Introduction of DCS System

Solutions Service Business Headquarters

Global Engineering Business Division
Productivity Enhancement Center Group 1

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 1. Overall DCS system configuration(1/1)
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CENTUM VP has a simple & common architecture consisting of human machine

interfaces, field control stations, and a control network.
Business domain
ENG/HIS
Exaquantum
Internal Ethernet

Previous CENTUM
domains(*1)
ENG/HIS HIS SENG Exaopc
WAC
Router
WAC Vnet
Bus-2 Router AVR
Vnet/IP
Bus-1
UGS FCS FCS SCS
N-IO

*1 There are some kinds of BCV. It connects between V net and Yokogawa conventional control network -
such as V net, VL net,HF-bus, and RL-bus.

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CENTUM VP has a simple & common architecture consisting of human machine

interfaces called human interface station (HIS), field control stations (FCS),
and a control network.
These three basic components support facilities from the tiny to very large and
complex with up to 1,000,000 tags.
Amount of Tags=Σ(PJT-A+B+C)
Project-A Domain-1

Project-B Domain-2 Project-C Domain-3

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★The Design Concept of CENTUM VP System Configuration

CENTUM VP is designed based on the concept to keep the plant operation availability
high.
(1).FCS concept
-1. Self-independent Controller
CENTUM VP’s FCSs are designed to work without HIS.
The fundamental controls can be done only by the FCSs

-2.The hardware availability of FCS

MTBF/(MTBF+MTTR)=99.99999% (Seven-Nine)

-3.Reliability,Continuity and Maintainability

Fault-avoidance :Not causing failures easily
Fault-tolerant :To continue controlling the plant even it fails
Maintainability :To recover from failures as quickly as possible

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(2).HIS concept
-1. A stand-alone HMI
- No server-client configuration
-2.Various types of the operation views
- Graphic, Trend graph, Overview, Tuning etc
-3.Calling up necessary information quickly
- One-touch operation for related information
-4.Avoiding human mistakes
- No direct Tag operation

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★CENTUM VP Components
 Human Interface Station (HIS)
CENTUM VP uses a PC for its human machine interface. It is called HIS when the
software packages for control and monitoring functions are installed there.
The desk top type and a console type with assembled displays are selectable.
 Engineering Station (ENG)
ENG is a PC used for system configuration and maintenance. A single PC can be used
for both HIS and ENG functions.
The engineering functions can be realized by applying the engineering related software.
 Human Interface Station/Engineering Station (ENG/HIS)
Human Interface Station (HIS) + Engineering Station (ENG) live together in one“PC”.

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 Field Control Station (FCS)

FCS is a high reliability controller.
FCS hardware can be selectable.
a cabinet type or a rack-mountable type.

It consists of a field control unit (FCU) and node units to mount

input/output modules. It enables to configure a scalable system by
connecting several node units in a FCS in accordance with the I/O
points.

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 Safety Instrumented System (ProSafe-RS)

This is Yokogawa’s TÜV SIL3 certified premier safety instrumented system. It
incorporates Yokogawa’s own Pair and Spare and Vnet/IP technologies and offers
unprecedented synergy with CENTUM VP.
-1. Safety Control Station (SCS)
SCS is a Yokogawa manufactured safety controller that executes logics for systems
including interlock, emergency shutdown and fire and gas protection.
-2.Safety Engineering Station (SENG)
An off-the-shelf PC that performs SCS generation and maintenance management.
Basically, there is no Human Interface Station for SIS.

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 Generic Subsystem Gateway (GSGW)

GSGW is a station for operation and monitoring subsystems. By using a PC as a platform,
it establishes subsystem communications via OPC DA(*1) interface defined by the OPC
Foundation.
Subsystem data is assigned to the GSGW’s function blocks to be controlled and
monitored via HIS in the same manners as other control stations.
*1: Open Product Connectivity, Data Access

 System Integration OPC Station (SIOS)

SIOS is a station to integrate CENTUM VP and the third-party process control systems
(PCSs).
It enables CENTUM VP to exchange data with and receives alarms and events from the
third-party PCS via OPC interface.

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 Unified Gateway Station (UGS)

-1.UGS is one of the components of CENTUM VP system which integrates distributed
data of different kinds of controllers into CENTUM VP system.

-2. Controller protocols supported by UGS

STARDOM FCN/FCJ
Modbus (TCP and RTU)
OPC DA & AE
Ethernet/IP controller
IEC61850 IED

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 Communication Gateway Unit (CGW)

CGW connects V net system and a supervisory computer via Ethernet.

 Bus Converter (BCV)

BCV relays CENTUM VP communications with other CENTUM VP and older CENTUM
systems such as CENTUM CS 3000, CENTUM CS 1000, CENTUM CS, CENTUM-XL,
CENTUM V, and μXL.

 V net Router (AVR)

AVR connects and transmits control communications between the Vnet/IP and V net
domains.
The control data can be sent and received in both ways between the Vnet/IP and V net
domains.
It enables control and monitoring of the control stations among other domains.

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Internal Ethernet Domain-10

System Domain
ENG/HIS HIS CENTUM VP 10
CS3000 2
Bus-2

Bus-1
Vnet/IP CENTUM CS 1
FCS
Supervisory computer Domain-2
Internal Ethernet

Domain-1
HIS CGW
ICS
AVR PICS-ENG
Bus-2

Bus-1
Vnet(10Base-5)
FCS BCV (Vnet-Vnet convertor)
Bus-2

Bus-1

FCS

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“ As a result of Yokogawa’s high R&D investment and the

consistent long term migration policy of the CENTUM DCS 2008 2011
family our investment are secure ” CENTUM VP [Release 5]

2001 2005
CENTUM CS 3000 R3 HIS
1998 ENG
1Gbps
CENTUM CS 3000
1993 Vnet/IP
Dual
Redundant
10 MBPS CENTUM CS HIS HIS
Dual ICS ENG AVR
Redundant
EWS PICS
Token Pass
V net FFCS-L FFCS-V

1983 1988
1MBPS CENTUM V CENTUM-XL ABC PFCS
Dual FFCS
COPS2 ENGS
Redundant LFCS KFCS
EOPS
Token Pass COPSV
HF-Bus

1975
CENTUM
CFCS2 CFCD2 EFCS EFCD
COPS CFFS • Full Lifecycle Support for Customers’ Legacy Systems
F-Bus
250 KBPS
Dual
The migration path for each legacy system is always
Redundant
Token Pass
taken into consideration before a new system is released
CFCS CFCD

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 Wide Area Communication Router(WAC)

-1.Realize control and monitoring among remote Vnet/IP domains through WAN lines
・Available for long distance connection
・Available for using WAN lines (public network, satellite connections, etc.)

-2.High reliable and dedicated to Vnet/IP network

・High reliable devices with redundant CPU, power, etc.
・Available for redundant wide area communication
・Availability of back up connection with different route

Satellite

Local Remote
domain
WAC WAC domain

Fiber optic
HIS FCS
Wide area network line

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 Advanced Process Control Station (APCS)

APCS performs advanced control and computation functions for improving plant
operation efficiencies which means users can develop instruments which CENTUM VP
Standard controllers don’t supply.
 Network-based Control System (STARDOM)
Yokogawa’s intelligent-hybrid remote telecommunication controllers are ideal for the oil
and gas upstream market.
They can be seamlessly integrated, via the UGS, to CENTUM VP.
- Autonomous Controller (FCN/FCJ)
These controllers utilize the global Standard IEC 61131-3 as the engineering tool.
- Versatile Data Server Software (ASTMAC VDS)
VDS is a SCADA software which uses Web browser (Internet Explorer) for HMI display.

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 OPC Interface Package (Exaopc)

Exaopc provides an OPC (Open Product Connectivity) interface bridge between the
control room and the outside world. Exaopc is an OPC server running on a Microsoft
Windows platform which can be connected to a variety of PCSs (Process Control
Systems) providing OPC clients with process data and alarm events.
 Plant Information Management System (Exaquantum)
Exaquantum is a Plant Information Management System (PIMS) product that provides
business benefits to users in the Hydrocarbons, Chemicals, Power & Utilities, Pulp &
Paper and many other industries.

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 Operation Efficiency Improvement Package (Exapilot)

Exapilot is an operating efficiency improvement support package aimed at automating
the tasks manually performed by operators such as unsteady state operations, steady
state operations, or abnormal situation operations in a plant.
Exapilot makes it easy to create semi-automatic sequences that incorporate the know-
how of skilled operators, and thus greatly reduce manual operation.

Exapilot Operation Main Window

Exapilot runs on a general PC or it coexists
on a human interface station (HIS) of
the CENTUM production control system.

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 Event Analysis Package (Exaplog)

The Exaplog Event Analysis Package is designed to provide managers, engineers and
supervising operators with tools to analyze the historical plant operation record file of
a DCS, so that the production process can be improved.
It can generate trend graphs for quantitative analysis.
PLView (Event Analysis Tool)

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 Plant Resource Manager (PRM)

The Plant Resource Manager (PRM) for the fieldbus era efficiently handles field device
management and maintenance work. FF Communication Card
(ALF111)
Vnet/IP
ENG/HIS
FCS
L2SW
L2SW
AKB336
Fieldbus Power Hub,
Motherboard
(MB-FB-4R.YO)
24VDC
Segment Protector
(R1-SP-N12)

Spur Cable
Trunk Cable Fieldbus Power Hub,
Motherboard
(HD2-FBPS-1.500)

DVC600f YTA EJA

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 Layer 2 Switch (L2SW)

L2SW relays communications among devices connected to the Vnet/IP network. The
Vnet/IP domain refers to the Vnet/IP system area connected by L2SW.
Use L2SW with 1 Gbps communication speed in the Vnet/IP domain.
 Layer 3 Switch (L3SW)
L3SW relays communications among Vnet/IP domains. Use L3SW with 1 Gbps
communication speed.

The above L2SW and L3SW are resale materials which means the original supplier is
“HIRSCHMANN”.
Yokogawa certified Buyout equipment for Vnet/IP and Recommends L2SW/L3SW.
Please refer to the following TI for more details.
Network Switch for Vnet/IP
TI 30A10A30-01E

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 3.Overview of CENTUM VP HIS(1/3)
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CENTUM VP introduces a new human interface station (HIS) that let operators to access
information more easily, quickly and intuitively. The HIS inherited the excellent operation
methods from traditional CENTUM series, and moreover, it adopts an ergonomic design
for effective operating and monitoring environments.

Figure Example of HIS Window

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Operation and Monitoring Functions

Figure Operation and Monitoring Functions

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Please refer to the following TI for more details.

Technical Information
Integrated Production Control System
CENTUM VP
System Overview (HMI Overview)
TI 33K01A11-50E

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In other words, Engineering is customizing the plant due to our client requirement.
CENTUM VP enables providing such an engineering to make it easier.
CENTUM VP Engineering Functions
1.COMMON

PJT Name

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1.COMMON

Builder Name Execution File

CAMS for HIS Alarm Builder CAMSAlm
CAMS for HIS Alarm Group Builder CAMSAlmgrp
CAMS for HIS Shelf Builder CAMSShelf
CAMS for HIS Message Monitor CAMSMsgMonitor
Definition Builder
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1.COMMON

The status transition matrix determines transition action for unit mode/status change
commands and the actions.

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2.HIS

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2.HIS

Graphic Control Group Trend

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3.FCS

AAV542-S
AAI141-S
FFCS-V

Slot No. 1 6

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3.FCS

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3.FCS

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3.FCS

OPEN
DR0001 Menu of function
blocks

Build a new
function block

IO definition

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3.FCS

Basic Control functions are contained in a ‘Function Block’

– Almost 200 types of function blocks are available
– Regulatory Control blocks, Sequence Control Blocks, Arithmetic blocks, etc.
– Any function block type can work in a controller at the same time
– Control logics are generated by the combination of function blocks

The processing of all the function blocks are executed periodically

– The processing period can be specified for each function block
• 1-sec, 500-msec, 250-msec, 100-msec and 50-msec can be selected

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3.FCS Function Block Types

PVI BLEND SI-1 BAND OPSBL SI-1E
Control Function Capacity PVI-DV FF-AI SI-2 BOR OPSFC SI-2E
Capacity of one Controller (FFCS-V) PID FF-DI SO-1 BNOT OPSFCP1 SO-1E
PI-HLD FF-CS SO-2 CALCU OPSFCP2 SO-2E
Category Item Max. PID-BSW FF-PID SIO-11 CALCU-C OPSFCP3 SIO-11E
Analog 1,760 ONOFF FF-RA SIO-12 SW-33 OPSFCP4 SIO-12E
Process IO ONOFF-G FF-AO SIO-21 SW-91 OPSFCP5 SIO-21E
Digital (On/Off) 4,096 ONOFF-E FF-DO SIO-22 DSW-16 ONOFF-E SIO-22E
Elements 18,000 ONOFF-GE FF-OS SIO-12P DSW-16C ONOFF-GE SIO-12PE
Tag Names PID-TP FF-SC SIO-22P DSET MC-2E SIO-22PE
Function blocks 7,000 PD-MR FF-IT TM DSET-PVI MC-3E
Control drawings 500 PI-BLEND FF-IS CTS BDSET-1L SI-1E
PID-STC FF-MDI CTP BDSET-1C SI-2E
Message Outputs Annunciator messages 2,000 MLD FF-MDO CI BDSET-2L SO-1E
Operator guide messages 2,000 MLD-PVI FF-MAI CO BDSET-2C SO-2E
MLD-SW FF-MAO RL BDA-L SIO-11E
Common switches 9,000 MC-2 FF-SUNV RS BDA-C SIO-12E
Internal switches
Global Switches 256 MC-3 SLCD VLVM INDST2 SIO-21E
RATIO SLPC LC64 INDST2S SIO-22E
PG-L13 SLMC ALM-R INDST3 SIO-12PE
BSETU-2 SMST-111 L_ST16E BSI SIO-22PE
BSETU-3 SMST-121 M_ST16E PBS5C VPM64
Signal SMRT ST16E PBS10C VPM128
SS-H/M/L SBSD L-ST16 Hybrid VPM256
AS-H/M/L SLCC M_ST16 _UTSW VPM512
SS-DUAL SLBC ST16 _UTPB VPM64A
FOUT STLD ADD _UTAS VPM128A
FFSUM _SFCSW MUL _UTSW-N VPM256A
XCPL _SFCPB DIV _UTPB-N VPM512A
SPLIT _SFCAS AVE _UTAS-N FSBSET
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From previous page

Communication Devices
1. CGW,BCV,AVR

2. Communication devices
with data from controllers in a subsystem
Generic Subsystem Gateway Reference (GSGW)
System Integration OPC Station Reference (SIOS)
Unified Gateway Station Reference (UGS)

*2:CENTUM VP supports the following subsystem communications.

• FA-M3 communication (for Yokogawa’s FA-M3 and FA500)
• DARWIN/DAQSTATION communication (for Yokogawa’s DARWIN and DAQSTATION)
• MELSEC communication (for Mitsubishi general-purpose MELSEC sequencers)
• MELSEC-A communication (for Mitsubishi general-purpose MELSEC-A sequencers)
• PLC-5/SLC 500 communication (for Rockwell Automation’s PLC-5/SLC 500 family of
programmable controllers)
• Modbus communication (for Yokogawa’s STARDOM, Schneider’s Modicon and Yasukawa
Electric Corporation’s Memocon-SC)
• YS communication (for Yokogawa’s YS100 SERIES and YEWSERIES 80)
• YS communication with direct connection (for Yokogawa’s YS100 SERIES)
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How to do our DCS engineering is described in the following documents.

No. Title figure number HIS FCS Communication Device

1 Field Control Stations Reference IM 33K03E10-50E 〇 〇 〇
2 Function Blocks Overview IM 33K03E21-50E 〇
3 Function Blocks Reference Vol.1 IM 33K03E22-50E 〇
4 Function Blocks Reference Vol.2 IM 33K03E23-50E 〇
5 Function Blocks Reference Vol.3 IM 33K03E24-50E 〇
6 Human Interface Stations Reference Vol.1 IM 33K03F21-50E 〇
7 Human Interface Stations Reference Vol.2 IM 33K03F22-50E 〇
8 Engineering Reference Vol.1 IM 33K03G21-50E 〇 〇 〇
9 Engineering Reference Vol.2 IM 33K03G22-50E 〇 〇 〇
10 Engineering Reference Vol.3 IM 33K03G23-50E 〇 〇 〇
11 Batch Management System Reference IM 33K03J10-50E 〇
12 SEBOL Reference IM 33K03K10-50E 〇
13 Communication with Subsystems Using RIO IM 33K03L10-50E 〇
14 Communication with Subsystems Using FIO IM 33K03L20-50E 〇
15 Communication Devices Reference IM 33K03M10-50E 〇
16 Communication with PROFIBUS Systems IM 33K03P10-50E 〇
17 Generic Subsystem Gateway Reference IM 33K03R10-50E 〇
18 System Integration OPC Station Reference IM 33K03R20-50E 〇
19 Unified Gateway Station Reference IM 33K03R30-50E 〇
20 FOUNDATION fieldbus Reference IM 33K20T10-50E 〇
21 FOUNDATION fieldbus Engineering Guide IM 33K20T20-50E 〇

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The following engineering is out of scope in CENTUM VP Engineering Station (ENG).

 Safety Instrumented System (ProSafe-RS)

 Advanced Process Control Station (APCS)
 Network-based Control System (STARDOM)
- Autonomous Controller (FCN/FCJ)
- Versatile Data Server Software (ASTMAC VDS)

They must be done in other platform Engineering Stations.

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High availability process controller

– Seven 9’s (99.9999959) hardware availability
– Pair & Spare technology for
higher control loop availability (Please see next page)

Large capacity Controller

– One controller handles 1,760 analog signals and 4,096 digital signals
– Various field digital protocols can be handled
• Foundation Fieldbus, ISA100, PROFIBUS, EtherNet/IP, HART, etc
Please see next next page
– Up to 13 extra I/O racks
– Up to 50km distance remote I/O rack
Various types of control functions are prepared
– Regulatory Control blocks, Sequence Control Blocks, Arithmetic blocks, etc
– 7,000 functions work on a controller

Self-Independent controller
– All the control application runs in the highly reliable controller hardware

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Pair & Spare CPU Architecture

Both CPU modules are processing independently allowing CENTUM to
achieve a real faultless switchover (For Redundancy purposes)

Vnet/IP A pair of CPU chips is on

each CPU module
– Each CPU is processing
independently
Vnet/IP I/F Vnet/IP I/F
•This is not
Comparator

Comparator
CPU module CPU module
CPU 1 CPU 1 for redundancy purposes
Main Main
memory memory
with with Result checking
ECC CPU 2 CPU 2 ECC
– Processed results of
PIO I/F PIO I/F CPUs are every time
PIO I/F PIO I/F compared each other
– If the results are not
Power card IO bus IO bus
Power card congruous, control
I/F I/F
switches to the stand-by
Coupler Coupler module
(To avoid the effect
I/O bus of transient errors)
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 Digital Field networks ALE111 Ethernet Communications

(Various field digital protocols ) Module
•EtherNet/IP (CIP) MW100
ALP121 PROFIBUS-DP •Modbus TCP
•PLC-5/SLC500
Module
• Redundant Configuration is available PLC-5

CIP Control Logix

PROFIBUS-DP
Linking Device SLC500

ALF111 Foundation Fieldbus

Module DeviceNet
• World’s First Dual-Redundant Fieldbus Ports
• 4 Ports per ALF111
• 31 Devices per Port
• 1,500 Fieldbus faceplate blocks per FCS

Modbus/TCP
Foundation Fieldbus HART
4-20mA
I/O

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Online Maintenance
Through an online maintenance function, FCS applications can be modified without
shutting down the FCSs. It means, you can change logics and parameters without
interrupting the process control. This is useful for expansion or modification of the plant
in operation.

Open Structure and High Reliability

Yokogawa is committed to reduce costs for our customers by enabling the use of
commercial off-the-shelf technology where appropriate. Third-party cables, switches and
other network communication devices can be used with Yokogawa’s Ethernet based
Vnet/IP. Plant reliability is in no way compromised as the communication response is
guaranteed (deterministic as opposed to probabilistic) thanks to Yokogawa’s renowned
reliability, dedicated protocol, and redundant configuration.

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2. Hardware
FCS Type: CENTUM VP supports the following FCS.

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Please refer to the following TI for more details.

Technical Information
Integrated Production Control System
CENTUM VP
System Overview (FCS Overview)
TI 33K01A11-50E

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Thank you very much for taking
your time with us.

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Copyright © Yokogawa Electric Corporation - 43 -
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