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Seminar TI-14 – Erik Fjordside/ Carsten Hounsgaard

Introduktion til DCS systemer


Nearly 40 years History and the continuity

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


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

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

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

1975 • Full Lifecycle Support for Customers’ Legacy Systems


CENTUM

COPS CFFS
CFCS2 CFCD2 EFCS EFCD The migration path for each legacy system is always
F-Bus taken into consideration before a new system is released
250 KBPS
Dual
Redundant
Token Pass
CFCS CFCD

-2-
DCS Installation Map As of Dec 2012

EUROPE
AUSTRIA (30)
AZERBAIJAN (1)
BELGIUM (199)
BELARUS (8)
BULGARIA (5)
CROATIA (5) 2,144
DENMARK (6) 862
FINLAND (1) Europe
FRANCE (232)
North
GERMANY (256) 19407 TOTAL America
GREECE (18)
HUNGARY (63)
IRELAND (3)
580
Middle
Asia
24,377
ITALY (149)
East
KAZAKHSTAN (7) UNITS NORTH AMERICA
LITHUANIA (1) 366 CANADA (19)
NETHERLANDS (173) USA (843)
NORWAY (5) Africa
POLAND (17)
PORTUGAL (8) AFRICA South
599
ROMANIA (12)
RUSSIA (545)
ALGERIA (35)
ANGOLA (15)
America
SERBIA (10) BOTSWANA (4) Oceania 419 ASIA
SLOVAKIA/CZECH (112)
CONGO (4) BANGLADESH (1) SOUTH AMERICA
SLOVENIA (2) EGYPT (60) INDIA (1,425) ARGENTINE (11)
SPAIN (162) MYANMAR (5)
SWEDEN (1)
GABON (6)
GHANA (5)
MIDDLE EAST PAKISTAN (6)
BRAZIL (498)
BAHRAIN (34) CHILE (4)
SWITZERLAND (17) KENYA (3) CHINA (2,565) COSTA RICA (1)
DUBAI (1)
TURKMENISTAN (5) LIBYA (4) KOREA (1,101) COLOMBIA (16)
IRAN (105)
UK (83) MOROCCO (22) TAIWAN (479) CUBA (12)
IRAQ (9)
UKRAINE (8) MOZAMBIQUE (1) JORDAN (5)
OCEANIA JAPAN (12,399) EL SALVADOR (1)
NAMBIA (1) AUSTRALIA (407) MALAYSIA (284) MEXICO (41)
KUWAIT (14)
NIGERIA (38) NEW ZEALAND (2) INDONESIA (284) NICARAGUA (1)
OMAN (48)
SENEGAL (2) NEW CALEDONIA (1) PHILIPPINES (172) PANAMA (2)
QATAR (9)
SOUTH AFRICA (153) PAPUA NEW GUINEA (3) SINGAPORE (225) PERU (1)
SAUDI ARABIA (256)
SUDAN (6) FIJI (6) THAILAND (423) TRINIDAD TOBAGO (2)
SYRIA (6)
SWAZILAND (2) VIETNAM (35) URUGUAY (1)
TURKEY (33)
TUNISIA (1) BRUNEI (1) VENEZUELA (8)
U.A.E (52)
UGANDA (4) SRILANKA (2)
YEMEN (8)
Release Information
CENTUM VP Features
• Scalability and flexibility
– CENTUM VP meets the requirements for both simple small scale systems and huge
scale 1,000,000 tag level systems
– CENTUM VP is suitable for different application types and system architectures

• Super-high plant operation availability


– Seven 9’s (99.9999959) hardware availability
– Pair & Spare technology to keep higher control loop availability

• Operators’ perspective design


– Real-time plant operation environment
– Intuitive look & feel HMI design

• Open Architecture
– The latest technologies can be applied in the control systems
– Easy integration with other subsystems
CENTUM VP System Configuration Overview
Client PC Exaquantum
Plant Information
Management
HIS System
(Operator Station)
PR
Plant Asset Solid Style Open Style Desktop type TSE Engineering
Mmanagement Console Console HIS
serve Station
r OPC
server

Vnet/IP
Real time Control Network FCS UGS
Field Control Station
Unified Gateway Station

Digital Field Network


SCS
Safety Control Station

Subsystems
Operation and Monitoring
Operator Station (HIS)
Client PC Exaquantum
Plant Information
Management
HIS System
(Operator Station)
PR Solid Style Open Style Desktop type Engineering
Plant Asset TSE
Mmanagement Console Console HIS
Station
serve
r OPC
server

Vnet/IP
Real time Control Network FCS UGS
Field Control Station
Unified Gateway Station
SCS
Digital Field Network Safety Control Station

Subsystems
HIS (Operation Station) Features
• Various types of the operation views are prepared
– Graphic, Trend graph, Overview, Tuning etc.

• One-touch operation for related information


– Alarm dialog, trend graph, Graphics, and
faceplates can be called up from each other
based on the related tag without engineering
Ex.) Click alarm message,
then the related faceplate is shown

• Performance and function


for achieving real-time plant operation
– 1 second graphic call up
– 1 second screen refresh
– Data gather mechanism for real-time trend
without the affection by the network delay
– Frame display
– Window History function
• Real-time Alarm Management View
HIS (Operation Station) Features
• Large Capacity
– Max. No. of Tags: 1,000,000 per system
– Max. Graphic Displays: 4,000 per HIS
– Real-time trend Points: 3,328 per HIS

• Various types of operation environment


are available
– Single, dual, quad monitor are available
– Wide monitor is also available
– Mouse operation
– Operation keyboard and touch screen
are also available

• Higher Compatibility with the former CENTUM


systems
– Similar operation is also available
– Accessible to the FCSs of the former CENTUM
systems with different control networks
HIS Hardware
• HIS works on the latest Microsoft Windows OS platform
– Windows 7, VISTA and 2008 server

• Three types of hardware can be chosen


– Desktop, Solid Style Console, and Open Style Console

• Various Operation Styles


– Mouse/Operation Keyboard/Touch panel
– Single, Dual and Quad-monitor are available

Solid Style
Console Desktop
Type

Open Style
Console
Operation Keyboard Features

• Calling up necessary information quickly


– 64 function keys
– Alphanumeric buttons
– Tab switching

• Avoiding human mistakes


– Highlighting the instrument plates
– Security key
• Authorized Operator
• System Engineer
– IEC9241-11 Complied Key pitch

• Easing the installation


– Power supply via USB (AC adapter is not needed)
– 2 built-in speakers for buzzer and for other sound
Operation Keyboard (OPKB) Description

Mode Selection Control Keys


USB Power Supply AIP831: Eight-Loop
Switch
AIP830:Single-Loop

Operation
Confirmation Keys

IEC 9241-11 64 Function


Key Pitch
Keys

Numeric
keypad

Built-in Window Call Container Window Buzzer Reset Key / Alarm


Speakers Keys Key Acknowledgement Key
(for Frame Tab Switch)
HIS Screen Overview
System Message Banner
– Buttons to call-up the alarm & event dialogs quickly
– Latest 3 alarm messages are always displayed in real-time
Navigation
– Graphics & trend
views are arranged in
a hierarchy display
– Alarm status are
shown as the icon color

Favorite
– Frequently used views
can be registered by
operators’ drag & drop

Operation History
– Last 20 call-up
operations are listed
– Double-click the listed
operation to call up the
same view again
Graphics, trend graphs and other views are displayed
The Latest Browser-like Operation Provided
Tab Display

Similar operation to the Internet Explorer

Tab operation
4 views on a sreen
Quick call up of up to five
frequently used tabs
Less memory consumption to
show multiple tabs

Each tab can be divided


into 4 frames
4 frames can be shown at the
same time to monitor overall
Trend Data Acquisition
• Trend data is acquainted by each trend block on the HIS
– 34 trend blocks per HIS
– Up to 128 data points can be assigned in each trend block
– Other 16 trend blocks can be used for accessing the trend data
acquainted in other HISs

• Data Acquisition period is specified for each trend block


– 1-sec, 10-sec, 1-min, 2-min, 5-min or 10-min
– The mechanism to achieve more accrued trend data acquisition
• For 1-second and 10-second trends, the trend data buffer is prepared in the FCS to
eliminate the affection of network delay between FCS and HIS
• The capacity of the trend data buffer in an FCS is 8 trend data blocks
Trend Graph Display
• Up to 8 trend lines can be display in each trend graph
– Displaying/hiding of each trend line is by a single click
– Drag & Drop dynamic trend line assignment is available
– The trend lines with different acquisition periods can be displayed on a trend
graph together

• Data export function for csv/bitmap format


– To ease to generate the report for analysis

• Drag & Drop zooming function


– For more quick and intuitive operation

• Index marks to show the data values on the trend graphs


– To refer and to compare the data easily
Trend Graph Display Example
Trend line Assignment Index
– Drag & Drop to assign the data points – Up to three indexes can be displayed
from any trend blocks on a trend view – Data values on the trend graphs can be checked

Legend Area
Faceplate Display
– Assigned data points and the current data are shown
– Click the Legend Area, then the Faceplate
– Check/Uncheck to show/hide trend line is shown next to the trend graph view
Trend Export Reporting Function
•Trend data export
– Right-click on the view,
then the trend data
can be exported
• Copied to the Clip Board
– It can be easily used for
reporting or analysis
Real-time Alarm View (CAMS)
Click blinking icons The latest three alarms
to open the CAMS View are always shown

Shelving Pane
– Non-urgent alarms
can be shelved in temporary
– Operators can concentrate
to the alarms which requires
urgent actions

Filter Pane
– Based on the priority, consequence, tag, etc.
– Only the related alarm message for the operator can be
shown to reduce the workload The Alarm list is shown here
Real-time Alarm Management – Filtering

• To avoid overlooking important alarms in an alarm flooding situation, the


displayed alarms can be filtered based on various conditions
– E.g. Alarm priority, Alarm purpose, Consequence, tag, etc.

Filter Pane
– Filters can be pre-configured
and can be configured by operators Only the filtered alarms are displayed
during the operation
– Operators can concentrate to the related important
– Alarms from ProSafe-RS, System alarms, alarms which require urgent actions
and Process Alarm filters
– Less opportunities to overlook the important alarms
are prepared in default
Real-time Alarm Management – Eclipsing

• To avoid overlooking important alarms in the alarm flooding situation, the


displayed alarms can be grouped based on tag
– Only the highest priority alarm for each tag is displayed
– It can reduce the number of lines on the displayed list, so less opportunity to
overlook important alarms

Click to open/close
the grouped alarm messages

Only a single line per tag


Support Quick Actions against the Alarms

• A single operation calls up related dialogs

Context menu on the alarm message


– Right-click on a alarm message to show the
context menu
– It calls up that alarm related faceplate,
tuning view, trend graph or graphic
by a single mouse click
Remote Operation
Client PC Exaquantum
Plant Information
Management
HIS System
(Operator Station)
PRM Solid Style Open Style Desktop type TSE Engineering
Plant Asset
management Console Console HIS Station
server

OPC
server

Vnet/IP
Real time Control Network FCS UGS
Field Control Station
Unified Gateway Station

Digital Field Network SCS


Safety Control Station

Subsystems
Remote Operation and Monitoring
- Graphic
- Faceplate operation
- Trend view
- Alarm monitoring Office LAN

Firewall

Ethernet
HIS
Terminal
Server
Vnet/IP

Controller
Field Control Station (FCS)
Field Control Station (FCS)
Client PC Exaquantum
Plant Information
Management
HIS System
(Operator Station)
PR Solid Style Open Style Desktop type TSE
Plant Asset Engineering
Mmanagement Console Console HIS
server Station

OPC
server

Vnet/IP FCS
Real time Control Network
Field Control Station UGS
Unified Gateway Station
Digital Field Network
SCS
Safety Control Station

Subsystems
FCS (Field Control Station)
• High availability process controller
– Seven 9’s (99.9999959) hardware availability
– Pair & Spare technology for
higher control loop availability

• Large capacity Controller


– One controller handles 1,760 analog signals and 4,096 digital signals
– Various field digital protocols can be handled
• Foundation Fieldbus, ISA100, PROFIBUS, EtherNet/IP, HART, etc
– Up to 13 extra I/O racks
– Up to 50km distance remote I/O rack

• Various types of control functions are prepared


– Regulatory Control blocks, Sequence Control Blocks, Arithmetic blocks, etc
– 7,000 functions work on a controller

• Self-Independent controller
– All the control application runs in the highly reliable controller hardware
Highly Reliable Process Controller

• CENTUM-VP Controller hardware Availability


– 0.999999959; Jun ’93 to May ’10
(Seven 9’s!)

• Benefit : Case of the users in a petrochemical Facility


– CENTUM Annual Failure Rate 0.29 loops for facility
• 26 CENTUM Systems, uptime for 33,000 loops
• From 1981 for first installation
– Other-vendor DCS Annual Failure Rate 2.86 loops for facility
• 2 Systems (one is 6-yrs old, one is 9-yrs old)
• Uptime of approximately 3,200 loops

“We’ve never had a processor fail and,


only once, replaced a couple of I/O cards
because we washed down the cabinets.”
Jeff Bolhius, Flieshman’s Yeast
Key Technologies for Highly Available FCS
• Extremely low failure rate design of each hardware

• Self-diagnosis function
– Each portion is checked just before working
– If some abnormalities are detected, the module set its status flag to FALSE

• Dual hardware configuration


– Each of dual hardware components is checking the status flags of the partner hardware
through backplane bus

• Real-time abnormality detecting

• Seamless switching
– Immediately switching from the active module to the stand-by module without affecting
the input/output for process

• Hot swapping
– Abnormal modules can be removed and spare modules can be inserted instead without
stopping any other input/output or any other hardware
Redundant Configuration of CENTUM VP

All data are equalized in real time without


affecting the control communication
among all HISs Dual CPU module Dual Power

Dual Vnet/IP
Dual Vnet/IP

Dual I/O modules Dual Power


Dual remote I/O network

Dual ESB bus

Analog, Digital, Fieldbus, Serial Dual ESB/ER bus


Pair & Spare CPU Architecture
• Both CPU modules are processing independently allowing CENTUM to
achieve a real faultless switchover (For Redundancy purposes)
A pair of CPU chips is on
each CPU module
Vnet/IP
– Each CPU is processing
independently
• This is not
Vnet/IP I/F Vnet/IP I/F for redundancy purposes
Comparator

Comparator
CPU module CPU module
CPU 1 CPU 1 Result checking
Main Main
memory
with
memory
with – Processed results of
ECC CPU 2 CPU 2 ECC
CPUs are every time
PIO I/F PIO I/F compared each other
PIO I/F PIO I/F – If the results are not
congruous, control
Power card IO bus IO bus
Power card switches to the stand-by
I/F I/F
module
Coupler Coupler

I/O bus
Control Function

• Basic Control functions are contained in a ‘Function Block’


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

• The processing of all the function blocks are executed periodically


– The processing period can be specified for each function block
• 1-sec, 500-msec, 250-msec, 100-msec and 50-msec can be selected
Control Function Capacity
Capacity of one Controller (FFCS-V) Function Block Types
Category Item Max. PVI BLEND SI-1 BAND OPSBL SI-1E
PVI-DV FF-AI SI-2 BOR OPSFC SI-2E
Analog 1,760 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 18,000 ONOFF FF-RA SIO-12 SW-33 OPSFCP4 SIO-12E
Tag Names
Function blocks 7,000 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 500 ONOFF-GE FF-OS SIO-12P DSW-16C ONOFF-GE SIO-12PE
Message Outputs Annunciator messages 2,000 PID-TP FF-SC SIO-22P DSET MC-2E SIO-22PE
PD-MR FF-IT TM DSET-PVI MC-3E
Operator guide messages 2,000 PI-BLEND FF-IS CTS BDSET-1L SI-1E
Common switches 9,000 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
I/O Nodes

Up to 13 I/O nodes can be connected per FCS


One I/O node has 8 I/O module slots
I/O nodes are connected by the remote I/O bus (ESB Bus)
– Up to 10 m from the FCS CPU node to the end of the I/O node if
electric cables are used as the ESB bus
– Up to 50 km in case of optical cables as the ESB bus

CPU node

I/O node

Max 9 I/O nodes/Line


Total Max 13 I/O nodes

35
ESB Bus for Remote I/O

Up to 50km per line by using optical fiber cables


13 nodes per FCS, 9 I/O nodes per line
Star configuration is available
8 Lines per FCS
Up to two-hop is available
SOE Recording from remote sites is available

Optical fiber cables


FCS I/O node

Optical fiber cables


Optical fiber cables

I/O node
I/O node I/O node

36
Remote I/O installation
•FM Class1, Div 2
Explosive sites •CSA Class 1, Div 2
•ATEX Zone 2

Corrosive sites
(ISA G3)
FCS Remote I/O network

ooo

Separated sites
CCR (Central Control Room)
Various Field Digital Communication Protocols
ALE111 Ethernet Communications
Module
•EtherNet/IP (CIP) MW100
ALP121 PROFIBUS-DP •Modbus TCP
•PLC-5/SLC500
Module
• Redundant Configuration is available PLC-5

CIP Control Logix


PROFIBUS-DP
Linking Device SLC500

ALF111 Foundation Fieldbus


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

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

• FIO HART Module Lineups


– AAI135-H: 8 input, channel isolated
– AAI835-H: 4 input / 4 output, channel isolated
– AAI141-H: 16 input, non-isolated
– AAI841-H: 8 input / 8 output, non-isolated
– AAI143-H: 16 input, Isolated
– AAI543-H: 16 output, Isolated
– ASI133-H: 8 input, IS module
– ASI533-H: 8 output, IS module

Input Signal from HART Device


Analog Signal
Analog Signal + HART Signal
(Current)

HART Modem
HART Variable

HART Module
Real time Control network (Vnet/IP)
Control Network (Vnet/IP)
Client PC Exaquantum
Plant Information
Management
HIS System
(Operator Station)
PR Solid Style Open Style Desktop type TSE
Plant Asset Engineering
Mmanagement Console Console HIS
server Station

OPC
server

Vnet/IP
Real time Control Network FCS UGS
Field Control Station
Unified Gateway Station

Digital Field Network SCS


Safety Control Station

Subsystems
Vnet/IP Specifications

• General specifications
– Topology: Star topology
– Transmission speed: 1 Gbps for Yokogawa hardware, 100 Mbps for general
Ethernet equipment
– Access control: Full duplex
– Scale: 64 stations/domain
– Configuration: Redundant
– Control communication: Functionally compatible with Vnet
– Open communication: UDP/IP
– Network equipment: Commercially available switching hubs and routers (Layer
2 switches and Layer 3 switches)
– Cables: CAT5e or higher UTP cables or single-mode fiber optic cables
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
Vnet/IP Unique Architecture -- Open Communication

PIMS OPC HIS/ENG HIS 3rd Pty Appl.


Open Open Vnet Open Vnet Open Vnet Open

LAN2 cable

Open Communication (UDP/IP)

Control Communication (Vnet Protocol)

Control Communication (Vnet Protocol)

LAN1 cable
Vnet Open Vnet Open Open
Field Eye
FCS UGS PLC
Server
Wide Area Communication with Vnet/IP

WAC(Wide Area Communication) Router


– Realize control and monitoring among remote Vnet/IP domains through WAN
lines
• Available for long distance connection
• Available for using WAN lines (public network, satellite connections, etc.)
– High reliable and dedicated to Vnet/IP network
• High reliable devices with redundant CPU, power, etc.
• Available for redundant wide area communication Satellite
• Availability of back up connection with different route

Local Remote
domain
WAC WAC domain

Fiber optic
HIS FCS
Wide area network line

- 45 -
Engineering Function
Quick & High-quality Engineering
• The shutdown time for a new plant construction or reconstruction should be
minimal
– A longer time results in larger financial disadvantage

• CENTUM VP provides the following configuration environment


– Total Project management
– Reuse of configuration data between several stations or plants
– Several engineers can work at the same time
– Online maintenance
– DCS Tag equalization for Historian
Total Project Management
• The application of all stations in a system is contained in one database

All graphics,
all control logic
are in a database

HIS No.1 HIS No.2 ooo FCS No.1 ooo FCS No.2
Benefits of Project Management

• The application of all stations in a system is contained in one database


– At least 1 PC is required to generate whole over a system so there is no need to
create the same or similar graphics for all the HMIs
– One PC (with configuration software) can handle several projects
– The application database of a plant can be reused on another plant by a project,
by a station, by a graphic or by a control logic
• This shortens the configuration time
• This makes the configuration quality excellent because the copy source has been
operational in an actual plant
– Optimum management of application data is available
Reuse of Configuration Asset (Application)
Graphics can be re-used for as a basis of other graphics,
on another HIS or on the HIS in different projects
Control application can be re-used for others in the controller,
in different controllers in the project or in another project

ooo ooo ooo

Plant A Plant B
(project A) (project B)
Reuse of Configuration Asset (Application)

Tag 1
Export CSV file to use within MS-EXCEL
Tag 2 Import CSV file to reuse data
Tag 3
•Configuration tool is not needed
for simple entry work

ooo ooo ooo

Plant A Plant B
(project A) (project B)
Concurrent Engineering

• Multiple engineers can work at the same time

Only one database


Advanced Debugging

• The delivery time of controller and construction time of field wiring is


much longer than the delivery time of PC
– If you can advance your configuration work only with PC,
you can shorten your total configuration time
– If you can advance your debugging work without actually connecting the
controllers and field devices, you can shorten your total configuration time

• Yokogawa provides excellent debug capability


Virtual Test
You can debug only with a PC
Target Test
You can debug without field wiring

Back
Advanced Debugging Theory

Virtual test (only with PC)


– Check simple entry mistakes
– Try new control logic
– Check graphic work
– Operator training
Advanced Debugging Theory

Virtual test (only with PC)


– Check simple entry mistakes
– Try new control logic
– Check graphic work
– Operator training

Target test (without wiring)


– Check actual FCS CPU
performance
– Check the actual relationship
among each station
Advanced Debugging Theory

Virtual test (only with PC)


– Check simple entry mistakes
– Try new control logic
– Check graphic work
– Operator training

Target test (without wiring)


– Check actual FCS CPU
performance
– Check the actual relationship
among each station

Only minimum check is needed


at start up!
On-line maintenance

• For a more productive plant operation, online maintenance of the control


application or HMI application is sometimes required
– Application modification without stopping the controller
– Application modification without affecting the rest of other application

• CENTUM VP provides the ‘On-line maintenance’ capability to meet the above


needs
On-line Maintenance Example

No effect Control logic No effect


No effect

Controller CPU
is Non-stop !
No effect

• Modifying the configuration of No effect


one of control loops, and
downloading to the controller
under operation
– No impact for any other loops,
graphics or processes
– Controller CPU is not stopped ooo

Controlling No effect
Integration with other systems
Unified Gateway Station - UGS
• DCS and intelligent control Subsystem
are ’truly integrated’ Subsystem data and
alarms via faceplate for
– UGS enable to perform supervising data and the Shadow Block
alarms of various subsystems in the same
manner as CENTUM series system tag based
faceplate operation
– UGS can have the Shadow blocks
Vnet/IP Access by tag name + item name
inside to represent the data
of the subsystem and the Shadow blocks can
Redundant UGS Server
generate alarms FIC001 FIC002 FIC003
Shadow Block
with alarm information
• High capacity monitoring
– UGS provide high capacity monitoring large
amount of subsystems
– 1 UGS can treat 256 controllers and 750,000 STARDOM MODBUS/TCP, 3rd party IED via
MODBUS/RTU, OPC IEC61850
data items Server
Ethernet/IP
Unified Gateway Station – UGS Redundancy
• High availability of UGS Redundant system
– The switch-over is achieved by the L2SWs connected on Vnet/IP
– Specific Hirschmann L2SWes are required separately from Vnet/IP L2SWes
– 10 to 20 seconds are required for switch-over.
– Subsystem data value would be shown on HIS within 10 sec – 3 min after switching over
completed.
Note: Generally speaking, the server PC failure rate is less than 1% per year. Fail-over would hardly occur.

FCS is recommended for critical


control and monitoring subsystem to UGS redundancy system
avoid black out at HIS.
L2SW
• Cause of switch-over of UGS Redundancy
– No power on UGS PC (Active) (Stand-by)
– OS stopped on UGS PC
– UGS service stopped on UGS PC
– Vnet/IP driver stopped on UGS PC
Trouble of each subsystem does not affect to
switch-over of UGS redundancy to protect
communication of other subsystems.
Safety Integration
• DCS and SIS are ’truly integrated’ Integrated Monitoring
– SIS and DCS data are within the same window - Faceplate
- Trend
– SIS data can be used in the FCS - Graphic
– Sequence of Event (SOE) data from the SIS and DCS are - System status
- Alarm
integrated - SOE
SCS and FCS Faceplates System status
CENTUM VP

Time shared
on the same
network
Vnet/IP FCS SCS SCS FCS

SIS data can be SOE Viewer


used in FCS
FCS and SCS information integrated
ProSafe-RS SCS CENTUM VP FCS
Plant Asset Data Integration
• Device information
can be called-up

Device status

Device diagnostic
Help information

Result of device Diagnosis