Centum VP Engneering Course Training Day 1

Yokogawa Electric Corporation

Yokogawa Vietnam Company Ltd. Training Center

CENTUM VP Engineering Course Trainer: Email:

@vn.yokogawa.com

Schedule for the day: Session Starts: Tea Break: Lunch: Session Resume: Tea Break: Sessions Ends:

9:00 – 10:30 10:30 – 10:45 12:00 – 1:00 1:00 – 3:00 3:00 – 3:15 5:00

am am pm pm pm pm

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Course Contents

Day 1

Day 3

Centum VP System specifications

Regulatory Control Function

Project Creation/Attribution Utility

Sequence Control Function

Project Common Definition Day 4

FCS Configuration I/O Module Configuration Day 2

HIS Configuration Window Configuration

Software Switches Configuration Message Configuration Control Drawing Builder

Day 5

Graphic Builder

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What is CENTUM VP CENTUM VP is the integrated production control system to achieve the safe, reliable, and optimum plant operation for various industries

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35 years History and the continuity Dual redundant Token-passing bus for our DCS since 1975 as reliable & robust control bus

2008

2011

CENTUM VP CENTUM VP R5

2001

CENTUM CS 3000 R3

1998 CENTUM CS 3000

1993 10 MBPS Dual Redundant Token Pass V net

1MBPS Dual Redundant Token Pass

1983

1988

CENTUM V

CENTUM-XL

COPS2 COPSV

HF-Bus

ENGS

CENTUM CS

HIS HIS

PICS

EWS

HIS

ICS

ABC

2005

AVR FFCS

PFCS

Vnet/IP

NFCS

1Gbps Dual Redundant

FFCS

LFCS KFCS

EOPS

1975 CENTUM COPS

CFCS2 CFCD2 CFFS

F-Bus 250 KBPS Dual Redundant Token Pass

CFCS EFCD

• CENTUM series has been keeping the operation continuity and the application compatibility for customers to use the CENTUM continuously for a long term. • 20,000 + systems have been installed worldwide

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Yokogawa DCS Evolution

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Centum Capacity

System Max. no. of tags

Centum VP 100 000 (When using LHS4000, up to 1,000,000 per system)

Max. no. of stations Max. no. of domains Max. no. of stations per domain

256 16 64 (HIS (16) , FCS, BCV, CGW)

HIS : Human Interface Station FCS : Field Control Station BCV : Bus Converter CGW : Communication Gateway Yokogawa Vietnam Company Ltd. Training Center

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CENTUM VP System Configuration - Overview Client PC

Operator Station (HIS) Asset management station for FF/HART devices PRM

3rd party wireless gateway

Ethernet Enclosed Display Open Display Style Console Style Console Desktop type TSE server HIS HIS and/or ENG HIS

Dual Redundant Vnet/IP Real-time Control Network

FCS

ProSafe-RS SENG

Plant Information Management System OPC server Exaquantum Exaopc

Sub system gateway

Safety Instrumented System Controller ESD / F&G

Field Network ProSafe-RS SCS

Unified Gateway Station (UGS) 3rd party Sub systems

STARDOM -Vnet/IP: Real-time Control Network -Ethernet: Information Network -Exaopc: OPC Server -Exaquantum : Plant information management system Yokogawa Vietnam Company Ltd. Training Center

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System Specification Centum VP Integration Highlights

HIS-TS

Web Server Ethernet Console

Open

HIS EWS

APCS

GSGW

SOE

VnetIP router

Vnet ABC-H

LFCS

PFCS

KFCS

FFCS

Pro-SAFE

HF-Bus

Safety Loop Digital IOs

CENTUM-XL

Conventional Analog

Subsystems

Fieldbus

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CENTUM VP VNET/IP System Components

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Plant Resource Manager (1)

Plant Resource Manager (PRM) is designed to improve the efficiency of the management and maintenance of field devices, that were registered and assigned to plant hierarchy. Also, it automatically creates management documents on devices so that they can be managed electronically. It can also access devices with a field communication function such as devices that support FOUNDATION fieldbus, manage device parameters, and execute device adjustment and diagnosis available with devices and so forth.

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PRM Configuration

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PRM Configuration

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HIS: Human Interface Station Features : ¾ Various types of the operation views are prepared – Graphic, Trend graph, Overview, Tuning etc. ¾ 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

¾ 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

¾ Various types of operation environment are available – – – –

Single, dual, Quad LCD are available. Wide monitor is also available. Mouse operation Operation keyboard and touch screen are also available ¾ Real-time Alarm Management View Yokogawa Vietnam Company Ltd. Training Center

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HIS Hardware ¾ HIS works on the latest Microsoft Windows OS platform Windows 7 64bit, VISTA, and 2008 server

¾ Three types of hardware can be chosen Desktop, Solid Style Console and Open Style Console

¾ Various Operation Styles Mouse/Operation Keyboard/Touch panel Single, Dual and Quad-monitor are available Solid Style Console

Desktop Type

Open Style Console

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New Screen Design

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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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System Specification Engineering PC (ENG)

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EWS Engineering PC (ENG)

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Operation Keyboard Features ¾ Flat membrane type dedicated keyboard ¾ 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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Field Control System I. Process Control Functions The FCS is the controller that executes control strategy and computation to control the plant Four Types of FCS to choose from, for Flexible System Configuration: FIO, FCS for RIO, Compact FCS for FIO, and Compact FCS for RIO, according to your application requirements, for system expansion or replacement.

FFCS (Compact) FIO

PFCS (Compact) RIO

KFCS/KFCS2 (Standard/Enhanced) FIO

LFCS/LFCS2 (Standard/Enhanced) RIO

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Field Control System

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Field Control System

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FCS (Field Control Station)

Address setting on the backside of the FCS (CPU card) Yokogawa Vietnam Company Ltd. Training Center

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Setting Domain Number

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Setting Station Number

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Redundant Configuration of CENTUM VP All data are equalized in real time without affecting the control communication among all HIS’s Dual CPU module

Dual Power

Dual Vnet/IP

Dual Vnet/IP

Dual I/O modules

Dual Power

Dual ER bus

Analog, Digital, Fieldbus, Serial

Dual ESB/ER bus

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Pair & Spare CPU Architecture ¾ Both CPU modules are processing independently, so CENTUM achieves real bumpless switchover (For Redundancy purpose) Vnet/IP

Vnet/IP I/F

CPU 1

CPU 1

CPU 2

CPU 2

Comparator

Comparator

CPU module Main memory with ECC

Vnet/IP I/F

PIO I/F

PIO I/F

PIO I/F

PIO I/F

Power card

IO bus I/F

IO bus I/F

Coupler

Coupler

CPU module Main memory with ECC

Power card

¾ A pair of CPU chips is on each CPU module – Each CPU is processing independently • This is not for redundancy purpose ¾ Result checking – Processed results of CPUs are every time compared each other – If the results are not congruous, control switches to the stand-by module (To avoid the effect of transient error)

I/O bus

Error-Correcting Code repairs transient bit inversion errors Yokogawa Vietnam Company Ltd. Training Center

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Control Network (Vnet/IP) ¾ Vnet/IP is the control network that incorporates general communication function without losing highly reliable, real-time, and stable communication – High reliability and real-time capability of Vnet are succeeded – Open communication capability is incorporated ¾ 1G bps Ethernet based control network – 100 Mbps is also available ¾ Being published by IEC as industrial communication standard PAS (IEC/PAS 62405/Ed.1) PAS: Publicly Available Specification Open

Reliable

Realtime

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Vnet/IP Specifications ¾ 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: TCP/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

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Vnet/IP Network Configuration HMI

ENG

Vnet Router

Vnet System

Controller

Plant Asset Management

OPC Server

ProSafe-RS

Domain1

Third party system Interface

Field network

OPC Server

ENG

HMI

Controller

Plant Asset Management

ProSafe-RS

Field network

Domain2 Yokogawa Vietnam Company Ltd. Training Center

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Vnet/IP – 1 Gbps Control Network

PIMS

OPC

HIS/ENG

HIS

3rd Pty Appl.

Open

Open Vnet

Open Vnet

Open Vnet

Open

LAN2 cable Open Communication (TCP/IP) Control Communication (Vnet Protocol)

Control Communication (Vnet Protocol) LAN1 cable

Vnet

Open

Vnet Open

Open

FCS

Field Eye Server

GSGW

PLC

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1 GBps Bandwidth

Vnet/IP Features (bandwidth partitioning Control)

In case of errors in BUS 1, control is shrift to BUS 2

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Control Network

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IP addressing Vnet/IP HISDDSS

DD = Domain Number SS = Station Number

Vnet: 172.16. DD.SS VnetOpen: 192.168.[128+DD]. [SSx2] HIS0156

Domain 1 Station 56

Network Address: Vnet: 172.16. 1.56 Open: 192.168.129.112

HIS0324

Domain 3 Station 24

Network Address: Vnet: 172.16. 3.24 Open: 192.168.131.48

HIS0234

Domain 2 Station 34

Network Address: Vnet: 172.16. 2.34 Open: 192.168.130.68

Alternate Addressing for VnetOpen: 192.168.[128+DD]. [128+DD+SS] Yokogawa Vietnam Company Ltd. Training Center

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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

Connection

Cable Standard

Transmission Rate

Max Distance

Between stations &L2 Switch

1000BASE-T

1GBps

100m

1000BASE-T

1GBps

100m

Between L2 Switches

1000BASE-LX

1GBps

5km

1000BASE-T

1GBps

100m

1000BASE-LX

1GBps

5km

Between L2- & L3 Switches

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I/O Node

Node

The Node is a signal processing devices that convert process input/output signals to or from the field equipment and transmit them to the field control unit.

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I/O Nodes ¾ Up to 13 I/O nodes can be connected per FCS (EC402) 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

Max 9 I/O nodes/Line Total Max 13 I/O nodes (without CPU node)

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System Specification (FFCS)

Eight FIO slots

Centum VP Compact type Detachable bottom unit EC401 ESB bus coupler(Note)

Power supply unit

CP401 CPU module AIP504 VnetIP coupler (10BASE2 VnetIP cable is used.) Note: Two I/O slots are to be used for NIU extension. Yokogawa Vietnam Company Ltd. Training Center

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HW/SW Requirement: Software Operating system: Windows XP, Service Pack 3, Windows 7 64Bits Processor:

Intel Core 2 Duo

Color pallet :

Above High color (65536). With at least 8MB of VRAM, 16000000 colors can be specified.

Memory :

2 GB or more RAM 80GB HDD (recommended minimum)

Memory :

CRT or LCD (21” min recommended) Video memory (512 MB minimum)

PCI/Express Slot: Vnet/IP card (VF701/VI701/VI702) Ethernet port

LAN connection (for Vnet only)

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Test Function The Test function allows combination of monitoring/operation and control functions to be tested before being put into operation. The Engineers use this tool to debug the changes they are about to do. Virtual Test

Target Test

ooo

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Types of Test Function 1. Virtual Test Function It 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.

Virtual Test

FCS simulator

Operation and monitoring Function

ooo

HIS01XX FCS01XX Yokogawa Vietnam Company Ltd. Training Center

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Types of Test Function 2. Target Test It 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. These use actual HIS and FCS for the test.

Tag01 PID

I/O simulator HIS01XX

FCS01XX ooo

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Engineering Work Flow Specification Review Review the I/O list, process control methods and necessary hardware. Basic Design Using organized and structured windows to realize the desired control functions (regulatory control, sequence control and unit supervision) and the operation and monitoring functions.

Detailed Design Design detailed items (program configuration, creation of data list) for the regulatory control, sequence control, unit supervision and the operation and monitoring windows according to the basic design.

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Engineering Work Flow System Generation Construct a system using various builders based on the basic design and detailed design.

Unit Test Check the control loop operation as well as the operation and monitoring windows by using the virtual test function.

Integration Test Using the actual FCS, check the overall validity of functions and execution timings that were checked individually through the unit test.

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Engineering Work Flow Start Up Install and wire the target machine, carry out test operation and then normal operation.

Maintenance Back up engineering data, inspect hardware, etc.

Expansion and Modification Expand the station, as well as add and change functions. Review the I/O list, process control methods and necessary hardware.

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Project Creation 1. Start System View Start Æ Programs Æ YOKOGAWA CENTUM Æ System View

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Project Creation Start Default Project Creation When the System View could not identify an existing current or default project, it will prompt the user to create a default project with the dialog box as shown below. Click [YES] to create the default project.

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Project Creation Project Outline The project information area allows the project creator to enter arbitrary characters. Enter information on the process and the person in charge of DCS to manage the project.

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Project Creation Project Property Project name is an alphanumeric character string less than 8 characters. The comment within 32 alphanumeric characters or 16 double - byte characters may be entered as the project description. Moreover, an alias can be created for a project. An alias of project can be defined with 8 alphanumeric characters.

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Project Creation Creating an FCS folder A folder for the first FCS database files is created when the default project is created. Assign the correct station type and station address as they cannot be modified upon confirmation. Additional FCS can be created in future for more FCSs.

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Project Creation Creating a HIS folder A folder for the first HIS database files is created when the default project is created. Assign the correct station type and station address as they cannot be modified upon confirmation. Additional HIS can be created in future for more HISs

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Project Creation Project folders The project consists of 3 basic folders – Common, FCS and HIS. Additional FCS, HIS or other stations can be created under the pull down menu. Select project Æ Right click on project Æ Create New Æ HIS or FCS

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Project Creation

Subfolders of your project

Now you have your new project under the name TRAINVP Yokogawa Vietnam Company Ltd. Training Center

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Project’s Attribution Utility ¾ The Project’s Attribution Utility is an engineering tool that makes it convenient to register a project created from other PC, to change a project’s properties or to remove the registration of a project. ¾ Before using the Project’s Attribution Utility, check that the System View is not running. If it is running, the Project Attribute Change Utility cannot run. ¾ Only one project can exist as default project or current project in System View

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Project’s Attribution -Differences

Default

Current

User-defined

Created the first time when the System View starts

Yes

-

-

Virtual test with the FCS simulator.

Yes

Yes but target test

Yes

Yes but off line

Yes but on line

No

Can be downloaded to HIS.

Yes

Yes

No

Multiple projects can be created in System View.

No

No

Yes

Can be downloaded to the FCS of the target system

When any one of the FCS’s created in default project is successfully downloaded, the attribute changes to a current project. Yokogawa Vietnam Company Ltd. Training Center

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Project’s Attribution Utility

Click “Programs” Click “start”

Click “Project’s Attribution Utility”

Click “YOKOGAWA CENTUM” Yokogawa Vietnam Company Ltd. Training Center

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Project’s Attribution Utility

Click

To change the Attribute of a Project

To remove a Project from System View Yokogawa Vietnam Company Ltd. Training Center

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Project’s Attribution Utility

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Project Common Item Definition ¾ ¾ ¾ ¾ ¾ ¾

Station Configuration Viewer Security Builder Operation Mark Builder Engineering Unit Symbol Builder Switch Position Label Builder Alarm Builder 9 Alarm Priority Builder 9 Alarm Processing Table Builder 9 System Fixed Status Character String Viewer

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Project Common Item Definition From the System View

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Project Common Item Definition Station Configuration Viewer

The Station Configuration Viewer displays the overview of the station configured for the project and a print out can be generated. However, modification to the configuration is not allowed in this viewer Yokogawa Vietnam Company Ltd. Training Center

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Project Common Item Definition Security Builder

The security policy is set to prevent illegal operations and other problems and ensuring the safety of the system.

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Security Level

An attribute called “Security Level” is assigned to the function blocks. The security policy is set to prevent illegal operations and other problems and ensuring the safety of the system

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Security Builder – Tag View OFFUSER

ONUSER

ENGUSER

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Security Builder – Window Monitoring OFFUSER

ONUSER

ENGUSER

Properties of Function Block FIC100

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Security Builder – Window Operation OFFUSER

ONUSER

ENGUSER

Users with S3 rights can write data to Block mode, SV and MV, but users with S2 rights cannot write data to Block mode, SV and MV.

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User Name & User Switching

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Privilege Level

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Automatic User Time-Out

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User Group Users group classified into groups based on their operation and monitoring authorities/Scopes. The following attributes are assigned to each user group: User group name, Operation scope, Operation and monitoring scope, Windows scope, Confirmation operation scope, Messaging scope, Comment

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Valid User Valid User classified into User name based on their users group of operation and monitoring authorities/scopes. Users can be defined to automatic user out time, the users automatically changes to OFFUSER when automatic user out time elapsed

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Operation Mark Builder

Tag Label: Up to 8 single-byte characters can be entered as the text on the label (string). The operation mark label maybe temporarily changed during the operation on the HIS Setup window. Yokogawa Vietnam Company Ltd. Training Center

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Operation Mark: Privilege level & Color Privilege Level: The privilege level required for a user to attach/remove the operation mark.

Tag Level write access right on function blocks can be changed

Colors: The following colors maybe used on operation Marks and maybe temporarily changed on the HIS Setup window.

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Project Common Item Definition Engineering Unit Symbol Builder

Up to 256 engineering unit symbols can be used for one project

Engineering Unit symbols nos. 1-8 cannot be changed or deleted. Default values are from nos. 9-126

The following symbol cannot be used to define engineering unit: @, /, (‘),(“),(,) and #

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Alarm Priority Builder - Alarm Action

The alarm processing level is defined for each function block. The output operation for each alarm priority can be selected.

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Alarm Priority Builder - Rewarning

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Alarm Processing Table Alarm Processing Level Numbers: 1- 4 System fixed - High - Medium - Low - Alarm Logging 5 – 16 User defined - High - Medium - Low - Alarm Logging - Reference Alarm

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System-fixed Status Character String Viewer/ Alarms

Alarm Status Bit Positions

1- 4 System fixed 5 – 16 User defined

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End of Presentation

THANK YOU FOR YOUR ATTENTION

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