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Distributed Control System ( DCS ) An application on Yokogawa CENTUM VP
Thesis · June 2015

DOI: 10.13140/RG.2.2.34828.72327
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‫الجمهورية الجزائرية الديمقراطية الشعبية‬
People’s Democratic Republic of Algeria
‫وزارة التعليم العالي و البحث العلمي‬
Ministry of Higher Education and Scientific Research
Mohammed Khider University -Biskra-

Faculty of Sciences and Technology
Department of Electrical Engineering
Branch : Automatic
Option :Advanced Automatic
Ref:…………
A thesis submitted in partial fulfillment of

The requirements for the degree of
MASTER
Submitted by:
ACHOUR Abdeldjalil
Date submitted: 01 June 2015
Board of Examiners:
Mr. ABADA Khaled MAA Chairman
Mrs. TERKI Nadjiba MCA Member
Mr. BENELMIR Okba MCB Supervisor
Academic Year: 2014 / 2015

‫الجمهورية الجزائرية الديمقراطية الشعبية‬
People’s Democratic Republic of Algeria
‫وزارة التعليم العالي و البحث العلمي‬
Ministry of Higher Education and Scientific Research
Mohammed Khider University -Biskra-

Faculty of Sciences and Technology
Department of Electrical Engineering
Branch : Automatic
Option :Advanced Automatic
A thesis submitted in partial fulfillment of

The requirements for the degree of
MASTER
Distributed Control Systems -DCS-

An application on YOKOGAWA CENTUM VP
Submitted by: Approval of supervisor:
Student : ACHOUR Abdeldjalil Name Signature
Mr. BENELMIR Okba
Approval of chairman:
Name Signature
ABADA Khaled
Stamp and signature

Dedication
Dedication
To the Memory of my uncle and my aunt ….
This work is lovingly dedicated to my respective parents who have been my

constant source of inspiration. They have given me the drive and discipline to
tackle any task with enthusiasm and determination. Without their love and support
this project would not have been made possible.
To my dear brothers , Walid , Abderraouf , Abderahmane .
To all my family ,
To all My friends and Colleagues
ACHOUR Abdeldjalil
Page I
Acknowledgment
Acknowledgment
First, to Allah, Aza Wa Jal, I acknowledge the strength and success in writing this
work.
I would like to thank my supervisor Mr. Benelmir Okba for his insightful and
invaluable remarks as well as his boundless patience, which proved to be very
decisive for this work. Without his unflagging encouragement, enduring support and
wise advice this humble work would have never seen daylight.
Besides my supervisor, I would like to thank the rest of my dissertation committee:

Mrs. Terki Nadjiba and Mr. Abada Khaled, for their encouragement, insightful
comments, and hard questions.
I would also like to acknowledge the support and the help given me by Mr. Bahaz
Said during my training period at Hassi Messoud training center.
I take this opportunity to express gratitude to all of the Electrical Department

members for their help and support .
Last but not least , I am immensely grateful to all those who have taught and
trained me throughout my educational career.
Page II
List of tables
List of tables
Table I.1 summary of the differences between DCS and SCADA ...……………….. 18
Table II.1 I/O modules for FIO ………………………………………………………. 26
Table II.2 Some of function blocks …………………………………………………... 37
Page III
List of figures
List of figures
Fig I.1 Classical plant …………………………………………………………….. 3
Fig I.2 Pneumatic controller………………………………………………………. 4
Fig I.3 An analog control room. ………………………………………………….. 5
Fig I.4 TRW 300………………………………………………………………….. 5
Fig I.5 The IBM 1710 from 1961…………………………………………………. 6
Fig I.6 Ferranti Argus 200………………………………………………………… 7
Fig I.7 An IBM1800 minicomputer from 1964…………………………………… 7
Fig I.8 From left to right, Honeywell TDC 2000 and Yokogawa CENTUM……... 8
Fig I.9 DCS typical architecture…………………………………………………... 9
Fig I.10 Industrial communication protocols……………………………………….. 10
Fig I.11 Pyramidal architecture of DCS…………………………………………… 11
Fig I.12 Human Machine Interface…………………………………………………. 12
Fig I.13 Control Station…………………………………………………………….. 13
Fig I.14 Communication Medias…………………………………………………… 14
Fig I.15 Petroleum Process…………………………………………………………. 14
Fig I.16 System redundancy………………………………………………………... 15
Fig I.17 Honeywell DCS ; PKS EXPERION ; programming……………………… 15
Fig I.18 Typical SCADA…………………………………………………………... 17
Fig II.1 History of Yokogawa’s DCS……………………………………………… 21
Fig II.2 Centum VP typical architecture…………………………………………… 22
Fig II.3 Field Control Station (FCS) ………………………………………………. 22
Fig II.4 Processors Design…………………………………………………………. 23
Fig II.5 FCS components…………………………………………………………... 23
Fig II.6 Field Control Unit…………………………………………………………. 24
Fig II.7 Node Unit………………………………………………………………….. 24
Fig II.8 Terminal Block connector…………………………………………………. 25
Fig II.9 Vnet/IP Network Configuration…………………………………………… 27
Fig II.10 Vnet / IP specifications……………………………………………………. 27
Fig II.11 Human Interface Station features………………………………………….. 28
Fig II.12 Concurrent Engineering…………………………………………………… 29
Fig II.13 Virtual Test Function……………………………………………………… 30
Fig II.14 Target Test Function………………………………………………………. 30
Fig II.15 Display screen……………………………………………………………... 31
Fig II.16 System message banner……………………………………………………. 31
Fig II.17 Browser Bar……………………………………………………………….. 32
Fig II.18 Graphic View with Graphic Attribute…………………………………….. 33
Fig II.19 Some representative faceplates……………………………………………. 33
Fig II.20 Trend View………………………………………………………………… 34
Fig II.21 Tuning View……………………………………………………………….. 34
Page 1
List of figures
Fig II.22 The operations performed by the CPU of the control station……………... 35
Fig II.23 Control drawing using CENTUM VP…………………………………… 36
Fig III.1 On-Off Control response…………………………………………………... 41
Fig III.2 Proportional-only control………………………………………………….. 42
Fig III.3 Responses to a momentary step-and-return……………………………….. 46
Fig III.4 Responses to a multi-slope ramp………………………………………….. 47
Fig III.5 Ration control……………………………………………………………… 47
Fig III.6 Cascade control……………………………………………………………. 48
Fig III.7 Feedforward Control………………………………………………………. 48
Fig III.8 Crude oil separation unit…………………………………………………... 49
Fig III.9 Separation stages……………………………...…………………………… 50
Fig III.10 Three phases separator…………………………………………………….. 51
Fig III.11 The level controllers mounted on a separator……………………………... 51
Fig III.12 A pneumatic controller in detail………………………………………...…. 52
Fig III.13 The separation battery in simulation with CENTUM VP…………...…….. 53
Fig III.14 System view……………...………………………………………………... 54
Fig III.15 Control drawings…………………………...……………………………… 54
Fig III.16 Level control drawing……………………………………………..………. 55
Fig III.17 Pressure control drawing…………………………………………………... 55
Fig III.18 Creating a function block…………………………………………………. 55
Fig III.19 Graphic builder……………………………………………………………. 56
Fig III.20 Alarm level………..………………………………………………………. 57
Fig III.21 Instrument faceplate and tuning…………………………………………… 57
Fig III.22 Tuning results……………………………………………...………………. 58
Page 2
List of Abbreviations
List of abbreviations
A/D Analog to Digital
BMS Burner management system
CPU Central Processing Unit
CRT Cathode Ray Tube
DCS Distributed Control System
DDC Direct Digital Control
ERB Enhanced Remote bus
ESB Extended Serial Backboard bus
ESD Emergency Shut Down
F&G Fire and Gas
FAT Factory Acceptance Tests
FCS Field Control Station
FCU Field Control Unit
FIO Field Network I/O
HART Highway Addressable Remote Transducer
HIS Human Interface Station
HKU House Keeping Unit
HMI Human Machine Interface
HP/MP High/Medium Pressure
I/O Input / Output
ICI Imperial Chemical Industries
IP Internet Protocol
IT Information Technology
LAN Local Area Network
LCD Liquid Crystal Display
LIC Level Indicator Controller
LSP Lower Set Point
MIL Military
MTBF Mean Time Between Failures
MTU Master Terminal Unit
NIU Node Interface Unit
OPC Open Platform Communications
P&ID Piping and Instrumentation Diagram
PC Personal Computer
PIC Pressure Indicator Controller
PID Proportional Integral Derivative
PLC Programmable Logic Controller
PRM Plant Resource Manager
Page VI
List of Abbreviations
RISC Reduced Instruction Set Computer

RTU Remote Terminal Unit
SCADA Supervisory Control and Data Acquisition
SDV Shut Down Valve
TRW Thomson Ramo Wolridge
TS Terminal Service
UDP User Datagram Protocol
UGS Universal Gateway Station
USP Upper Set Point
Page VII
Abstract
Abstract
Process plant automation has evolved from pneumatics to electronics to distributed control
systems. Use of DCS leads to various advantages like the overall optimization, ease of operation
and maintenance tasks, easy monitoring of more plant parameters and ensure tighter control on
them. The main intent of this work is to highlight the salient features of the present DCS used in
the process industry and the working of it; with a focus on the new generation of YOKOGAWA,
the CENTUM VP. This work also deals with a case study to give a clear view of this system.
Résumé
L’automatisation des processus industrielle a évolué à partir du pneumatique à l'électronique

et enfin vers les systèmes de contrôle distribuées. L'utilisation du DCS conduit à des divers
avantages comme l'optimisation globale, la facilité des tâches d'exploitation et d'entretien, la
surveillance aisée de plusieurs paramètres de l'installation et d'assurer un contrôle plus stricte sur
eux. Le but principal de ce travail est de mettre en évidence les caractéristiques principales des
DCS présents utilisés dans l’industrie et le fonctionnement de celui-ci avec un accent sur la
nouvelle génération de YOKOGAWA ,le CENTUM VP. Ce travail porte aussi une étude de cas
pour donner une vision claire de ce système.
‫ملخص‬
‫ باستخدام هذه األخيرة‬.‫لقد تطورت أتمتة األنظمة الصناعية من الهوائي إلى اإللكتروني وأخيرا إلى أنظمة التحكم الموزعة‬
‫ مراقبة سهلة للعديد من المتغيرات في النظام‬،‫ وسهولة مهام التشغيل والصيانة‬، ‫يؤدي إلى مزايا مختلفة مثل تحسين األداء العام‬
‫ في وقتنا‬DCS ‫ الغرض الرئيسي من هذا العمل هو تسليط الضوء على المالمح الرئيسية ل‬.‫وضمان وجود تحكم صارم عليها‬
‫ كما يشمل هذا العمل‬. CENTUM VP , ‫الحاضر و المستخدمة في المصانع مع التركيز على الجيل الجديد من يوكوجاوا‬
.‫أيضا دراسة حالة إلعطاء رؤية واضحة لهذا النظام‬
Page VIII
Table of contents
Table of contents
GENERAL INTRODUCTION 2
CHAPTER I : An Introduction to Distributed Control System
I.1 Introduction………………………………………………………………………… 4
I.2 Definition…………………………………………………………………………... 4
I.3. Historical review…………………………………………………………………... 4
I.3.1 Classical approach to plant automation……………………………………….. 5
I.3.2 The 1950s - The Pioneering period…………………………………………… 7
I.3.3 The 1960s - Direct Digital Control……………………………………………. 8
I.3.4 The 1970s - Cheaper computers……………………………………………….. 9
I.3.5 DCS Emerges………………………………………………………………….. 10
I.4 System Architecture………………………………………………………………... 11
I.4.1 The pyramidal architecture of a DCS………………………………………….. 12
I.4.2 DCS minimum system components…………………………………………… 13
a- Human machine interface……………………………………………………. 13
b- Distributed controllers……………………………………………………….. 14
c- Communication media and protocol………………………………………… 15
I.5 Important features of DCS…………………………………………………………. 16
I.5.1 To handle complex processes…………………………………………………. 16
I.5.2 System redundancy……………………………………………………………. 16
I.5.3 Lot of predefined function blocks……………………………………………... 17
I.5.4 More sophisticated HMI………………………………………………………. 18
I.5.5 Scalable platform……………………………………………………………… 18
I.5.6 System security………………………………………………………………... 18
I.6 Differences between PLC, SCADA and DCS……………………………………... 18
I.6.1 PLC…………………………………………………………………………….. 18
I.6.2 SCADA……………………………………………………………………….. 19
I.7. Conclusion………………………………………………………………………… 20
CHAPTER II: DCS Yokogawa CENTUM VP
II.1. Introduction………………………………………………………………………. 22
II.2. System description………………………………………………………………... 22
II.3. System Architecture………………………………………………………………. 23
II.3.1. Field Control Station (FCS)………………………………………………….. 24
a- Field Control Unit (FCU)……………………………………………………. 26
b- Node Unit (NU)………………………………………………………………. 26
c- ESB Bus and ER Bus………………………………………………………... 27
d- Input/Output Modules………………………………………………………… 27
II.3.2. Real Time Process Control Network – Vnet/IP……………………………… 29
II.3.3. Operator Interface, Human Interface Station – HIS…………………………. 30
a- Operation Capability…………………………………………………………. 30
b- Terminal Service……………………………………………………………... 31
c- Engineering Work Station - ENG……………………………………………. 31
d- Test Function………………………………………………………………… 32
II.4. Display Layout……………………………………………………………………. 33
II.4.1 System Message Banner……………………………………………………… 33
Page IX
Table of contents
II.4.2 Browser Bar…………………………………………………………………... 34

II.4.3 Graphic View with Graphic Attribute………………………………………... 34
II.4.4 Graphic View with Control Attribute………………………………………… 35
II.4.5 Trend View…………………………………………………………………… 35
II.4.6 Tuning View………………………………………………………………….. 36
II.5 Control Function……………………………..……………………………………. 37
II.5.1 Control function configuration……………………………………………….. 38
• Control Drawing……………………………..……………………………… 38
II.5.2 Function Block……………………………..…………………………………. 39
II.6. Centum VP major features……………………………..………………………… 40
II.6.1 Expandability and Sizing……………………………..………………………. 40
II.6.2 Subsystem Integration………………………………………………………… 40
II.6.3 Plant Resource Manager (PRM)……………………………………………… 40
II.6.4 HART Communication……………………………..………………………… 41
II .7. Conclusion……………………………..………………………………………… 41
CHAPTER III : Application of CENTUM VP
III.1 Introduction……………………………..………………………………………... 43
III.2 PID Control……………………………..………………………………………... 43
III.2.1 Feedback Control……………………………..……………………………... 43
III.2.2 Proportional control mode (P)……………………………………………….. 44
III.2.3 Integral control mode (I)……………………………..……………………… 46
III.2.4 Derivative control mode (D)……………………………..………………….. 47
III.2.5 P, I, and D responses graphed……………………………………………….. 48
III.3 Control Loop Types……………………………..……………………………….. 49
III.3.1 Ration control……………………………..…………………………………. 49
III.3.2 Cascade Control……………………………..……………………………….. 50
III.3.3 Feedforward Control………………………………………………………… 50
III.3.4 Split Range Control………………………………………………………….. 51
III.4 Application of CENTUM VP on the crude separation unit of GASSI TOUIL 51
site:……………………………..……………………………..…………………………….
III.4.1 General Information about the Crude oil separation unit……………………… 51
 Phase separator……………………………..…………………………………. 52
III.4.2 Control strategy used on a separator…………………………………………… 53
III.4.3 The Problem……………………………..…………………………………….. 54
III.4.4 the implementation on the DCS……………………………………………….. 55
a) Hardware configuration……………………………..………………………… 55
b) Control Drawings……………………………..………………………………. 56
c) The operating station……………………………..…………………………… 58
• Graphic Builder……………………………..……………………………. 58
• alarm level……………………………..…………………………………. 59
• Instrument faceplate and tuning………………………………………….. 59
III.5 Conclusion……………………………..…………………………………………… 61
GENERAL CONCLUSION 63
Bibliography 64
Appendices
Page X
General Introduction
General
INTRODUCTION
General Introduction
The failure of control system likely result in the loss of production and equipment damage. This
is why control system reliability are extremely important consideration. In today’s competitive
production environment, process industries demand a totally integrated control and optimization
solution that can increase productivity, reliability, and quality while minimizing cost .
A radically new concept appeared in the world of industrial control in the mid-1970: the notion
of distributed control systems. Direct digital control during that era suffered a substantial problem:
the potential for catastrophic failure if the single digital computer executing multiple PID control
functions were to ever halt. Digital control brings many advantages, but it isn’t worth the risk if
the entire operation will shut down (or catastrophically fail!) following a hardware or software
failure within that one computer.
Distributed control systems directly addressed this concern by having multiple control stations
– each one responsible for only a handful of PID loops – distributed throughout the facility and
networked together to share information with each other and with operator display consoles. With
individual process control “nodes” scattered throughout the campus, each one dedicated to
controlling just a few loops, there would be less concentration of liability as there would be with
a single-computer DDC system .
Yokogawa launched CENTUM, the world’s first distributed control system (DCS), in 1975.
While Yokogawa’s corporate philosophy remains unchanged, CENTUM has been making
progress and expanding its functions along with advances in technology, environmental changes,
and changing demands since its release. Yokogawa released CENTUM VP R5, the newest version
of CENTUM, in September 2011.
This work is considered as an application of CENTUM VP DCS on a crude separation unit, we

started with an introduction to distributed control system ; its history ; architecture and major
features .After that , the chapter two is a presentation of the yokogawa’s newest DCS ; CENTUM
VP ; its hardware and software . At last, we proposed a replacement of the old control technology
used on the separator with another based on the implementation of CENTUM VP to solve the
problem of the level control in the separation unit .
Page 2
CHAPTER I : an Introduction to DCS
CHAPTER I
An Introduction to
Distributed Control system
I.1. Introduction :
Generally, the concept of automatic control includes accomplishing two major operations; the
transmission of signals (information flow) back and forth and the calculation of control actions
(decision making). Carrying out these operations in real plant requires a set of hardware and
instrumentation that serve as the platform for these tasks.
Distributed control system (DCS) is the most modern control platform. It stands as the
infrastructure not only for all advanced control strategies but also for the lowliest control system.
This chapter deals with the introduction to process control system, system concepts of
distributed control system and the development history of process control system.
I.2. Definition:
A distributed control system (DCS) refers to a control system usually of a manufacturing
system, process or any kind of dynamic system, in which the controller elements are not central in
location (like the brain) but are distributed throughout the system with each component sub-system
controlled by one or more controllers. The entire system of controllers is connected by networks
for communication and monitoring. DCS is a very broad term used in a variety of industries, to
monitor and control distributed equipment [1].
A DCS typically uses custom designed processors as controllers and uses both proprietary
interconnections and communications protocol for communication. Input and output modules form
component parts of the DCS. The processor receives information from input modules and sends
information to output modules. The input modules receive information from input instruments in
the process (or field) and transmit instructions to the output instruments in the field. Computer
buses or electrical buses connect the processor and modules through multiplexer or demultiplexers,
buses also connect the distributed controllers with the Human–machine interface (HMI) or control
consoles [1].
I.3. Historical review :
The modern DCS has been constructed in layers, with each phase of its history contributing to
a particular and essential quality. The following is a brief review of this history, including the
contextual background of this evolution. The expectations and challenges associated with the
Page 4
various phases of evolution provide a perspective of the technology-driven market expectations

and application challenges that had to be overcome for the DCS to displace then-current solutions
[2] .
I.3.1. Classical approach to plant automation:
Industrial plant automation has in the past undergone three main development phases:
 Manual control
 Controller-based control
 Computer-based control.
The transitions between the individual automation phases have been so vague that even modern
automation systems still integrate all three types of control.
At the dawn of industrial revolution and for a long time after, the only kind of automation
available was the mechanization of some operations on the production line. Plants were mainly
supervised and controlled manually. Using primitive indicating instruments, installed in the field,
the plant operator was able to adequately manipulate the likely primitive actuators, in order to
conduct the production process and avoid critical situations [3] .
Fig I.1 : Classical plant
The application of real automatic control instrumentation was, in fact, not possible until
the 1930s and 40s, with the availability of pneumatic, hydraulic, and electrical process
instrumentation elements such as sensors for a variety of process variables, actuators, and the
basic PID controllers. At this initial stage of development it was possible to close the control
loop for flow, level, speed, pressure, or temperature control in the field .In this way, the plants
Page 5
steadily became more and more equipped with field control instrumentation, widely
distributed through the plant, able to indicate, record, and/or control individual process
variables. In such a constellation, the duty of the plant operator was to monitor periodically the
indicated measured values and to preselect and set the controlling set-point values [3] .
Fig I.2: Pneumatic controller
Yet, the real breakthrough in this role of the plant operator in industrial automation was
achieved in by introducing electrical sensors, transducers, actuators, and, above all, by placing the
plant instrumentation in the central control room of the plant. In this way, the possibility was
given to supervise and control the plant from one single location using some monitoring and
command facilities [3].
In fact, the introduction of automatic controllers has mainly shifted the responsibility of the
plant operator from manipulating the actuating values to the adjustment of controllers' set-point
values. In this way, the operator became a supervisory controller [3].
The largest part of the cost of analog control systems were the analog devices themselves,
meaning that the cost of adding a control loop was practically independent of the number of already
existing control loops. A consequence of this is that it might not be economically defensible to
automate certain simpler procedures, simply due to the cost of the analog devices required for this.
Adding more control loops also meant that the analog devices would consume more space, and
the space required would practically grow linearly with the number of control loops. In addition,
with each control loop added, additional analog indicators, buttons, and knobs had to be added to
the operator supervision panel to facilitate convenient process operator supervision. This kind of
setup is cool to look at, but relatively inconvenient to work with [4].
Page 6
Fig I.3: An analog control room.
I.3.2 The 1950s - The Pioneering period:
In 1956, the automotive and aerospace company Thomson Ramo Wolridge (TRW) together
with the oil company Texaco initiated a study to evaluate if it was possible to make use of
computers for process control. Three years later a computer-controlled system based on TRW’s
RW-300 computer was online. To get a feel on the state of art of computers at this time, an addition
could take 1ms, a multiplication 20ms, and the mean time between failures (MTBF), i.e. how often
the CPU performed incorrectly, was 50–100h. It should be obvious that these computers could not
be used for real time control. Instead, they were used for supervision, printing instructions for the
process operator, or changing set points of analog control equipment. The analog equipment then
still performed the control, but with the help of a computer [4].
Fig I.4 : TRW 300

Following the TRW and Texaco example many more similar studies were made by various
companies in various industries in the following years. The outcome of these studies were
improved understanding of the processes, as well as specialized computers for process control.
Page 7
One such computer that was widely used in paper mills and oil refineries for quality control
and process optimization was the IBM 1710 which was launched in 1961 and consisted of the IBM
1620 general purpose computer and an IBM 1711 A/D converter. It had support for interrupts,
which was a contribution from the studies due to special requirements for process control, and was
something that did not exist in the general purpose computers at the time [4].
Fig I.5: The IBM 1710 from 1961
I.3.3 The 1960s - Direct Digital Control:
The next leap in process control was made in 1962 when the British chemical company Imperial
Chemical Industries (ICI) replaced a complete analog control system in an ammonia/soda plant by
an Argus computer. Instead of just being used for supervisory tasks for the analog control system,
a computer was now actually performing the control. This form of pure digital control would come
to be called Direct Digital Control (DDC) [4].
There were several advantages with replacing the analog control system by a computer, e.g.
lower cost, improved operator interfaces, and better flexibility. An Argus computer was fairly
expensive but if it was used to replace a large heap of analog equipment, then for sufficiently large
systems the total cost would be lower. Computer based digital operator panels instead of large
analog indicator boards also made the operator supervision more convenient [4] .
Finally, instead of having to rewire the analog equipment one could simply replace the
program. Switching between and evaluating new control strategies could now be done much faster,
and it was also easy to roll back if the new program was incorrect or had poor performance [4].
Page 8
Fig I.6: Ferranti Argus 200

In the years to come DDC languages emerged which made it almost trivial to implement control
designs in DDC systems. No programming was required, one simply organized I/O configurations
and connections in tables and the DDC system would then execute the control based on these
tables. This made it very easy to implement the common control schemes that were implemented
in the DDC system, but very difficult to do anything else. In a way, this held back the development
of more sophisticated control schemes, as implementing these required a huge effort compared to
the common control schemes. Due to its simplicity and efficiency, DDC is still widely used for
building automation, i.e. for heating, ventilation, and air conditioning systems. The most used
building block of today’s DCS systems, i.e. the Function Block, also has its roots in the table
oriented DDC languages [4].
I.3.4 The 1970s - Cheaper computers
With the birth of the minicomputers in the mid-60s came more opportunities. Minicomputers
meant that computers became cheaper, faster, and more reliable. Cheaper meant that it became
profitable to implement smaller systems with computers instead of analog control systems. Faster
computers meant that computers could be used to control faster processes. More reliable meant
that more critical processes could be implemented safely using computers [4].
Fig 1.7: An IBM1800 minicomputer from 1964.
Page 9
One popular minicomputer was the IBM 1800 Data Acquisition and Control System, a process
control variant of the IBM 1130 which was released in 1964.It was described as ”a computer that
can monitor an assembly line, control a steel-making process, or analyze the precise status of a
missile during test firing.”. The last operating IBM 1800s were decommissioned in June 2010 [4].
The invention of the microcomputers in the early 70s was the final blow to the analog control
systems. The price was brought down drastically from approximately $10000 for a minicomputer
to approximately $500 for a microcomputer.
Computers were now so cheap that no matter how small the control system, it was cheaper to
implement it with a computer than with analog devices [4].
I.3.5 DCS Emerges:
The DCS largely came about due to the increased availability of microcomputers and the
proliferation of microprocessors in the world of process control.
In 1975, both Honeywell and Japanese electrical engineering firm Yokogawa introduced their
own independently produced DCS's at roughly the same time, with the TDC 2000 and CENTUM
systems, respectively. US-based Bristol also introduced their UCS 3000 universal controller in
1975. In 1978 Metso (known as Valmet in 1978) introduced their own DCS system called Damatic
(latest generation named Metso DNA) [5].
The definition of a distributed control system (DCS) has dramatically changed over its history.
The DCS was originally conceived as a replacement for large panels, located in central control
rooms and containing hundreds, sometimes thousands, of process instruments. The information-
processing role of the DCS quickly expanded, adding advanced control such as model reference
control and expert systems; information-analysis tools, such as statistical process control and
intelligent alarming; decision support applications such as predictive maintenance and document
management; and business system integration capabilities. Today the DCS is expected to be the
real-time component of a manufacturing facility’s enterprise management and control system,
affecting virtually every aspect of the operation and profitability of both continuous and batch
processes [2].
Page 10
Fig I.8: From left to right, Honeywell TDC 2000 and Yokogawa CENTUM
I.4 System Architecture:
The DCS architecture has always been focused on distributing control on a network so that
operators can monitor and interact with the entire scope of the plant. As such, the classic DCS
originated from an overall system approach. Coordination, synchronization and integrity of
process data over a high-performance and deterministic network are at the core of the DCS
architecture [6].
These distributed controllers are connected to both field devices and operating PCs through
high-speed communication networks as shown in figure.
Control stations
Fig I.9: DCS typical architecture
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Discrete Field devices such as sensors and actuators are directly connected to input and output
“ control racks “ modules through communication bus. These field devices or smart instruments
are capable of communicating with PLC’s or other controllers while interacting with real world
parameters like temperature, pressure, etc .
Each control rack contains a microprocessor to implement all necessary control functions, with
individual I/O (input/output) “cards” for converting analog field instrument signals into digital
format, and visa-versa. Redundant processors, redundant network cables, and even redundant I/O
cards address the possibility of component failure. DCS processors are usually programmed to
perform routine self-checks on redundant system components to ensure availability of the spare
components in the event of a failure [7] .
Controllers are distributed and connected to operating and engineering stations, which are used
for data monitoring, data logging, alarming and controlling purpose via another high-speed
communication bus.
The communication protocols are of different types such as foundation filed bus, HART,
Profibus, Modbus, etc. DCS provides information to multiple displays for user interface [8] .
Fig I.10: Industrial communication protocols
I.4.1 The pyramidal architecture of a DCS:
A popular automation hierarchy of a Distributed industrial manufacturing plant is shown in

Figure below. Here, Level 0 is the lowest level; the field instrumentation is installed for the
measurement of process parameters. This level, would forward the measured values (data) to Level
1 for process control functions. At this level, functions such as process monitoring and control,
inter process operation and monitoring, system coupling, etc. are performed by the control stations
installed at this level. At the Level 2, supervisory functions are implemented. These include data
collection and logging, process optimization, etc. The mathematical models of the process
efficiently take care of overall process optimization. Level 3 is the plant (management) level where
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functions such as plant resource allocation, production planning and scheduling, maintenance
scheduling, production accounting, etc are done.
Fig I.11 : Pyramidal architecture of DCS

I.4.2 DCS minimum system components:
Distributed control systems consist of the following components:
a- Human machine interface :
In the years before DCS, most operator interaction took place from a hard-wired panel control
board with dedicated faceplates for each measurement, control, and alarm function. From this
control panel, operators controlled the process, handled alarms, and viewed current and historical
information [9] .
The modern HMI is extremely reliable, and in most cases, it eliminates the need for maintaining
an expensive control board as a backup. An HMI, in its simplest form, typically consists of a
desktop PC running a commercially available Windows-based operating system. In addition to the
Microsoft packages, this PC has an HMI package, with its embedded graphic user interface,
historian, alarm management, and report utilities [10] .
Today’s HMIs employ liquid crystal display (LCD) hardware and Microsoft Windows
operating systems and offer the user a choice of physical configurations, including desktop or
consoles, and enable the operator to interact with the process via a choice of display views:
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intuitive process graphics, familiar faceplates, informative process trends, tuning displays, and
unified alarm display [9].
These operating stations are of different types such as some operating stations (PC’s) used to
monitor only parameters, trends and alarms display, and others are designed to accomplish more
functions like I/Os configuration ; control parameter modification ...etc. (engineering workstation).
Fig I.12: Human Machine Interface
b- Distributed controllers:
The use of centralized computer control systems had problems of providing expensive
communication systems for bringing in the (field) signals to the centralized computer location;
and output control signals to the field devices (valves, motors, actuators etc.) [11].
With the advent of microprocessors and microcomputers, distributed control architecture

became very popular because such systems were capable of tackling the problems and limitations
of centralized control system [11].
Since industrial processes are geographically located over wide area, it is essential that the
computing power required to control such processes be also distributed and more emphasis be put
to locations where major (control) activity takes place; this limits the data flow to a single sink and
instead ensures continuation of operation of the plant even if there are failures at some sub systems
[11].
The process controllers that are a part of the classic DCS architecture have fundamentally
different operating philosophies than found in a PLC. While the PLC runs “as fast as it can,” the
process controller favors repeatability. That means, the control strategy runs on fixed clock
cycles—running faster or running slower are not tolerated. Repeatable control every cycle means
repeatable quality, repeatable yield and repeatable results for the plant [6] .
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Fig I.13: Control Station
c- Communication media and protocol:
Communication media consists of transmission cables to transmit the data such as coaxial
cables, copper wires, fiber optic cables and sometimes it might be wireless. Communication
protocols selected depends on the number of devices to be connected to this network [8].
Initially, DCS suppliers designed and built their own proprietary digital communications busses
to link the different system stations together into a cohesive network. High throughput, high speed,
and high determinism were all key considerations to ensure that the network could handle the
momentarily heavy traffic loads often encountered in process plants; that measurements, control
signals, and other messages moved over the network in a timely manner; and that the messages
actually arrived at the appropriate station [8] .
Over time, it became apparent that the industry-standard Ethernet technology used in
enterprise-level business networks could be modified to meet the high-availability, deterministic
data communications requirements in industrial process plants.
In DCS, two or more communication protocols are used in between two or more areas such as
between field control devices and distributed controllers and other one between distributed
controllers and supervisory control stations such as operating and engineering stations [8] .
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Fig I.14: Communication Medias
I.5 Important features of DCS :
I.5.1 To handle complex processes:
In factory automation structure, PLC-Programming Logic Controller is used to control and

monitor the process parameters at high-speed requirements. However due to limitation of number
of I/O devices, PLC’s cannot handle complex structure.
Hence, DCS is preferred for complex control applications with more number of I/Os with
dedicated controllers. These are used in manufacturing processes where designing of multiple
products are in multiple procedures such as batch process control [8] .
Fig I.15: Petroleum Process
I.5.2 System redundancy:
DCS facilitates system availability when needed by redundant feature at every level. Resuming
of the steady state operation after any outages, whether planned or unplanned is somewhat better
compared to other automation control devices.
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Redundancy raises the system reliability by maintaining system operation continuously even in
some abnormalities while system is in operation [8] .
Fig I.16: System redundancy
I.5.3 Lot of predefined function blocks:
DCS offers many algorithms, more standard application libraries, pre-tested and pre-defined
functions to deal with large complex systems. This makes programming to control various
applications being easy and consuming less time to program and control [8] .
Fig I.17 : Honeywell DCS ; PKS EXPERION ; programming
 Powerful programming languages:
It provides more number of programming languages like ladder, function block, sequential
…etc, for creating the custom programming based on user interest.
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I.5.4 More sophisticated HMI:
Similar to the SCADA system, DCS can also monitor and control through HMI’s (Human
Machine Interface) which provides sufficient data to the operator to charge over various processes
and it acts as heart of the system. However, this type of industrial control system covers large
geographical areas whereas DCS covers confined area [8].
DCS completely takes the entire process plant to control room as a PC window. Trending,
logging and graphical representation of the HMI’s give effective user interface. Powerful alarming
system of DCS helps operators to respond more quickly to the plant conditions.
I.5.5 Scalable platform:
The structure of DCS can be scalable based on the number I/O’s from small to large server
system by adding more number of clients and servers in communication system and by adding
more I/O modules in distributed controllers [8].
I.5.6 System security:
Access to control various processes leads to plant safety. DCS design offers perfect secured
system to handle system functions for better factory automation control. Security is also provided
at different levels such as engineer level, entrepreneur level, operator level, etc [8].
I.6 Differences between PLC, SCADA and DCS:
I.6.1 PLC:
Programmable Logic Controllers; PLCs; are specialized, computer-based, solid-state electronic

devices that form the core of industrial control devices. Sometimes referred to as programmable
controllers (PCs), PLC is the preferred nomenclature to avoid confusion with the abbreviation for
personal computer. Initially developed to meet requirements specified by the Hydramatic Division
of General Motors in 1968, PLCs were first used to replace hard-wired relay logic circuits. Some
of the major initial requirements set forth were that the devices should be easily programmed and
reprogrammed; easily maintained and repaired; smaller in size and cheaper than the relay circuits
they would replace; capable of operating within a plant and capable of communicating with central
data collection systems [12].
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I.6.2 SCADA:
A SCADA; Supervisory Control and Data Acquisition system is a purely software layer,
normally applied a level above control hardware within the hierarchy of an industrial network. As
such, SCADA systems do not perform any control, but rather function in a supervisory fashion.
The focus of a SCADA is data acquisition and the presentation of a centralized Human Machine
Interface (HMI), although they do also allow high-level commands to be sent through to control
hardware. SCADA systems are tailored towards the monitoring of geographically diverse control
hardware, making them especially suited for industries such as utilities distribution where plant
areas may be located over many thousand square kilometers [12] .
The typical SCADA system consists of multiple Remote Terminal Unit (RTU) devices
connected to process transmitters and final control elements, implementing basic control functions
such as motor start/stop and PID loop control. These RTU devices communicate digitally to a
Master Terminal Unit (MTU) device at a central location where human operators may monitor the
process and issue commands [7] .
Fig I.18 : typical SCADA
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Table I.1 : summary of the differences between DCS and SCADA
DCS SCADA
Process driven Event driven
Small geographic areas Large geographic areas
Suited to large integrated systems such as Suited to multiple independent systems such as
chemical processing and electricity generation discrete manufacturing and utility distribution
Good data quality and media reliability Poor data quality and media reliability
Powerful, closed-loop control hardware Power efficient hardware, often focused on

binary signal detection
I.7. Conclusion
Conceptually, the DCS is similar to the simple PC network. However, there are some
differences. First, the hardware and software of the DCS is made more flexible, i.e. easy to modify
and configure, and to be able to handle a large number of loops. Secondly, the modern DCS are
equipped with optimization, high-performance model building and control software as options.
Therefore, an imaginative engineer who has theoretical background on modern control systems
can quickly configure the DCS network to implement high performance controllers.
In more complex pilot plants and full-scale plants, the control loops are of the order of hundreds.
For such large processes, the commercial distributed control system is more appropriate. There are
many vendors who provide these DCS systems such as Foxboro, Honeywell, Rosemont,
Yokogawa, etc.
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CHAPTER II : The DCS Yokogawa CENTUM VP
CHAPTER II
DCS Yokogawa
CENTUM VP
II.1. Introduction
CENTUM VP is Yokogawa’s latest integrated production control system, also known as a

distributed control system (DCS).
CENTUM VP integrated production control system is applied to control and manage plant
operations in various industries such as oil and gas, petrochemicals, chemicals, power, pulp and
paper, pharmaceuticals, food, iron and steel, waste, and water and sewage treatment.
With this brief chapter of CENTUM VP, we hope to give a good understanding of the basic
architecture; major components and the software based functions without going into too detailed
information.
II.2. System description:
Yokogawa's Distributed Control System - CENTUM - was released in 1975 as the first real
Distributed Control System (DCS) in the world. Since then, it has been continuously enhanced and
upgraded, incorporating state-of-the-art technology maintaining continuities and backward
compatibility of the system [13].
CENTUM VP as a DCS is the key component in Yokogawa's concept “Enterprise Technology

Solutions “. The CENTUM VP is a truly open system. It provides, besides straightforward process
control, excellent capabilities for :
 Integration of sub-systems such as PLC's, analyzers, etc.

 Integrated Instrument Management with Plant Resource Manager (PRM)
 Integration over the control network (Vnet/IP) for ESD system (ProSafe-RS case).
Altogether comprising in a total integrated production and facilities control system, and
operated via a single window. Due to the modularity and system architecture, these functions can
all be implemented in a segregated way.
By using these segregation features, the process control system can be implemented in such a
way that the plant segregation is fully reflected in the production control system architecture [13].
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Fig II.1: History of Yokogawa’s DCS
II.3. System Architecture :
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 provide for scalability from small scale to very large and complex facilities
[13].
The CENTUM VP System Architecture is straightforward. Highly flexible networks can be

designed using of commercially available network equipment like switching HUB (Layer2 &
Layer3 ) [13] .
Although open and control communication data can be transferred on the physically same
Vnet/IP cables, these communications are logically segregated so that they do not have an effect
on each other. It will enable integration of non- CENTUM components to the network .
The System Architecture allows up to 1,000,000 Tags and 512 Stations. Different Domains can
be defined to segregate functional disciplines within the user's organization [13] .
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Fig II.2: Centum VP typical architecture

CENTUM VP major components are:
II.3.1. Field Control Station (FCS):
The Field Control Station (FCS) is a state of the art generation model that integrates process
and batch control, and computer functions. The Integrated Control Functions include:
 Regulatory and Advanced Control Functions (Control Loops)

 Sequence Control Functions (Sequence Table, Logic Charts, Sequential Function Chart)
 Subsystem Integration Functions
 Field Instrument Management Functions [13] .
Fig II.3: Field Control Station (FCS)
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The FCS is the heart of the CENTUM VP Control System. It consists of dual power supplies,
dual communication cards and single or "pair and spare" redundant RISC processor(s) depending
on the required availability of the system. The FCS performs all process control related actions. It
contains the actual PID and other controllers, switches, logics, sequences and advanced control
algorithms. It communicates via the ESB/ER bus with the NIUs and via Vnet / IP (the real time
process control Local Area Network (LAN)) with the operator interface and the engineering
environment [13] .
Fig II.4: Processors Design

The FCS Components are :
 Filed Control Unit (FCU)

 Node Unit (NU)
 ESB bus, ER bus
 House Keeping Unit (HKU)
Fig II.5: FCS components
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a- Field Control Unit (FCU)
FCU consists of cards and modules executing control computation for FCS ; for duplexed FCU,
processor and power modules are duplexed. I/O modules could been mounted. For adding node
units, a bus interface module is needed [14] .
Fig II.6: Field Control Unit
b- Node Unit (NU)
Node unit (NU) is a signal processing unit converting and transmitting analog or digital process
I/O signals received from field devices to the FCU.
Node unit (NU) includes ESB bus node unit (local node) mounted in FCS station and ER bus
node unit (remote node) mounted in cabinets or panels close to plant-site. Node unit is composed
of ESB bus slave interface module or ER bus slave interface module, I/O module, and power
supply module [14] .
Fig II.7: Node Unit
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c- ESB Bus and ER Bus
ESB bus (Extended Serial Backboard bus) is a communication bus available for dual
redundancy connecting ESB bus node units and FCU. ER bus (Enhanced Remote bus) is a high-
speed communication bus available for dual-redundancy connecting ESB bus node units and ER
bus node units. Using ER bus, node units can be located away from FCU cabinet as well as in the
cabinet. This availability for ER bus node units serves for the cases such as locating node units
close to field devices, limiting power supply capacity for safety, or locating node units separately
due to space issue [14] .
d- Input/Output Modules :
The Input modules convert process signals to the digital data format used in the FCS. Output
modules convert the digital data format used in the FCS to analogue or contact signals. I/O modules
are available for all types of signals available in process industry.
FIO (Field network I/O) is a series of low-cost I/O modules, which have been developed to
improve packaging density. The large available range of modules enables the system configuration
to match the requirements for process signals, and to provide for different levels of isolation [15].
FIO modules offer lots of flexibility in selection of connection with field signals viz. Pressure
clamp terminals, MIL connectors and KS cable (Yokogawa's own system cable) interface adapter.
Dual redundancy is possible for all I/O modules and signal types. HART compatible I/O modules
are available, and realize a direct input of HART signal to I/O module, without an intermediate
HART multiplexers etc [14] .
Mil connector cover
I/O Module
Pressure clamp terminal
KS cable Interface adapter
Fig II.8: Terminal Block connector
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Table II.1 : I/O modules for FIO
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II.3.2. Real Time Process Control Network – Vnet/IP:
Yokogawa's Vnet/lP is a control network with high reliability and quick response. It is a control
bus conforming to IEEE 802.3 and UDP/IP, and has a transmission rate as high as 1 Gbps. It uses
commercially available cables, layer 2 switches, layer 3 switches and the like.
Vnet/IP connection topology utilizes a tree formation. Devices within domains are connected
using layer 2 switches. In a dual-redundant Vnet/IP, buses 1 and 2 are independent subnets. Two
independent communication routes exist in each bus [13].
In a Vnet/IP network, a region in which devices are connected without using a router, layer 3
switch or Vnet router is called a domain. Vnet/IP constructs a network for each domain [13] .
Fig II.9: Vnet/IP Network Configuration
Vnet/IP has two communications bands. The first is for real-time process control, which
requires a secure and deterministic response. The other is for Ethernet communications and is used
for both internal station-to-station communications by Plant Resource Manager (plant asset
management), Exaopc (OPC for data exchange), and a universal gateway station (UGS) and
communications with general-purpose Ethernet equipment [16] .
Fig II.10: Vnet / IP specifications
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II.3.3. Operator Interface, Human Interface Station – HIS:
The HIS is the operator interface of the system. It provides dedicated screens for operation,
monitoring, reporting, trending etc. It is directly connected to Vnet/IP, ensuring real-time
communication between the operator interface and plant behavior, e.g. faceplates and alarms etc.
The HIS is also connected to Ethernet which interconnects all HIS allowing for client-server
features on the operator interface level such as sharing of trend files, event data bases etc [13].
Fig II.11 : Human Interface Station features
Depending on customer requirements, several platforms can be used for HIS functions viz.
desktop or console type. The Yokogawa Console Type with dual/Quad stacked LCD or CRT is
state-of-the-art, ergonomically designed for ease of use and faster response to the operator. A
general purpose PC is installed inside the console to achieve maximum synergy with installed
base, minimize spare parts and different maintenance contracts. Standard IBM compatible PC
workstation can also be used as an operator station [13] .
a- Operation Capability
The HIS provides powerful operation environment by many capability and much capacity. The
HIS can be operated as stand-alone station without depending to a central server etc. Each operator
is able to do the daily operation independently by using dedicated HIS. All HIS has a capability to
communicate and exchange necessary data flexibly, and realize mutual back-up configuration by
any other HIS [13] .
The following functional capability and capacity can be built up into each HIS station.
 Number of Tags: 100,000 (Expandable up to 1,000,000)
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 Graphic Window: 4,000 (400 data per window)

 Trend Window: 800 (8 colored trends per window)
 Trend Point Window: 6,400
 Trend Data Save Period: No limitation
 Window Display Update Period: 1 second (as standard specification)
 Historical Message Save Period: No limitation
b- Terminal Service
The CENTUM VP HIS is able to provide a Terminal Service (TS) by utilizing Windows 2003
TS technology. The TS Server allows to access CENTUM VP application simultaneously,
maximum eight clients. Operating and monitoring function can be realized from remote PCs same
as local HIS [13] .
c- Engineering Work Station - ENG
An ENG is the engineering environment of the system and contains the master database of the
application. The engineering environment allows engineering in a fully graphical way by using
"pick and click" and "drag and drop" standard Windows features, the entire configuration can be
built in a graphical manner, including logics, sequences, control loops, graphics etc.
With the concurrent engineering possibility, multiple engineers can work on a configuration
simultaneously, thereby allowing for testing, configuration etc. at the same time [13] .
Fig II.12 : Concurrent Engineering
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d- Test Function
The ENG provides testing environment at the phase of in-house engineering, FAT, site service,
etc. Typically, two types of test function are configured by ENG station, namely Virtual Test
Function and Target Test Function. The Virtual Test Function provides testing environment
without actual FCS controllers. A FCS simulator is used on PC to simulate the functions and
actions of FCS. The Virtual Test Function mainly includes the capabilities of FCS operation,
Wiring simulation, Break point, One-shot execution, Tuning parameter saving, etc [13].
Fig II.13: Virtual Test Function
The Target Test Function provides testing environment with actual FCS, but without field
wiring or I/O cards. Even if the field wiring is furnished, this testing function is available by
ignoring the actual field wiring. Process I/O signals are simulated by software I/O in FCS, and PC
is able to receive input signal and send output signal from/to FCS. The Target Test Function mainly
includes the capabilities of FCS operation, Wiring simulation, I/O disconnection, Break point,
One-shot execution, Tuning parameter saving, etc [13] .
Fig II.14: Target Test Function
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II.4. Display Layout

The HIS display is composed of a system message banner, browser bar and HIS desktop area
as shown below.
Fig II.15: Display screen
II.4.1 System Message Banner
The System Message Banner expresses the alarm occurrence status visually. The alarm
occurrence status is shown by colors and flashing of operation buttons, and the message display.
The System Message Banner is always displayed at the top of the display, so will never be hidden
behind other windows [17] .
Fig II.16: System message banner
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II.4.2 Browser Bar
The browser bar is used to call up operation and monitoring windows. It can display a list of
operation and monitoring windows and plant hierarchical structures in a tree-like fashion, allowing
the entire system to be easily confirmed [17] .
In addition, if the browser bar is not used, its display can be minimized at the end of the screen.
Fig II.17 : Browser Bar
II.4.3 Graphic View with Graphic Attribute
The graphic view with graphic attribute displays plants in a visually easy to understand manner
using abundant drawing objects. Plant conditions are graphically displayed and can be intuitively
operated and monitored. In addition, various windows can be called up from the graphic view.
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Fig II.18: Graphic View with Graphic Attribute
II.4.4 Graphic View with Control Attribute
The graphic view with control attribute displays function block statuses using instrument
faceplates. The faceplate view allows compact and graphical displays of data values, the mode of
function blocks, status of contact inputs, and the like. Some representative faceplate views are
shown below [17] .
Fig II.19: some representative faceplates
II.4.5 Trend View
The trend view graphically displays various process data changes with time, time-series
changes in the process data are called trend data. The trend view allows the selection and display
of up to eight pens from multiple trend display modes. In addition, trend data of different sampling
Page 35
periods can be displayed on one trend view. Moreover, the trend data can be easily used in other
applications [17] .
Fig II.20: Trend View
II.4.6 Tuning View
A tuning view displays the tuning parameters and tuning trend of each instrument. The display
magnification of the tuning trend time and data axes can be changed [17].
Fig II.21 : Tuning View
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• SV : Set point value • SVH: Higher Set point limit
• DV : Deviation value • SVL : Lower Set point limit
• SUM : Totalizer • SH : Process Value High limit
• MV : Manipulated value • SL : Process Value low limit
• HH : High High Value • P : Proportional band
• PH : High Value • I : Integral Action
• PL : Low Value • D : Derivative action
• LL : Low Low Value • GW : Gap width
• DL : Deviation limit • DB : Dead Band
• VL : Velocity limit • CK : Gain Coefficient
II.5 Control Function
The CENTUM VP provides function blocks for monitoring, control, manipulations,

calculations, logic functions, and sequence control. Not only regulatory control but also advanced
control, complicated sequence control, and batch control are all executed in a redundant, secure,
and reliable controller environment. Plant systems can be flexibly designed, ranging from small-
to large-scale, through the combination of these control blocks .
Fig II.22 : The operations performed by the CPU of the control station
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II.5.1 Control function configuration
Those functions are programmed by combining function blocks and connecting them among
themselves or input / output process under control schemes (drawing).
Fig II.23 : control drawing using CENTUM VP
 Control Drawing
Small control groups composed by function blocks and inputs/outputs are to be described in
the control drawings. Engineering and maintenance works are simplified by unifying the process
device control as a control drawing. Monitoring the whole plant or each process can also be
specified as control drawings instead of specifying individual process unit or functions in between
the different devices. The features of control drawings are described below [14] .
 Connecting I/O and control blocks by connecting a line between the I/O and function block,
or between the function blocks, the data flow definition can be visualized.
 Defining the order of control block implementation The implementation priority or order
of performance can be determined among several function blocks described in the control
drawing.
 Mix of Regulatory Control and Sequence Control Regulatory control and Sequence control
can be mixed in Control drawing. Control functions Can be flexibly configured according
to the requirement for process.
 Free Signal Flow between Control Drawing Function block belonging to different Control
drawing can be connected to another Control drawing.
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II.5.2 Function Block:
Function block is a basic unit for control and calculations. Continuous control, sequence control
(sequence tables and logic charts) and calculations are performed by function blocks. Regulatory
control blocks, calculation blocks, and sequence control blocks are interconnected in a manner
similar to the conventional instrument flow diagrams [14] .
Table II.2 : Some of function blocks
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II.6. Centum VP major features

II.6.1 Expandability and Sizing
CENTUM VP provides a hierarchical system configuration to ensure flexible system

expansions. The basic concept of the hierarchical system configuration is illustrated below. For
every system domain a total of 64 FCS and HIS can be connected. Incase more stations are needed
to fulfil the end user's requirements, more domains Can be specified, up to maximum of 31
domains. The total system however remains fully transparent throughout all these domains [13] .
II.6.2 Subsystem Integration
CENTUM VP can easily realize the total integrated control and management solutions not only
with subsystems such as high level computers, programmable logic controllers (PLC), machine
monitoring systems etc., but also with multi-vendor software such as advanced control packages
to provide single window operation.
As an interface to subsystems, such as PLC, Vibration Monitoring System etc. a

communication card located in the FCS is provided. This card has RS232C or RS485/RS422
interface port or Ethernet, and the cable from the subsystem is plugged into the port directly. The
communication cards contain the subsystem driver function [13] .
II.6.3 Plant Resource Manager (PRM)
Today, networked production sites are becoming the norm. These networks greatly improve
maintenance work. Plant Resource Manager (PRM), the software package from Yokogawa, offers
a new style of maintenance tailored using the benefits of intelligent field instruments. PRM is
applied for both HART and Fieldbus application plant to enable remote and automated
maintenance functions [13] .
PRM acquires device information including the device ID, various parameters, and self-
diagnostic information and other device related details, in addition to measured data.
This wealth of information is used for administration and supervision of assets such as field
devices, and for remote automated inspections. PRM transforms the style of maintenance from
manual work mainly done on site, into IT -based automated device management. PRM can support
its users to embed the competency gap between the latest technologies and current maintenance
practices.
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II.6.4 HART Communication
The HART (Highway Addressable Remote Transducer) Protocol is the global standard for
sending and receiving digital information across analog wires between smart devices and control
or monitoring system [18] .
The FCS is able to connect HART devices directly via HART compatible I/O modules, without
any intermediate multiplexers. The analog data and HART variable from field devices are stored
in the I/O image area in analog I/O module, and exchanged between I/O module and FCS controller
[13] .
II .7. Conclusion
CENTUM VP is one of the most advanced DCS systems in nowadays ,because of its great
stability and availability ( pair and spare architecture) , it has also other subsystems integrated with
, such Emergency shutdown system (ESD) , Fire and gas system (F&G) and Burner management
system (BMS) ; all relied with yokogawa’s proper network Vnet/IP .
Page 41
CHAPTER III : Application
CHAPTER III
Application
Of CENTUM VP
III.1 Introduction
Most of the applications of industrial control process used simple loops which regulated flows,
temperatures, pressures and levels. Occasionally ratio and cascade control loops could be found.
There are many benefits for using regulatory control. One of the most important is simply closer
control of the process. Process control is one part of an overall control hierarchy that extends
downwards to safety controls and other directly connected process devices, and upward to
encompass process optimization and even higher business levels of control such as scheduling,
inventory management.
III.2 PID Control :
III.2.1 Feedback Control:
The principle of feedback is one of the most intuitive concepts known. An action is taken to
correct a less satisfactory situation then the results of the action are evaluated. If the situation is
not corrected then further action takes place. Feedback control can be classified by the form of the
controller output. One of the simplest forms of output is discrete form, also called on-off or two
position control [19] .
Fig III.1: On-Off Control response
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As we can see, the degree of control is rather poor. The process variable “cycles” between the
upper and lower set points (USP and LSP) without ever stabilizing at the setpoint, because that
would require the actuator to be position somewhere between fully closed (0%) and fully open
(100%) [7].
This simple control algorithm may be adequate for temperature control in a house, but not for
a sensitive chemical process! Can we imagine what it would be like if an automobile’s cruise
control system relied on this algorithm? Not only is the lack of precision a problem, but the
frequent cycling of the final control element may contribute to premature failure due to mechanical
wear.
In the heat exchanger scenario, thermal cycling (hot-cold-hot-cold) will cause metal fatigue in
the tubes, resulting in a shortened service life. Furthermore, every excursion of the process variable
above set-point is wasted energy, because the process fluid is being heated to a greater temperature
than what is necessary [7].
Clearly, the only practical answer to this dilemma is a control algorithm able to proportion the
final control element rather than just operate it at zero or full effect (the control valve fully closed
or fully open). This, in its simplest form, is called proportional control [7] .
III.2.2 Proportional control mode (P)
Imagine a liquid-level control system for a vessel, where the position of a level-sensing float
directly sets the stem position of a control valve. As the liquid level rises, the valve opens up
proportionally:
Fig III.2: Proportional-only control
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Despite its crude mechanical nature, this proportional control system would in fact help regulate
the level of liquid inside the process vessel. If an operator wished to change the “setpoint” value
of this level control system, he or she would have to adjust the coupling between the float and
valve stems for more or less distance between the two. Increasing this distance (lengthening the
connection) would effectively raise the level setpoint, while decreasing this distance (shortening
the connection) would lower the setpoint [7] .
Proportional – sometimes called gain or sensitivity – is a control action reproducing changes in

input as changes in output. Proportional controller action responds to present changes in input by
generating immediate and commensurate changes in output. This control action works
immediately (never too soon or too late) to match changes in the input signal [7] .
We may generalize the proportional action of this mechanism to describe any form of controller
where the output is a direct function of process variable (PV) and setpoint (SP):
𝑚 = 𝐾𝑝 × 𝑒 + 𝑏 (III.1)
𝑚 = 𝐶𝑜𝑛𝑡𝑟𝑜𝑙𝑙𝑒𝑟 𝑜𝑢𝑡𝑝𝑢𝑡
𝑒 = 𝐸𝑟𝑟𝑜𝑟 (𝑑𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑃𝑉 𝑎𝑛𝑑 𝑆𝑃)
𝐾𝑝 = 𝑃𝑟𝑜𝑝𝑜𝑟𝑡𝑖𝑜𝑛𝑎𝑙 𝑔𝑎𝑖𝑛
𝑏 = 𝐵𝑖𝑎𝑠
Mathematically defined, proportional action is the ratio of output change to input change. This
may be expressed as a quotient of differences, or as a derivative (a rate of change, using calculus
notation):
𝑑 𝑂𝑢𝑡𝑝𝑢𝑡 𝑑𝑚
𝐺𝑎𝑖𝑛 𝑣𝑎𝑙𝑢𝑒 = =
𝑑 𝐼𝑛𝑝𝑢𝑡 𝑑𝑒
A legacy term used to express this same concept is proportional band: the mathematical
reciprocal of gain. “Proportional band” is defined as the amount of input change necessary to evoke
fullscale (100%) output change in a proportional controller. Incidentally, it is always expressed as
a percentage, never as fraction or as a decimal:
∆ 𝐼𝑛𝑝𝑢𝑡
𝑃𝑟𝑜𝑝𝑜𝑟𝑡𝑖𝑜𝑛𝑎𝑙 𝐵𝑎𝑛𝑑 𝑣𝑎𝑙𝑢𝑒 = %
∆ 𝑂𝑢𝑡𝑝𝑢𝑡
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III.2.3 Integral control mode (I):
Integral – sometimes called reset or floating control – is a control action causing the output
signal to change over time at a rate proportional to the amount of error (the difference between PV
and SP values). Integral controller action responds to error accumulated over time, ramping the
output signal are far as it needs to go to completely eliminate error. If proportional (P) action tells
the output how far to move when an error appears, integral (I) action tells the output how fast to
move when an error appears. If proportional (P) action acts on the present, integral (I) action acts
on the past. Thus, how far the output signal gets driven by integral action depends on the history
of the error over time: how much error existed, and for how long. This control action drives the
output further and further the longer PV fails to match SP [7] .
If we add an integral term to the controller equation (III.1), we get something that looks like
this:
1
𝑚 = 𝐾𝑝 × 𝑒 + ∫ 𝑒 𝑑𝑡 + 𝑏 (III.2)
𝑇𝑖
𝑇𝑖 = 𝐼𝑛𝑡𝑒𝑔𝑟𝑎𝑙 𝑡𝑖𝑚𝑒 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 (𝑚𝑖𝑛𝑢𝑡𝑒𝑠)
𝑡 = 𝑇𝑖𝑚𝑒
Mathematically defined, integral action is the ratio of output velocity to input error:
𝑑𝑚
𝑂𝑢𝑡𝑝𝑢𝑡 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 1
𝐼𝑛𝑡𝑒𝑔𝑟𝑎𝑙 𝑣𝑎𝑙𝑢𝑒 (𝑟𝑒𝑝𝑒𝑎𝑡𝑠 𝑝𝑒𝑟 𝑚𝑖𝑛𝑢𝑡𝑒) = = 𝑑𝑡 =
𝐼𝑛𝑝𝑢𝑡 𝑒𝑟𝑟𝑜𝑟 𝑒 𝑇𝑖
For example, if an error of 5% appears between PV and SP on an integral-only process
controller with an integral value of 3 repeats per minute (i.e. an integral time constant of 0.333
𝑑𝑚 𝑒
minutes per repeat), the output will begin ramping at a rate of 15% per minute ( = ).
𝑑𝑡 𝑇𝑖
In most PI and PID controllers, integral response is also multiplied by proportional gain, so the
same conditions applied to a PI controller that happened to also have a gain of 2 would result in
𝑑𝑚 𝑒
an output ramping rate of 30% per minute ( = 𝐺𝑎𝑖𝑛 𝑣𝑎𝑙𝑢𝑒 × ) . The direction of this
𝑑𝑡 𝑇𝑖
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ramping in relation to the direction (sign) of the error depends on whether the controller is
configured for direct or reverse action.
III.2.4 Derivative control mode (D):
Derivative – sometimes called rate or pre-act – is a control action causing the output signal to
be offset by an amount proportional to the rate at which the input is changing. Derivative controller
action responds to how quickly the input changes over time, biasing the output signal
commensurate with that rate of input change. If proportional (P) action tells the output how far to
move when an error appears, derivative (D) action tells the output how far to move when the input
ramps. If proportional (P) action acts on the present and integral (I) action acts on the past,
derivative (D) action acts on the future: it effectively “anticipates” overshoot by tempering the
output response according to how fast the process variable is rising or falling. This control action
is cautious and prudent, working against change [7] .
If we modify the controller equation (III.2) to incorporate differentiation, it will look

something like this:
1 𝑑𝑒
𝑚 = 𝐾𝑝 × 𝑒 + ∫ 𝑒 𝑑𝑡 + 𝑇𝑑 × 𝑑𝑡 + 𝑏 (III.3)
𝑇𝑖
𝑇𝑖 = 𝐼𝑛𝑡𝑒𝑔𝑟𝑎𝑙 𝑡𝑖𝑚𝑒 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 (𝑚𝑖𝑛𝑢𝑡𝑒𝑠)
𝑇𝑑 = 𝐷𝑒𝑟𝑖𝑣𝑎𝑡𝑖𝑣𝑒 𝑡𝑖𝑚𝑒 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 (𝑚𝑖𝑛𝑢𝑡𝑒𝑠)
𝑡 = 𝑇𝑖𝑚𝑒
Mathematically defined, derivative action is the ratio of output offset to input velocity:
𝑂𝑢𝑡𝑝𝑢𝑡 𝑜𝑓𝑓𝑠𝑒𝑡 ∆𝑂𝑢𝑡𝑝𝑢𝑡

𝐷𝑒𝑟𝑖𝑣𝑎𝑡𝑖𝑣𝑒 𝑡𝑖𝑚𝑒 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 (𝑚𝑖𝑛𝑢𝑡𝑒𝑠) = 𝑇𝑑 = =
𝐼𝑛𝑝𝑢𝑡 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑑𝑒
𝑑𝑡
For example, if the PV signal begins to ramp at a rate of 5% per minute on a process controller
with a derivative time constant of 4 minutes, the output will immediately become offset by 20%
𝑑𝑒
( ∆𝑂𝑢𝑡𝑝𝑢𝑡 = 𝐷𝑒𝑟𝑖𝑣𝑎𝑡𝑖𝑣𝑒 𝑣𝑎𝑙𝑢𝑒 × ) . In most PD and PID controllers, derivative response is
𝑑𝑡
also multiplied by proportional gain, so the same conditions applied to a PD controller that
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happened to also have a gain of 2 would result in an immediate offset of 40% ( ∆𝑂𝑢𝑡𝑝𝑢𝑡 =
𝑑𝑒
𝐺𝑎𝑖𝑛 𝑣𝑎𝑙𝑢𝑒 × 𝐷𝑒𝑟𝑖𝑣𝑎𝑡𝑖𝑣𝑒 𝑣𝑎𝑙𝑢𝑒 × ) . The direction (sign) of this offset in relation to the
𝑑𝑡
direction of the input ramping depends on whether the controller is configured for direct or reverse
action [7] .
III.2.5 P, I, and D responses graphed :
A very helpful method for understanding the operation of proportional, integral, and derivative
control terms is to analyze their respective responses to the same input conditions over time. This
section is divided into subsections showing P, I, and D responses for several different input
conditions, in the form of graphs. In each graph, the controller is assumed to be direct-acting (i.e.
an increase in process variable results in an increase in output) [7] .
 Responses to a momentary step-and-return

Proportional action directly mimics the shape of the input change (an up-and-down step).
Integral action ramps at a rate proportional to the magnitude of the input step, for as long as the
PV is unequal to the SP. Once PV = SP again, integral action stops ramping and simply holds the
last value. Derivative action interprets both steps as infinite rates of change, and so generates a
“spike” at the leading and at the trailing edges of the step. Note how the leading (rising) edge
causes derivative action to saturate high, while the trailing (falling) edge causes it to saturate low.
Fig III.3: Responses to a momentary step-and-return
 Responses to a multi-slope ramp

Proportional action directly mimics the ramp shape of the input. Integral action ramps slowly
at first (when the error is small) but increases ramping rate as error increases, then accelerates its
Page 48
increase as the PV ramps even steeper. Once PV = SP again, integral action stops ramping and
simply holds the last value. Derivative action offsets the output according to the input’s ramping
rate: first positive, then more positive, then it spikes negative when the PV suddenly returns to SP
[7].
Fig III.4: Responses to a multi-slope ramp
III.3 Control Loop Types:
III.3.1 Ration control
Figure III.5 shows the P&ID of a process heater in which the fuel flow is measured and
multiplied by the required air-to-fuel ratio; this results in the required air flow rate, which is
introduced as a setpoint of the feedback controller. The required air-to-fuel ratio is automatically
adjusted as the output of the stack O2 controller [19] .
Fig III.5: Ration control
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III.3.2 Cascade Control
In figure III.6 the temperature controller cascades a steam flow controller. The temperature
controller would react to outlet temperature drop by increasing the setpoint of the steam flow
controller, which in turn would increase the signal to the valve. The flow will quickly respond to
increased demand from the temperature controller and thus reaching the desired setpoint of the
outlet temperature stream [19] .
Fig III.6: Cascade control
III.3.3 Feedforward Control
With feedforward control, the objective is to drive the controlling device from a measurement
of the disturbance that is affecting the process, rather than from the process variable itself. In figure
III.7 , the application was analyzed the variation in process inlet temperature was the principle of
disturbance. Hence, a feedforward controller is used to drive the fuel flow controller by sensing
the inlet temperature [19] .
Fig III.7: Feedforward Control
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III.3.4 Split Range Control
Split range control when one process variable such as plant inlet pressure is used to manage
two different output devices such as plant bypass control valve and flow control loop for
fractionation area. The 4-12 mA signal is used to control the flow control loop. If the plant cannot
handle all incoming feed, the 12-20 mA signal control the plant bypass valve to direct extra feed
to the outside of the plant [19] .
III.4 Application of CENTUM VP on the crude separation unit of GASSI

TOUIL site:
The GASSI-TOUIL region is oil and gas vocation, located 1000 km south-east of Algiers and
150 km south of Hassi Messaoud,. It covers an area of about 17,850 km2, in a desert region nature
subject to sand storms and lightning.
Crude Oil separation unit of GASSI TOUIL site, like any other hydrocarbon processing site,
have everyday some technical problems which, in reality, do not significantly affect the overall
operation of the unit. Those problems are; in general, a consequence of the old measurement and
control technology used in [20] .
III.4.1 General Information about the Crude oil separation unit:
Fig III.8 : Crude oil separation unit
The Crude separation is mainly based on the phenomenon of phase separation by density
difference (water, oil, gas).
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The Crude separation unit consist of three stages depends on the pressure (High, Medium and
Low pressure), the first two stages (HP, MP) form a” battery “. There is six main batteries, placed
in parallel, which treat effluents previously homogenized. The third stage consists of two
separators (LP1.LP2. Atm) that address the entire oil production from the six batteries [20].
Fig III.9 : separation stages
 Low GOR : from wells with a low gas/oil ratio

 URGA : associated gas reinjection unit (in French “unité de réinjection des gaz associé“)
 Manifold : the main oil inlet
 R21;R22,R23 : oil storage tanks
 ATM1;ATM2 : low pressure separation stage
 Phase separator :
The term separator in oilfield terminology designates a pressure vessel used for separating well
fluids produced from oil and gas wells into gaseous and liquid components. A separator for
petroleum production is a large vessel designed to separate production fluids into their constituent
components of oil, gas and water.
Separators reside on onshore well pads and offshore platforms and can be horizontal, vertical,
or a sphere. They are used in upstream oil and gas applications for periodic well testing (as a test
separator) or continuous production measurement (as a production separator), and can function in
either two-phase or three-phase depending on operation strategy [21].
Page 52
Fig III.10: Three phases separator
III.4.2 Control strategy used on a separator:
The separator is governed by a pneumatic control, because of the simplicity, robustness and
lower cost of instruments, and the almost universal availability fluid necessary for its
implementation.
Two level loops are installed, one for the oil level, and the other for the water. Each loop consist
of a level transmitter, a controller and a level valve, they are all pneumatic.
The controllers of the oil and water are equipped with buoyancy plungers, suspended from a
torsion bar. The device measures a torque created by the weight of the plunger and the reaction
force of the torsion bar. This torque changes with the buoyant force on the plunger when the liquid
level moves.
Fig III.11: the level controllers mounted on a separator
Page 53
Fig III.12: a pneumatic controller in detail
The controllers are proportional mode and act on relief valves in the direction and with the
suitable amplitude in order to stabilize the level on a desired value.
III.4.3 The Problem
The sudden opening of the well inlet valve generates the increase in flow at the inlet of the
separation vessel, which increases the level suddenly. This can cause the liquid to pass to the
associated gas reinjection unit (AGRU). If an important amount of the liquid pass with the gas to
the AGRU, that may cause a shutdown of AGRU.
After the determination of the different instruments used on the separator, we can say that the
problem is due to:
 Slow response of the safety valve, due to pneumatic technology.

 The inadequacy of the proportional action in the current pneumatic control system;
Therefore, we proposed the change of the old control technology with another strategy based
on the implementation of a DCS Yokogawa CENTUM VP for the whole unit.
Because of the similarity of the batteries, we decided to simulate one battery as an example.
At the inlet of the battery, the crude oil is introduced into the first stage (stage HP) where it
undergoes the first detent 800 psig to 400 psig, releasing a large portion of high pressure gas .
By density difference, water, crude and gas are separated within the capacity of the separator. The
Page 54
water drained from the bottom of the separator while the gas is discharged from the top to the
associated gas reinjection unit.
The oil leaves the bottom under level control and enters the second separator (stage MP) where
it will undergo a second expansion 400 psig to 40 psig. Similarly, the gas and oil separated. The
oil is sent to the third stage (stage ATM) where it is expanded from 40 psig to atmospheric pressure.
The oil is stored in floating roof tanks (three in number) and is prepared for expedition.
Crude
Inlet
Fig III.13: the separation battery in simulation with CENTUM VP
Where :
 SDV 501 : inlet safety shutdown valve

 LIC 5001 / 5003 : oil level controller
 LIC 5002 : water level controller
 PIC 5011/5012 : gas outlet pressure controller
 LV 5001/5003 : oil level control valve
 LV 5002 : water level control valve
 LSHH : level switch high high ( safety switch )
 LSLL : level switch low low
III.4.4 the implementation on the DCS
a) Hardware configuration :
Before any programming, a hardware configuration is necessary, this configuration includes

the choice of the type/number of the FCS, the nodes installed and the input / output modules.
Page 55
Fig III.14: system view
SYSTEM VIEW function allows creating, coping and deleting a project or a part . After
creating the project and naming it, we have to select the type and the FCS that we need .In our
case, one control station should be enough to simulate the example. We choose the “AFD40D”.
For the input / output modules, we choosed :
 AAI143 H ( 16 channel ; current input , HART compliant )

 AAI543 H (16 channel ; current output , HART compliant )
 ADV151 P ( 32 channel , status input )
 ADV551 P ( 32 channel , status output )
b) Control Drawings :
Fig III.15: control drawings
Page 56
Control drawing is used to setup control loops, CENTUM VP contains 200 control drawings
per FCS. In our work, we have set two drawings:
 The first for level control, it contains a signal generator , three PID controllers and the output
blocks
 The second for pressure control ,
Fig III.16: level control drawing
Fig III.17: pressure control drawing
Fig III.18: Creating a function block
Page 57
c) The operating station:
The operation station is the unit where the operator can interfere on the process, both of the
hardware configuration and the control drawings are done in engineering station.
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.
The HIS for CENTUM VP adopts a new design concept “Simple & Intuitive” from the
viewpoint of ergonomics. Icons and information allocation based on the above design concept and
the latest look-and-feel provide operators with comfortable operation and monitoring
environments causing fewer physical and mental burdens on operators.
 Graphic Builder :
The Graphic View displays the plant or control status in a visually easy-to-understand manner.
The user can create a Graphic View using the Graphic Builder, this module is used to design a
Graphic View on the HIS operation and monitoring window using Graphic Components. The
Graphic View can be saved as a Graphic File.
Fig III.19: Graphic builder
Page 58
 alarm level :
Fig III.20: alarm level
 Instrument faceplate and tuning :
Fig III.21: Instrument faceplate and tuning
Page 59
A reasonable criterion for tuning the controller parameters is that the control system has fast
control with satisfactory stability. These two requirements — fast control and satisfactory stability
— are in general contradictory: Very good stability corresponds to sluggish control (not desirable),
and poor stability (not desirable) corresponds to fast control.
However, after many experiences that we have done, we’ve obtained the a good performance
with this three values of PID actions
𝑃 = 100
𝐼 = 20
𝐷 = 10
In our example the main problem appears when the liquid level rises very quickly ,that the
controller can’t react with the same speed , even the safety valve SDV 501 takes a significant
time to close .
During the simulation with CENTUM VP , the problem were resolved , the response time of
the SDV 501 is so small that it is neglected , and the OIL level valve passes to fully opened when
the level reaches 60% for example.
Fig III.22: tuning results
Page 60
III.5 Conclusion
In this chapter , the objective was to study of the oil level control strategy in the HP5-MP5
separation battery of the crude processing unit. this strategy is based on pneumatic technology that
is known by its slowness and is affected by the leak of the instrument air or gas .
Indeed , we proposed a new control strategy based on use of yokogawa distributed control
system , CENTUM VP . However , we have faced one problem during the simulation , it’s the use
of signal generator to represent a measure variation .this problem is a result of the virtual test
function , this problem does not affect the whole simulation because the main objective is to have
a good reaction of the control strategy .
At the end of this chapter we designed monitoring screens using the CENTUM VP software.
We found this very rich display of options and proposals. Just imagine the design of the hole
facility and all the animation effects that will be required to show the real state of the system to
the operator with more information from the configured messages and allocation different colors
for the different states of objects.
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General Conclusion
General
CONCLUSION
General Conclusion
DCSs are used to control industrial processes such as power generation, oil and gas industries,
wastewater treatment and automotive production. DCS is a control architecture providing
supervisory level of control and controls multiple integrated sub-systems.
Today’s distributed control systems have extensive computational capabilities and, in addition
to proportional, integral, and derivative (PID) control, can generally perform logic and sequential
control. Modern DCSs also support neural networks and fuzzy application.
Yokogawa Distributed Control system , CENTUM VP , has been engineered to reduced

downtime, improved system availability, enhanced control reliability, and uninterrupted system
access. Control, I/O, operator stations, engineer stations, data management, and gateway functions
are distributed on an Ethernet network to ensure system integrity and timely data transmission.
Each node in the system is autonomous and yet closely integrated with its peers. The architecture
distributes risk so the loss of any one component does not affect the rest of the system. For
example, if a single controller fails, operation in other areas of the plant will be uninterrupted.
Page 63
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[19] Dr.Mohamed A A Hakim . “ Distributed control system and Programmable logic

controller “ . http://fr.slideshare.net/haki517/dcs-course-10833416
[20] ALLOUT Zakaria , BEN SALAH Said . “ Etude et amélioration de la boucle de
régulation de niveau d’huile dans la batterie de séparation HP2-MP2 -Unité traitement
brut GASSI TOUIL “ , Memoire fin d’étude de l’institut algerien de pétrole Promotion
2014
[21] http://www.emersonprocessxperts.com/2014/01/importance-of-flow-measurement-for-
separators/
Page 65
Appendix A
Appendix A : P&ID
A piping and instrumentation diagram/drawing (P&ID) is a diagram in the process industry
which shows the piping of the process flow together with the installed equipment and
instrumentation.
Contents and function
A piping and instrumentation diagram/drawing (P&ID) is defined by the Institute of

Instrumentation and Control as follows:
1- A diagram which shows the interconnection of process equipment and the instrumentation
used to control the process. In the process industry, a standard set of symbols is used to prepare
drawings of processes. The instrument symbols used in these drawings are generally based on
International Society of Automation (ISA) Standard S5. 1.
2-The primary schematic drawing used for laying out a process control installation.
P&IDs play a significant role in the maintenance and modification of the process that it
describes. It is critical to demonstrate the physical sequence of equipment and systems, as well as
how these systems connect. During the design stage, the diagram also provides the basis for the
development of system control schemes, allowing for further safety and operational investigations,
such as a Hazard and operability study commonly pronounced as HAZOP.
For processing facilities, it is a pictorial representation of
 Key piping and instrument details

 Control and shutdown schemes
 Safety and regulatory requirements
 Basic start up and operational information
List of P&ID items
 Instrumentation and designations

 Mechanical equipment with names and numbers
 All valves and their identifications
 Process piping, sizes and identification
 Miscellanea - vents, drains, special fittings, sampling lines, reducers, increasers and
swaggers
Page 66
Appendix A
 Permanent start-up and flush lines

 Flow directions
 Interconnections references
 Control inputs and outputs, interlocks
 Interfaces for class changes
 Computer control system
 Identification of components and subsystems delivered by
Identification and reference designation
Based on Standard ANSI/ISA S5.1 and ISO 14617-6, the P&ID is used for the identification of
measurements within the process. The identifications consist of up to 5 letters. The first
identification letter is for the measured value, the second is a modifier, 3rd indicates
passive/readout function, 4th - active/output function, and the 5th is the function modifier.
Page 67
Appendix A
An example of a P&ID
Page 68
Appendix B
Appendix B : OPC
Open Platform Communications
OPC is the interoperability standard for the secure and reliable exchange of data in the industrial
automation space and in other industries. It is platform independent and ensures the seamless flow
of information among devices from multiple vendors. The OPC Foundation is responsible for the
development and maintenance of this standard.
The OPC standard is a series of specifications developed by industry vendors, end-users and
software developers. These specifications define the interface between Clients and Servers, as well
as Servers and Servers, including access to real-time data, monitoring of alarms and events, access
to historical data and other applications.
When the standard was first released in 1996, its purpose was to abstract PLC specific protocols
(such as Modbus, Profibus, etc.) into a standardized interface allowing HMI/SCADA systems to
interface with a “middle-man” who would convert generic-OPC read/write requests into device-
specific requests and vice-versa. As a result, an entire cottage industry of products emerged
allowing end-users to implement systems using best-of-breed products all seamlessly interacting
via OPC.
Initially, the OPC standard was restricted to the Windows operating system. As such, the
acronym OPC was borne from OLE (object linking and embedding) for Process Control. These
specifications, which are now known as OPC Classic, have enjoyed widespread adoption across
multiple industries, including manufacturing, building automation, oil and gas, renewable energy
and utilities, among others.
Page 69
Appendix C
Appendix C : UDP
User Datagram Protocol
The User Datagram Protocol (UDP) is one of the core members of the Internet protocol suite.
The protocol was designed by David P. Reed in 1980 and formally defined in RFC 768.
UDP (User Datagram Protocol) is a connectionless protocol of the transport layer of the TCP /
IP model. This protocol is very simple since it does not provide error checking (it is not connection-
oriented ...).
With UDP, computer applications can send messages, in this case referred to as datagrams, to
other hosts on an Internet Protocol (IP) network without prior communications to set up special
transmission channels or data paths. UDP is suitable for purposes where error checking and
correction is either not necessary or is performed in the application, avoiding the overhead of such
processing at the network interface level. Time-sensitive applications often use UDP because
dropping packets is preferable to waiting for delayed packets, which may not be an option in a
real-time system .
Comparison of UDP and TCP
UDP is a protocol oriented "no connection". Basically, when a machine A sends packets to a
machine B, this flow is unidirectional. Indeed, the data transmission is done without informing the
recipient (host B), and the recipient receives the data out of acknowledgment to the transmitter
(Machine A). This is due to the fact that the encapsulation of data sent by UDP does not provide
the information about the issuer. Therefore, the recipient does not know the sender of the data
except the IP.
Unlike UDP, TCP is oriented "connection". When host A sends data to a machine B, machine
B is notified of the arrival of the data, and demonstrates the good reception of the data by a receipt.
Here comes the CRC data. This is based on a mathematical equation, to verify the integrity of
transmitted data. Thus, if the received data is corrupted, TCP enables recipients to ask the recipient
to return corrupted data.
Page 70
Appendix D
Appendix D : PRM
Plant Resource Manager
Plant Resource Manager (PRM) is a plant asset management (PAM) software tool that works
with production control systems such as CENTUM, STARDOM, and ProSafe-RS. With PRM and
intelligent field devices, operators and maintenance personnel can monitor the condition of plant
assets remotely. PRM’s diagnostic functions detect early signs of performance deterioration such
as valve sticking and impulse line blocking. By helping curtail excessive preventive maintenance
and enabling more predictive and proactive maintenance, PRM opens the way to asset
predictability .
A way to increase plant lifetime and availability
Maintenance people spend 35% of their working hours doing routine checks of field devices
and another 28% of their time responding to situations when no problem is found. This means that
unnecessary trips make up 63% of field maintenance work.
PRM enables online and centralized automation asset management.

By monitoring field device health and process interface conditions
online, PRM eliminates unnecessary maintenance trips and minimizes
the need for breakdown and preventive maintenance.
Based on open technology
PRM supports the FOUNDATION™ fieldbus, HART, PROFIBUS, and ISA100.11a

communications protocols, ensuring an extensive range of devices to choose from. PRM fully
embraces an open, rich, and intuitive access to intelligent field devices. Yokogawa has a wide
range of field digital solutions in association with these technologies.
Page 71
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Distributed Control System ( DCS ) An application on Yokogawa CENTUM VP

Thesis · June 2015

The user has requested enhancement of the downloaded file.

Mohammed Khider University -Biskra-

A thesis submitted in partial fulfillment of

Academic Year: 2014 / 2015

Mohammed Khider University -Biskra-

A thesis submitted in partial fulfillment of

Distributed Control Systems -DCS-

Stamp and signature

This work is lovingly dedicated to my respective parents who have been my

To my dear brothers , Walid , Abderraouf , Abderahmane .

To all My friends and Colleagues

Besides my supervisor, I would like to thank the rest of my dissertation committee:

I take this opportunity to express gratitude to all of the Electrical Department

RISC Reduced Instruction Set Computer

L’automatisation des processus industrielle a évolué à partir du pneumatique à l'électronique

II.4.2 Browser Bar…………………………………………………………………... 34

This work is considered as an application of CENTUM VP DCS on a crude separation unit, we

I.3. Historical review :

various phases of evolution provide a perspective of the technology-driven market expectations

I.3.1. Classical approach to plant automation:

Fig I.1 : Classical plant

Fig I.2: Pneumatic controller

Fig I.3: An analog control room.

I.3.2 The 1950s - The Pioneering period:

Fig I.4 : TRW 300

Fig I.5: The IBM 1710 from 1961

I.3.3 The 1960s - Direct Digital Control:

Fig I.6: Ferranti Argus 200

I.3.4 The 1970s - Cheaper computers

Fig 1.7: An IBM1800 minicomputer from 1964.

I.3.5 DCS Emerges:

I.4 System Architecture:

Fig I.9: DCS typical architecture

Fig I.10: Industrial communication protocols

I.4.1 The pyramidal architecture of a DCS:

A popular automation hierarchy of a Distributed industrial manufacturing plant is shown in

Fig I.11 : Pyramidal architecture of DCS

Distributed control systems consist of the following components:

a- Human machine interface :

Fig I.12: Human Machine Interface

With the advent of microprocessors and microcomputers, distributed control architecture

Fig I.13: Control Station

c- Communication media and protocol:

Fig I.14: Communication Medias

I.5 Important features of DCS :

I.5.1 To handle complex processes:

In factory automation structure, PLC-Programming Logic Controller is used to control and

Fig I.15: Petroleum Process

I.5.2 System redundancy:

Fig I.16: System redundancy

I.5.3 Lot of predefined function blocks:

Fig I.17 : Honeywell DCS ; PKS EXPERION ; programming

 Powerful programming languages:

I.5.4 More sophisticated HMI:

I.5.5 Scalable platform:

I.5.6 System security:

I.6 Differences between PLC, SCADA and DCS:

Programmable Logic Controllers; PLCs; are specialized, computer-based, solid-state electronic

Fig I.18 : typical SCADA

Table I.1 : summary of the differences between DCS and SCADA

Small geographic areas Large geographic areas