 1. When the timer is started, PV starts incrementing automatically Alarm status is NR 2. When the timer has finished timing, i.e. when PV = PH Alarm status is CTUP 3. When the timer is stopped while timing status is STOP 4. When the timer is paused while timing PAUS 5. When the DV < DL Alarm Status is
Any of the alarm status can be referred in sequence table as a condition signal.
90
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Counter Used to count internal events or external pulses. Counter PV updates by one every time the counter is started INT - Internal counter Counter types P - Pulse counter Max.9999 Counts
Counter operation is same as timer except that pause option is not available.
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Operator Guide Messages Operator Guide Messages are used to guide the operator regarding the current process status and/or the actions to be taken. Operator Guide messages are also activated through sequence table on a specific condition. Operator Guide messages appear on operator guide message panel. System Code: %OGXXXX
Condition
CO1 Y
Action
%OGXXXX.PV.NON
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Message Annunciator messages are user defined alarms. Annunciator messages are also activated through sequence table on a specific condition. Annunciator messages appear on Alarm Summary Panel. System Code: %ANxxxxSddssaa
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Sequence Instruments Sequence instruments (or) status input output instruments are used to i) Switch ON/OFF motors, pumps, heater etc.. ii) OPEN / CLOSE on-off valves iii) Indicate the ON/OFF status of motors, pumps, heaters etc. iv) Indicate the OPEN/CLOSE status of on-off valves.
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Model SO-1
One DO is linked with the instrument.
Loop Connection
Condition C01 Y
Tag No.
OPEN
MV = 2 DO = ON
SO - 1
OUT
C02
TAGNO.CSV.2
Y Y
Wiring
TAGNO.CSV.0
CLOSE
MV = 0 DO = OFF
DOTAGNO.PV
(OR) %Znnuscc
PIO
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Model SO-2
Two DOs are linked with the instrument.
Loop Connection
Condition C01
Tag No.
OPEN
MV = 2 DO1 = ON
SO - 2
OUT
SI0 Model
Action TAGNO.CSV.0
Y Y Y
Wiring
TAGNO.CSV.1 TAGNO.CSV.2
DOTAGNO.PV
(OR) %Znnuscc
PIO
CLOSE
MV = 0 DO2 = ON This DO number and the next consecutive DO number will be taken as the 2 output signals automatically.
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Model SI-1
One DI is linked to the instrument.
Condition
Tag No.
OPEN
PV = 2 DI = ON
TAGNO.PV.2 TAGNO.PV.0
Y Y
SI - 1
IN
Action
CLOSE
PV = 0 DI = OFF
DITAGNO.PV
(OR)
PIO
%Znnuscc
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Model SI-2
Two DIs are linked to the instrument.
Tag No.
OPEN
PV = 2 DI1 = ON
Condition TAGNO.PV.0 Y Y Y
SI - 2
IN
TAGNO.PV.1 TAGNO.PV.2
TRAVERSE
Action
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Model SIO-11
1 DI and 1 DO is linked to the instrument.
Output Signal MV = 2 DO = ON Answerback Signal PV = 2 DI = ON
Tag No.
IN
Condition
START
SI0 - 11
OUT
Action
Y Y Y Y Y Y Y Y
STOP
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Model SIO-21
2 DIs and 1 DO are linked to the instrument.
Condition MV = 2 DO = ON PV = 2 DI1 = ON TAGNO.PV.2 TAGNO.PV.1 TAGNO.PV.0 Y Y Y
OPEN
Action
Y Y Y Y
TRAVERSE
DITAGNO.PV DOTAGNO.PV
PV = 0 DI2 = ON MV = 0 DO = OFF
First DI No. will be taken as the first answerback signal. Next DI No. will be taken as the second answerback signal.
CLOSE
<ISD-MASP-S03054> Yokogawa Electric Corporation Copyright by Yokogawa Electric Corporation <March 2, 2009>
Model SIO-12
1 DI and 2 DOs
Condition
MV = 2 DO1 = 0N
PV = 2 DI = ON
FORWARD
TAGNO.PV.0 TAGNO.PV.2
Y Y
IN
OUT
DITAGNO.PV
DOTAGNO.PV
PV = 0 DI = OFF MV = 0 DO2 = ON
REVERSE
First DO No. will be taken as the first output signal. Next DO No. will be taken as the second output signal.
<ISD-MASP-S03054> Yokogawa Electric Corporation Copyright by Yokogawa Electric Corporation <March 2, 2009>
Model SIO-22
2 DIs and 2 DOs
Condition
MV = 2 DOI = ON PUMP 1 PV = 2 DI1 = ON
Y Y Y
IN
OUT
Y Y Y Y Y
DITAGNO.PV
DOTAGNO.PV
MV = 0 DO2 = ON
First DI No.
PV = 0 DI2 = ON PUMP 2
First DO No.
<ISD-MASP-S03054> Yokogawa Electric Corporation Copyright by Yokogawa Electric Corporation <March 2, 2009>
Sequence Tables Interlocks are written in the form of sequence table. Each S.T. has 32 conditions, 32 actions and 32 rules. General Rules: Actions will be performed only if all the conditions in the rule are satisfied. Even if one condition is not satisfied, actions will not be performed. Condition Signal: Y/N Colour: Red: Condition is true (satisfied) Cyan: Condition is false (not satisfied)
<ISD-MASP-S03054> Yokogawa Electric Corporation Copyright by Yokogawa Electric Corporation <March 2, 2009>
Sequence Tables
1 2 3 4 32
Conditions
C01 C02 | |
C32
Actions
A01 A02 | |
Band Colour : Red : All the conditions in the rule are satisfied. Green : All the conditions in the rule are not satisfied.
A32
<ISD-MASP-S03054> Yokogawa Electric Corporation Copyright by Yokogawa Electric Corporation <March 2, 2009>
SFCS
HUMAN INTERFACE STATION
Proprietary info goes here
<ISD-MASP-S03054> Yokogawa Electric Corporation Copyright by Yokogawa Electric Corporation <March 2, 2009>
<ISD-MASP-S03054> Yokogawa Electric Corporation Copyright by Yokogawa Electric Corporation <March 2, 2009>