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System Overview

Training Services Center - SVD


Prepared by:
Muhammad Arwin

PT. Yokogawa Indonesia


Wisma Aldiron Dirgantara 2nd floor, suite 202-209
Jl. Jend. Gatot Subroto Kav.72 Jakarta 12780
Phone : 021-799 0102, Fax : 021-799 0070

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Training Center – Technical Support Group Page.1
Yokogawa Membuktikan Solusi Industri
Yokogawa menyediakan solusi terbaik dalam membangun pondasi dari
dunia industri manufaktur.

Integrasi
Manajemen Korporasi (ERP*) Oracle EBS, SAP R/3, iRenaissance, etc
Terintegrasi dengan sistem operasional bisnis

Manajemen Produksi (MES*)


Sistem untuk sistem kontrol yang lebih maju, APC & AOA Advance
Advanced Process Control &
Operation Assistance PIMS Process Data Acquisition
& Management

simulasi, manajemen produksi dan perencanaan


Paket Solusi

PCS Integrated Production


Control System Safety Instrumented System

Sistem Kontrol Produksi


Sistem Kontrol Produksi CENTUM Prosafe
STARDOM

Transmitter Magnetic Flowmeter


Field Instruments
Field instruments, sensor, instrumen pengukuran, DPharp EJA
analyzers dan peralatan lainnya
Digital Vortex Flowmeter Zirconia Oxygen Analyzer

* ERP = Enterprise Resource Planning Digital YEWFLO ZR 402


* MES = Manufacturing Execution System

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Evolusi Produk Yokogawa
Evolusi Tiada Henti untuk pengembangan yang
tidak ada Habisnya dalam Manajemen dan Era Network
Operasional Plant anda.
Digital
2000

Plant Resource
Analogue 1990s
Manager (PRM)
Kecerdasan yang
1970 diintegrasikan dalam field
untuk manajemen dan
Pneumatic YODIC600 Solution Based Packages Operasional
direct digital software suite for advanced 2001
control system control and advanced
1951 production management.
1971
AOK:pneumatic 1994
I series
controllers Kontroller Electric DPharp EJA STARDOM
fully-digital noise- Sistem Kontrol
1975 Berbasis Network
free sensing with
1957 CENTUM world’s first silicon Autonomous controllers
digital sensor. WEB base Packages
DCS pertama di
dunia IEC61131 lang.
p d/p:pneumatic
1998
transmitters 2003
1978 Foundation CS3000
UNI∆ Fieldbus on EJA
R3.04
field intelligence on
ultra-stable analog DCS termutakhir
transmitters. digital network.

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Conventional point-point wiring - DCS

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EVOLUSI DCS YOKOGAWA

CENTUM dibangun
sebagai sistem terbuka
2008
yang sesungguhnya.

1998
CENTUM-XL

CENTUM (2ND) 1993


1988

1984
1981
1975

CENTUM V
World’s first DCS

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Training Center – Technical Support Group
EVOLUSI DCS YOKOGAWA

Lifecycle Excellence

2008
CENTUM VP

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

1983 1988
CENTUM V CENTUM-XL ABC PFCS FFCS
ENGS
LFCS KFCS
COPS2
COPSV EOPS
HF-Bus

1MBPS
Dual 1975
Redundant
Token Pass
CENTUM Sejak dari tahun 1975, sistem
CFCS2 CFCD2
kontrol DCS Yokogawa sudah
CFCS EFCD
CFFS
COPS

menggunakan sistem Dual


F-Bus

250 KBPS
Dual
Redundant Redundant
Token Pass
CFCS CFCD

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Evolution of Industrial Control Technology

Governors and Relays and Stepping Switch


Mechanics Controllers

Direct-connected Electronic Logic


Pneumatic Controllers Controllers

Transmitter-Type Programmable Logic


Pneumatic Controllers Controllers (PLCs)

Electronic Analog Controllers


Discrete Device
Control Systems
Distributed Digital
Controls
Computer based
Control Systems
Direct Digital
Control (DDC) System

Supervisory Computer
Control System

1930 1940 1950 1960 1970 1980 1990

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Features of HIS

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Page 8
Hardware Requirement

Item Requirement Necessity

CPU Intel Core2 Duo Minimum


RAM 6 GB or more Windows 7 64bit

Windows Vista

Graphic Board Graphic memory: Min 512MB Minimum

HDD 40GB or more Recommend

Monitor SXVA (1280 x 1024) True color Minimum

WXVA, 1440 x 900, True color Option

Drive FDD Required


DVD-ROM Required

Mouse or other pointing devices. Required


Other
If VF701 or VI701 is installed,
PCI/PCI-X slot is required.

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Human Interface Station (HIS)

Equipment Nomenclature
Human Interface Stations (HIS)

The HIS is mainly used for operation and monitoring – it displays process variables,
control parameters, alarm, trend windows, etc.
There are two types of HIS:
• Console Type
Enclosed Display Console Open Display Console

• Desktop Type

Refer to Page A3
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SYSTEM CONFIGURATION
Equipment Nomenclature
Engineering PC (ENG or EWS/ Engineering Work Station)
This is the PC with engineering functions used to perform Centum VP system
generation and maintenance management.
It can be the same type of general-purpose PC as the HIS and can even be the same
PC as the HIS. By having HIS operation and monitoring functions on the same PC,
you can use the test (control station emulation) fucntions to provide an efficient and
easy-to-use engineering environment.

SFC

Logic Chart

Control
Drawing

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HIS (Operation Station)
The necessary information for right operators
correctly at the right timing
Intuitive Look & Feel design
– Windows based operation
• Mouse operation
• Operation keyboard and touch screen
are also available.
On the latest Microsoft technologies
– Windows Vista and XP O/S Platform
– OPC DA 2.0, AE 1.0 and HDA 1.0
Compatible with the former CENTUM systems.
– Similar operation is also available.
– Accessible to the FCSs of the former
CENTUM systems with different control
networks.

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HIS (Operation Station)
Performance and function for achieving
real-time plant operation.
– 1 second screen refresh
– Single, dual, Quad LCD are available.
– Frame display
– Window History function.

Large Capacity
– Max. No. of Tags: 1,000,000
– Max. Graphic Displays: 4,000
– Real-time trend Points: 3,328

Flexible environment
– Full resizable graphics
• Wide monitor is also available.

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Operation keyboard features

Flat membrane type dedicated keyboard.


Various functions for adequate operation.
– Security key
• Authorized operator
• System engineer
– Alphanumeric buttons
– Process control and plant
monitoring
– Special window call buttons
grouped by function
– User-definable function buttons.

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Full-Size Operator Keyboard

Eight faceplates
Security simultaneous
usage operation

Calling appropriate
window by one click

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Optional Desktop Keyboard

Security
usage

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New Screen Design
Universal Color Design
Intuitive
System Message Banner that
Look & allows for the compact
Feel display of information

LEVEL1

The Browser Bar


that can reach the
necessary
information, such
as Tree display or
Search function
immediately.
The Container
Window is capable of
combining and
displaying more than
one screen.

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Training Center – Technical Support Group
New Screen Design

Multiple “Frames”
retain recently-used view sets

“Favorites”
window to
save and call
up favorite
view sets

“History”
window
retains “View set” enables flexible grouping of graphics,
operational trends, and faceplates in accordance with the user
history roles and objectives

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Layout Frames

5 types of empty frame are prepared.

View1 View1
View1 View2
View2 View2 View3
FRLT1 FRLT2 FRLT3

View1 View2 View1 View2


View3 View3 View4

FRLT4 FRLT5

Use like FRLT1 1=GR0001, 2=GR0002

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Elements of New HIS Display
Windows Desktop = Whole Area of CRT

System Message Banner = Alarm Display Area

Browser Bar = Navigation Tool

Container Window = Container Window or Pop up Window


* Frame = An element of Container Window
* Tab = Switches display
* View = An element of
Frame or
Pop Up Window
(R3 HIS Window)

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Examples of Frames and Pop-Up Window

Frame = An element of Container Window

System Message Banner

Pop-Up Window

Browser
Bar

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EXAOPC

Exaopc
This provides OPC Server functions to enable applications in a supervisory
PC to access CENTUM VP data. It provides a link between control layer
and business data processing layer.

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Vnet - Domain

A Vnet/IP domain consists of two independent subnets of bus 1 and bus 2. In the
CENTUM VP, combining Vnet/IP and V net/VL net domains, up to 16 domains can
be set. To each domain, up to 64 Vnet/IP stations and up to 124 other general-
purpose Ethernet communication devices (PCs, routers, etc.) can be connected.

Vnet/IP is designed as a duplexed network. In Vnet/IP, a duplexed bus is


configured with independent subnets of bus 1 and bus 2.

If both buses are normal, bus 1 is used for control communication, and bus 2 is
used for open communication. If bus 1 fails, control communication is
performed using bus 2. In this case, because open communication is also
performed using bus 2, control communication and open communication
coexist. Therefore, to secure the band for control communication,
the band for open communication will be restricted.

Refer to Page A27


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L2SW, L3SW, & Vnet Router

• Layer 2 Switch
A device to connect equipment
• V net Router within the Vnet/IP domain.
The V net router is the
hardware dedicated to
connect a Vnet/IP domain
and a V net/VL net domain.

• Layer 3 Switch
A general-purpose layer 3 switch
is used to connect between
Vnet/IP domains in each bus.

Refer to Page A28, A29 and A30


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GSGW, APCS, Router

Generic Subsystem Gateway Package (GSGW)


With a general-purpose PC connected to Vnet/IP, GSGW packages can collect and
set various types of data from subsystems using an OPC DA server. They can
easily connect and set subsystem data without creating dedicated
communications programs.

Advanced Process Control Station (APCS)


An APCS advanced process control station implements control functions with
a general purpose PC connected to a Vnet/IP, aimed at improving advanced
control and plant efficiency.

Router
A router with Security function to ensure the security of a Vnet/IP network is
used to connect the bus 2 side with an external network such as Intranet.

Refer to Page A28


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SISTEM KONFIGURASI - FCS

Field Control Station (FCS)


FCS adalah otak dari DCS yang mengeksekusi kontrol dan mengkoputasi kontrol di lapangan.
KFCS (with FIO)
FFCS / FFCS-L
(Compact FCS for FIO)

PFCS (with RIO)

LFCS (with RIO)

FIO

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SISTEM KONFIGURASI - FIO

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Control Function Capacity
Capacity of one Controller. Function Block Type
Category Item Max. PVI BLEND SI-1 BAND OPSBL SI-1E
PVI-DV FF-AI SI-2 BOR OPSFC SI-2E
Analog 1,280 PID FF-DI SO-1 BNOT OPSFCP1 SO-1E
Process IO
Digital (On/Off) 4,096 PI-HLD FF-CS SO-2 CALCU OPSFCP2 SO-2E
PID-BSW FF-PID SIO-11 CALCU-C OPSFCP3 SIO-11E
Elements 5,800 ONOFF FF-RA SIO-12 SW-33 OPSFCP4 SIO-12E
Tag Names
Function blocks 2,500 ONOFF-G FF-AO SIO-21 SW-91 OPSFCP5 SIO-21E
ONOFF-E FF-DO SIO-22 DSW-16 ONOFF-E SIO-22E
Control drawings 200 ONOFF-GE FF-OS SIO-12P DSW-16C ONOFF-GE SIO-12PE
Message Outputs Annunciator messages 1,000 PID-TP FF-SC SIO-22P DSET MC-2E SIO-22PE
PD-MR FF-IT TM DSET-PVI MC-3E
Operator guide messages 1,000 PI-BLEND FF-IS CTS BDSET-1L SI-1E
Common switches 4,000 PID-STC FF-MDI CTP BDSET-1C SI-2E
Internal switches MLD FF-MDO CI BDSET-2L SO-1E
Global Switches 256 MLD-PVI FF-MAI CO BDSET-2C SO-2E
MLD-SW FF-MAO RL BDA-L SIO-11E
MC-2 FF-SUNV RS BDA-C SIO-12E
MC-3 SLCD VLVM INDST2 SIO-21E
RATIO SLPC LC64 INDST2S SIO-22E
PG-L13 SLMC ALM-R INDST3 SIO-12PE
BSETU-2 SMST-111 L_ST16E BSI SIO-22PE
BSETU-3 SMST-121 M_ST16E PBS5C VPM64
Signal SMRT ST16E PBS10C VPM128
SS-H/M/L SBSD L-ST16 Hybrid VPM256
AS-H/M/L SLCC M_ST16 _UTSW VPM512
SS-DUAL SLBC ST16 _UTPB VPM64A
FOUT STLD ADD _UTAS VPM128A
FFSUM _SFCSW MUL _UTSW-N VPM256A
XCPL _SFCPB DIV _UTPB-N VPM512A
SPLIT _SFCAS AVE _UTAS-N FSBSET

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FIO Node Overview

ESB or ER Bus Interface Redundant


Power Supply
Up to 8 I/O modules 100-120 V AC
220-240 V AC
24V DC

5 units
(222.3mm)

19 inches
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FIO Architecture (ESB bus & ER bus)

Enclosed Display Open Display Style


HIS/ENG Style Console HIS Console HIS

Control Network

ESB Bus

ER Bus
(Enhanced Remote Bus)

FFCS KFCS

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Connection Type with Field Wiring

Variety of Field Connections


– Weidmueller (pressure clamp) terminals: Most popular in
Europe and the same as PLCs’ terminals
– Dedicated terminal boards with M4 screw terminals,
connected by KS cables: Same as Yokogawa’s traditional
style
– MIL connectors: Popular in low-cost installations.

Weidmuller KS cable
terminals adapter MIL
connector

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Training Center – Technical Support Group
DESKRIPSI HARDWARE - FCS
FFCS (dengan FIO untuk Vnet I/P)
I/O Module Capacity :
Max up to 14 node.

Power Supply
Modules

I/O Modules

Node Expansion
Modules (ESB)

Control
Processor Cards

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Training Center – Technical Support Group
DESKRIPSI HARDWARE - FCS
Tampilan luar dari FFCS-L(AFV10)
Vnet/IP
SLOT 1 ~ SLOT 8

EC401 ESB bus coupler (Note) CP451 CPU module Power supply unit
Catatan: Dua slot I/O digunakan untuk ekstensi node.
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DESKRIPSI HARDWARE - Baterai

Mempertahankan memori database dalam


prosesor selama listrik mati.

Maksimum waktu back-up 72 jam !

Battery Life Temperature

3 years 30 ºC atau kurang

1½ year 40 ºC atau kurang

9 months 50 ºC atau kurang

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ARSITEKTUR CPU FCS KONTROLLERCONTROLLER
Teknologi Pair & Spare Yokogawa
Kehandalan sistem redundant yang
sangat tinggi diterapkan pada field
control unit (FCU) dengan dua modul
prosesor, dengan masing2 card
mempunyai sepasang (“Pair”)
microprocessor units (MPUs) yang
mengbandingkan hasil proses dari
masing2 kalkulasi. Sedangkan
processor cards kedua berfungsi
sebagai cadangan ("Spare").
CPU melakukan proses secara
independen dan setiap waktu akan
melakukan proses sinkronisasi time

Proses pindah tanpa ganguan !!

Konfigurasi “Pair & Spare” terdiri dari dua prosesor card yang independen beroperasi terus
menerus di waktu yang sama. Satu prosesor mengontrol sistem setiap saat sedangkan yang
lainnya bersiap siap menggantikan prosesor pertama tadi. Kedua prosesor harus berjalan dalam
program sistem yang sama dan dan akan melakukan sinkronisasi dengan sempurna apabila suatu
waktu terjadi perpindahan kontrol dari prosesor satu ke prosesor yang lainnya.

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ARSITEKTUR KONTROLER - FCS
Bus (Kabel) 1
KFCS (Dengan FIO) Vnet
Bus (Kabel) 2

FCU / CPU
 Bisa satu ataupun dua Koneksi
konfigurasi CPU FCS Redundant ke
kabel Vnet
 Tipe Prosesor VR5432 (133 Mhz)
 Kapasitas Memori: 32 MB

ESB Bus
I/O Racks
Dual redundant
 Bisa satu ataupun dua Kec. Transmisi: 128 Mbps
konfigurasi Power Supply
Jarak Transmisi :10 meter
 Dual redundant I/O bus
 8 I/O slots per node/rack
HKU (House
 10 nodes/racks per FCS (bisa Keeping Unit)
diekspan sampai 15)
Kecepatan Kipas
 Standar panel 19“ Temperatur udara dan
lingkungan

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ARSITEKTUR KONTROLER - FCS

ER BUS
 Dual redundant
 10 Mb/s
 4 segmen per FCS
 185 m maks (10 base 2) ER Bus Coupling

Remote area 2  2 km dengan fiber optik Module


 Dual redundant
 Max. 4 pairs
per FCS

Remote area 1

Remote I/O racks


 I/O modules single or dual redundant
 Dual redundant coupling to ER bus
 8 I/O slots per node/rack
 8 racks per FCS
 Option G3 and 70°C
 19 "x 5 U (22cm)

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Training Center – Technical Support Group
ARSITEKTUR KONTROLER - FIO
FIO (Field Inpu/ Output)

Kemampuan Field Input/Output


 Terisolasi dari (channel ke
channel dan dari sistem ke
lapangan)
 Penggantian komponen
secara On-line
 Sistem pengkabelan yang
mudah
 Full dual redundancy jika
dibuthkan
 Mendukung tipe protokol
field bus

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Training Center – Technical Support Group
ARSITEKTUR SISTEM Centum VP
Teknologi Vnet /IP

Vnet/IP adalah sebuah


kabel berbasis IP yang
real-time untuk proses
otomasi dan sudah
mmenggunakan sistem
komunikasi 1-Gbps
Ethernet.

Vnet/IP sama seperti fungsi komunikasi Ethernet dan digunakan sebagai


landasan kabel komunikasi di masa mendatang yang fungsinya sama
seperti teknologi Vnet.
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Field Control Station – FFCS-L
AFV10D Duplexed Field Control Unit (for Vnet/IP, for FIO, 19-inch rack mountable)
The dipswitches for setting
domain number and station
number are placed at the
rear of the module.

Domain
Number

Station
Number

Refer to Page A30


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Cables

Use a CAT5e (enhanced category 5) or higher UTP (Unshielded Twisted


Pair) cable for 1000BASE-T. It is required that the number of layer 2
switches be increased or the maximum distances be expanded by fiber
cabling according to the system configuration or equipment installation
location.

Refer to Page A32


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Setting Domain Number
To set domain number from 1 to 16
Total no. of 1s from bit 4 to bit 8 is odd => Bit 1 = “0”
Total no. of 1s from bit 4 to bit 8 is even => Bit 1 = “1”
0 1
1 1
2 0
3 0
4 0
5 0
6 1
7 1
8 0

1 0 0 0 0 1 1 0

2² 2¹
4 +2=6
Total no. of 1s from bit 4
to bit 8 is even.
Page A25
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Setting Station Number
To set station number from 1 to 64
Total no. of 1s from bit 2 to bit 8 is odd => Bit 1 = “0”
Total no. of 1s from bit 2 to bit 8 is even => Bit 1 = “1”
0 1
1 1
2 0
3 0
4 1
5 0
6 0
7 0
8 1

1 0 0 1 0 0 0 1

24 20
16 + 1 = 17
Total no. of 1s from bit
2 to bit 8 is even.
Page A26
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Test Function

The Test Function is a group of tools (option packages) for efficiently debugging
FCS software created by the user.

The Test Functions allow combinations of monitoring/operation and control functions


to be tested before being put into operation. There are two types of test functions:
. Virtual tests
Two types of tests
. Target :
tests

Test Function Virtual test

Target test I/O disconnection (Use virtual I/O)

Use real I/O

Page B1
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Test Function –Virtual Test
Virtual Test
Virtual test uses an FCS simulator instead of an actual FCS. The FCS simulator
simulates the functions and operation of the FCS and runs under an HIS.

Page B1
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Test Function –Target Test
Target Test
Target test uses an actual FCS. When there are no I/O modules and I/O test
devices, an FCS input and output can be simulated by using the I/O Disconnect
and Wiring Functions.

Page B2
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Concurrent Engineering
Using Windows File sharing, several people can share an Engineering
database on a network; concurrent engineering is possible.

Page B3
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Engineering Work Flow
Start
Start System View

Step 1: Project Creation


• Create necessary folders for target system

Step 2: Defining Project Common Item


• Define security function
• Define operation marks

Step 3: Defining FCS Control Functions


• Define FCS station configuration
• Define Process I/O modules
• Define Software I/O
• Define Messages
• Define Regulatory Control Functions
• Define Sequence Control Functions

Step 4: Defining HIS Control Functions


• Define HIS station configuration
• Define HIS constants
• Define Function Keys assignment
• Scheduler Function
• Trend Recording Functions
• Define Sequence Message
• Define User-defined windows
• Define Help Dialog

Step 5: Conducting Test Function


• Run a Virtual Test Function
Page B4
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The feature of Latest Control Network
A new control network that incorporates general communication
function and enables highly reliable, real-time, and stable
communication is now available
– Name: Vnet/IP
This new control network protocol is called Vnet/IP because it is compatible
with Vnet and used the IP Internet protocol for general-purpose
communications
– Position: The Vnet/IP is a 1-Gbps control network that is functionally
compatible with existing CS3000 control network (Vnet). Vnet/IP is based
on Giga bit Ethernet protocol

Reliable :
Securely transmitting information with failure,
load, and environmental factors including noise
taken into account
Open
Real-Time :
Transmitting information within a definite period
of time
Open : Real-
Reliable
Collaborating with various applications via open time
standard protocol

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Vnet/IP Overview
Both buses OK 1 bus failed
1 Gbps 1 Gbps 1 Gbps
General open communications:
Uses bus 2 (300 Mbps).
Restricted at exterior (hub, router,
etc.). General open General open
communications communications
Spare 300 Mbps
300 Mbps
Vnet/IP open communications:
Vnet/IP
Uses bus 2.
Spare, open
When bus switching occurs, VI701 200 Mbps communications
(for VF701 Vnet/IP) automatically 200 Mbps
restricts the transmission band (650 Vnet/IP Control
Open communi-
Mbps --> 200 Mbps). communications cations
650 Mbps change to
Control Control
communications bus 2 when communications
Control communications (Requires 500 500 Mbps bus 1 500 Mbps
Mbps.) failure
occurs.
In general, uses bus 1. Control
Changes to bus 2 when failure occurs. communications
Utilizes an architecture which changes 50Mbps
from failure point to point only, and Bus 1: Bus 2: Bus 2:
which is highly resistant to Control Control diagnosis Control
duplicated failures. commun- communications + communications +
ications Open communications Open communications
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SYSTEM ARCHITECTURE
Vnet I/P

ENG/HIS

Bus 2 Bus 1
(Open Communication) (Control Communication)

L2 switch L2 switch

FCS(FFCS-L)

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Training Center – Technical Support Group
SYSTEM ARCHITECTURE
Vnet I/P

ENG
HIS

Vnet Router GSGW/


SIOS
FFCS-L

To CS, CS3000/1000 PLC


(Vnet) OPC
Server
Field network

Foreign system

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Training Center – Technical Support Group
Vnet/IP Network Configuration
Plant Asset
ENG HMI OPC Server Management
Domain1

Vnet
Router Controller ProSafe-RS Third
party
system
Interface
Field network
Vnet
System

OPC Server

ENG HMI Plant Asset


Management

Controller ProSafe-RS

Field network

Domain2

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DOMAIN INTEGRATION
Vnet I/P Multiple Domains

L3 switch
1 Gbps

Domain 1

Domain 2

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Training Center – Technical Support Group
DOMAIN INTEGRATION
Vnet I/P   Vnet

Vnet Router

PT YOKOGAWA INDONESIA
Training Center – Technical Support Group
Centum VP Software – Virtual Test Function

Engineering function

Virtual Test Function

Operation & FCS


Monitoring Emulator

VIRTUAL TEST FUNCTION


• No actual FCS required.. just PC(s)!
• Concurent engineering  system generation and testing are easier
and more efficient  time and cost saving.

PT YOKOGAWA INDONESIA
Training Center – Technical Support Group
Centum Software – Virtual Test Function

Full-scale system test can be performed without target hardware.


Real Plant Virtual Test
Loading HIS configuration Loading HIS configuration

HIS HIS
Configuration Configuration
Data Data

FCS

Loading Loading
control function control function
FCS Simulator
Auto Wiring
Input Input

Output
Real Plant Output
Virtual Plant

In PC (HIS) Memory

PT YOKOGAWA INDONESIA
Training Center – Technical Support Group
PT YOKOGAWA INDONESIA
Training Center – Technical Support Group

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