Yokogawa Cs3000

CENTUM CS3000

Tr aining Manual Pr oblem Repor t

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CENTUM CS3000

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3

CENTUM CS3000 TABLE OF CONTENTS 1

2

3

4

5

6

7

8 9

System Overview .................................................................................................................................................6 1.1 Hardware terminology .................................................................................................................................8 1.2 Human Interface Station (HIS) ..................................................................................................................12 1.3 CS3000 Field Control Station....................................................................................................................14 1.4 I/O Modules and Nodes .............................................................................................................................15 1.5 Used I/O Modules......................................................................................................................................18 System Operations .............................................................................................................................................21 2.1 Operator Keyboard ....................................................................................................................................22 2.2 System Message area .................................................................................................................................26 2.3 HIS Operation Displays .............................................................................................................................27 2.4 Control Window ........................................................................................................................................31 2.5 Overview Window.....................................................................................................................................34 2.6 Tuning Window .........................................................................................................................................36 2.7 Trend Window...........................................................................................................................................38 2.8 Graphic Window........................................................................................................................................41 2.9 Process Alarm Window .............................................................................................................................43 2.10 Operator Guide Message Window.............................................................................................................45 2.11 Navigation..................................................................................................................................................47 System Maintenance Windows ..........................................................................................................................48 3.1 System Overview Window.........................................................................................................................50 3.2 System Alarm Window ..............................................................................................................................52 3.3 CS3000 Control Station Status Display Window.......................................................................................54 3.4 HIS Setup Display .....................................................................................................................................56 Process and Historical Reports ..........................................................................................................................57 4.1 Process Report Window.............................................................................................................................59 4.2 I/O Searches...............................................................................................................................................61 4.3 Historical Report Window .........................................................................................................................63 Control System Design ......................................................................................................................................64 5.1 Architecture ...............................................................................................................................................64 5.2 I/O Module Arrangement...........................................................................................................................65 Control Concept.................................................................................................................................................66 6.1 Tag naming standards ................................................................................................................................66 6.2 Tag alarms standards .................................................................................................................................67 Process screens standards ..................................................................................................................................68 7.1 Colors of medium ......................................................................................................................................68 7.2 Colors of device states ...............................................................................................................................68 7.3 Colors of electrical failures........................................................................................................................68 7.4 Basic types of equipment (shapes).............................................................................................................69 7.4.1 Pump, fan ...........................................................................................................................................69 7.4.2 Solenoid Valve (ON/OFF) .................................................................................................................70 7.4.3 Regulation valve ................................................................................................................................71 7.4.4 Analog measurement..........................................................................................................................72 7.4.5 Regulator............................................................................................................................................72 7.4.6 Faceplates ..........................................................................................................................................72 Operator displays ...............................................................................................................................................73 Pro-Safe .............................................................................................................................................................74 9.1 SCS System................................................................................................................................................74 9.2 Communication..........................................................................................................................................74 9.3 Used I/O Modules......................................................................................................................................75

4

CENTUM CS3000

5

CENTUM CS3000

1 System Overview OBJ ECTIVES OF THIS CHAPTER 1.

Learn the overall layout concept of CENTUM 3000.

2.

Learn the terminology of the CENTUM 3000 system.

3.

Show how to setup unit addressing.

4.

Learn the Field Control Station hardware.

5.

Identify the different types of I/O modules and how software addresses each point.

6

CENTUM CS3000

Ethernet

HIS

HIS

Vnet

FCS

FCS

7

CENTUM CS3000

1.1 Hardware terminology The CS3000 is a distributed control system, which means that the “intelligence” to run the process resides in the control hardware in the process area. The CS3000 system has a maximum of 64 stations per domain, (16 Domains and 256 stations maximum) and 100,000 tags (expandable to 1 000 000 tags). Human Inter face Station (HIS) This station is used mainly for operating and monitoring plant functions. With optional engineering software, system builder functions can be defined. Field Contr ol Station (FCS) The FCS provides control of the plant functions through instruments in its database. Process information is placed on the Vnet and Vnet/IP for monitoring or control by an HIS. Processing speeds of 1 second (Standard), 500 ms, 200 ms, 100ms and 50ms are selectable for the function blocks. Vnet (Vnet/IP) This is the communication highway that links the system components together for control and monitoring functions. New instruments are downloaded to the FCS from the HIS via the Vnet (Vnet/IP). Vnet (Vnet/IP) runs at a 10 Mbits/1Gbits rate. Ethernet Ethernet communication link between HIS units used to download files from the PC with “builder” if Vnet is used. Vnet/IP is using Bus 2 for inter HIS communication (open communication) Vnet - process communication highway Type of Bus 10BASE-5=10- speed 10Mbps;BASE data transmission in the BASEBAND;5-500 distance between station(PC)[YELLOW CABLE THICK]1cm 10BASE-2=THIN=5mm type of communication BUS 1 "Control communication" BUS 2 "Open communication" Redundant it means BUS 1 + BUS 2.Both busses are divided to several layers BUS

Ethernet communication link for loading soft and transmission data from printers, amount of PC station

8

CENTUM CS3000

FCS HIS

Ethernet Vnet

Domain 1 BCV

FCS HIS

Domain 2

9

Vnet

CENTUM CS3000

Bus conver ter (BCV) The ABC bus converter is used to connect CENTUM 3000 to existing CENTUM-XL or Micro XL systems. The ABC is also used for splitting the CENTUM CS3000 into what are called Domains. Domain A Domain is a grouping of stations on a Vnet segment. CS3000 Domains can have up to 64 stations; the domain address range on the V net is 1-16. A maximum of 256 stations are allowed per CS3000 system. CS1000 is fixed as Domain 1 with a maximum of 24 station. When CS1000 is connected to a uXL, the uXL is assigned Domain 17.

10

CENTUM CS3000

11

CENTUM CS3000

1.2 Human Interface Station (HIS) The HIS is used mainly used for plant operation and monitoring, but can have system engineering and test function software installed. The test function allows the engineer to create and test control function without the use of an FCS. The HIS can also have an optional spill resistant operator keyboard. Since the HIS runs Windows XP, this allows the user to run standard Windows XP based applications, like MS Word , or Excel for spreadsheets.

Minimum Requir ements: CPU Pentium 800MHz or higher. Memory 128 MB for operations and monitoring. 256 MB for operations and builder. Hard Disk Drive 1 GB (2 GB recommended for using builder functions). CRT 17 inch or larger; 1024 x 768 (16 bit color depth colors). Station Addr essing There is a card in the HIS that defines its station number on the Vnet by the physical switch settings. Vnet STATION ADDRESS Switches

ODD PARITY

ODD PARITY

DOMAIN NO.

STATION NO.

0 0 16 8 4 2 1

Domain 1

0 0 16 8 4 2 1

1 0

Station 24

1 0 12345678

12345678

*NOTE: Active switch positions are white

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CENTUM CS3000

FCS Application Capacity Process I/O Analog I/O: Contact I/O: Internal Status Switch Common: Number of Control Drawings CS3000 Number of Function Blocks Depends upon database type

8x16x14+6*16=1888 4096 4000

(shared within that FCS)

200

Addressing for both types of units is carried out through setting dip-switches on the unit. Vnet STATION ADDRESS Switches

ODD PARITY

ODD PARITY

DOMAIN NO.

STATION NO.

0 0 16 8 4 2 1

Domain 1

0 0 16 8 4 2 1

1 0

Station 1

1 0 12345678

12345678

*NOTE: Active switches are white

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CENTUM CS3000

1.3 CS3000 Field Control Station The Field Contr ol Station, if purchased as redundant, has dual processor cards; each processor running dual RISC processors. Depending on the FCS purchased, memory will be 16/32MB. Data is transferred to and from the FCS via the Vnet. Data is transferred to and from the Field Control Unit and the Node Interface Unit via the ESB bus. The ESB bus can connect up to 10 Nodes to the FCS; each Node can have up to 8 I/O modules. ESB bus can be extended by ER bus (10 Mbs Ethernet network, 10BASE2, 10BASETP), connecting max. 15 nodes.

FCS Application Capacity Process I/O Analog I/O: Contact I/O: Internal Status Switch Global (future): Common: Function Blocks Control Drawings: Function blocks:

Max. 640 4096 256 (shared with other FCSs) 4000 (shared within that FCS) 200 Depends upon FCS type.

The Node Inter face Unit houses the I/O modules that are wired directly to the process.

14

CENTUM CS3000

1.4 I/O Modules and Nodes

15

CENTUM CS3000 I/O connection:

16

CENTUM CS3000 CONTROL DRAWING SOFTWARE MODULE ADDRESSING When a user creates an instrument (called a “function block”), it must be told which input point it will be using for reference or output point for control. This is accomplished in an engineering screen called a “Control Drawing”.

Using FIC100 (on the previous page) as an example, this is how the function blocks running in the processor know which I/O module to use.

%Z 0 1 1 1 0 1 CS3000 NIU # (1-15)

%Z011107

1

Slot # (1-8) Terminal #

%Z011108

17

%Z011109

CENTUM CS3000

1.5 Used I/O Modules AAI143-H Cur r ent Input Module This module inputs 4 to 20 mA. Number of input channels 16, isolated Input signal 4 to 20 mA Accuracy ±16 A Data update period 10 ms Transmitter power supply 24.0 to 25.5 V (output current limit: 25 mA) Setting of 2-wire or 4-wire transmitter for each channel by setting pin Maximum current consumption 230 mA (5 V DC), 540 mA (24 V DC) Weight 0.3 kg External communication Pressure clamp terminal, MIL connector cable, Dedicated cable (KS1) HART communication

AAI543-H Cur r ent Output Module This module outputs 4 to 20 mA. Number of output channels 16, isolated Output signal 4 to 20 mA Between output and system: 1500 V AC, For 1 minute Allowable load resistance 0 to 750 Accuracy ±48 A Data update period 10 ms Maximum current consumption 230 mA (5 V DC), 540 mA (24 V DC) Weight 0.4 kg External communication Pressure clamp terminal, MIL connector cable, Dedicated cable (KS1) Circuit-open detection Less than 0.65 mA HART communication

18

CENTUM CS3000 AAT141-S TC Input Module These modules receive signals from mV and thermocouple (TC). Number of input channels 16, isolated Input signal TC: JIS C1602:1995, IEC584:1995, Type J, K, E, B(*1), R, S, T, N mV: -100 to 150 mV, -20 to 80 mV Switching input signals TC/mV can be set individually for CH1 to CH16. Withstanding voltage Between input and system: 1500 V AC, For 1 minute Data update period 1sec Weight 0.2 kg Maximum current consumption 450 mA (5 V DC) External connection Pressure clamp terminal

ADV157-S Digital Input Module The Digital Input Modules receive 32-channel 24 V DC ON/OFF signals. Number of input channels 32 Rated input voltage 24 V DC (sink/source) Input ON voltage 18 to 26.4 Input OFF voltage 5.0 V or less Input current (at rated input voltage) 4.1 mA_20 % / channel Maximum allowable input voltage 30.0 V DC Maximum current consumption 350 mA (5 V DC) Weight 0.4 kg Pressure clamp terminal,

19

CENTUM CS3000 ALR121 Ser ial Communication Module This Module exchanges data with a subsystem such as a programmable controller via a serial communication line using the Interface RS-422/RS-485 (2 ports) How connected Point-to-point Point-to-point (RS-422), Multipoint (RS-485) How communicates Half-duplex How synchronizes Start-stop synchronization Communication speed 1200/2400/4800/9600/19200/38400/57600/76800/115200 bps Transmission code ASCII/binary Character length 7/8 bits Stop bit length 1/2 bits Parity check None/even/odd When a signal is received after data transmission 1 ms Transmission distance Maximum 1200 m (total extended length) Cable with 3-pair shield Wiring connection Clamped with terminal block’s M4 screws (5 poles x 2) Current consumption 0.5 A Weight 0.3 kg

20

CENTUM CS3000

2

System Operations

OBJ ECTIVES OF THIS CHAPTER Upon completion of this chapter you should be able to: 1.

Identify the standard display windows of the CENTUM CS3000.

2.

Operate the Overview, Control Group, Operator Guide, and Process Alarm window.

3.

Explain the function of the above windows.

21

CENTUM CS3000

2.1 Operator Keyboard

22

CENTUM CS3000

OFF

ON EN

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

COPY

SYSTE

ES

1

!

2

@

Q

TA CAPS LOCK

SHIF

CTR

AUX

AL

3

#

W

A Z

$

4 E

S X

5

%

R D C

HELP

6

^

T F

7

&

Y G

V

?

B

8

*

U H M

9

(

I J N

,

P

L <

.

>

SPAC

;

[

{

:

] "

` }

/

?

SHIF

CTR

|

EX

BS

\ DE

RETUR

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~

+ =

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0

ITE NAM

C

.

CENTUM CS3000 OPERATOR KEYS

Programmable function key 1

Page forward and backward

SYSTEM

Display SYSTEM overview

Fast ramp

COPY

Screen hard copy

Ramp UP

AUX

AUX key

Ramp DOWN

HELP

Help message for the window

Target key

Circulate

?

Clear screen

Manual

Process alarm display

Auto

Operator guide message

Cascade

Control group Tuning panel Move cursor Trend panel Graphic panel

Select cursor item

Process report

ITEM

Define “Item”

Navigator window call key

NAME

Panel “Name

Upper window

CL

Clear line

Left “Brother” window Right “Brother” window

Acknowledge alarm

Process overview panel

Buzzer silence

Scroll keys Cancel . Confirm

24

Process Alarm Tool Box

System Alarm OperationGuide messages Message monitor

Display Always

User In

System Ststus Display

Window Call Menu

HELP Message Window

Operation Menu

Process Alarm Window

Preset Window Menu

Operator Guide Window

Tool Box

Control Window

Navigator

Tuning Window

Name Input

Trend Window

Circulate

Graphic Window

Clear All

25

Buzzer Reset

Process Report Historical Report

Next Level Up Navigate right Overview Window Save Window Set

Hard Copy Input Window Name

Navigate Left

Release Window Set Save Image

Larger Size Middle Size

CENTUM CS3000

Rotate Windows

CENTUM CS3000

2.2 System Message area At the top of the HIS screen is the “System Message Area”. Shown here are: The last pr ocess alar m OR last system alar m that occurred. The date and time are shown in the upper right-hand side.

Icons in the System Message Ar ea: Process alar m: Lights when an alarm condition occurs in an instrument. System Alar m: Lights when a system level occurrence happens, such as hardware failure or software file load. Oper ator Guide message: Lights when a message is generated by the system for the operator. Change user : Used to change security levels on the HIS, based upon the user who logs on. Window call menu: Allows access to display window without the use of the “Tool box” or the operator keyboard. Oper ation menu: Allows the user to manipulate windows related with the currently displayed operation window. Preset Window menu: Windows that the operator uses often can be shown here. They are defined under the “HIS Setup” icon on the “System” display. Tool Box: Gives access to different categories of displays. Navigator : Is used to display the plant window configuration. Icons under the Navigator can be selected to display their specific windows. Name: Used to enter the name of the window or function block to be displayed. Cir culate: Used to switch between an NT package and a HIS display. Clear all: Erases operation display screens Buzzer r eset: Silences alarm tones. Copy: Makes a screen copy of the current display. “Tool Box” Icons: These icons represent another way of accessing the operation displays without the use of the operator keyboard. The purpose of these icons is discussed in this chapter.

26

CENTUM CS3000

2.3 HIS Operation Displays The HIS can be defined as “Full-scr een mode" or “Windows mode” Full-screen mode has a window displayed as full screen, this is the “primary window”. In full-screen mode there can be up to 4 secondary windows displayed. Windows mode does not have a primary and secondary window. As displayed windows are called up, they move to the front. There is a maximum of 5 windows displayed, when a 6th window is displayed the secondary window at the back is closed.

27

CENTUM CS3000

Feedback Control Instrument

Switch Instrument

Tag Number Tag Comment Tag mark Mode

Cascade Mark

Alarm status Engineering Units

Index Mark Scale Manipulated Variable Limits

High High alarm setting Process Variable

High alarm setting Manipulated Variable Setpoint

Index Mark

Process Variable

Manipulated Variable

Scale

Drain (On/Off) Answerback

Puts the loop into MANUAL Puts the loop into AUTO and

Puts the loop into CASCADE

After the new mode has been selected, push the

.

28

to confirm the change.

CENTUM CS3000 INSTRUMENT FACEPLATE Instr ument mode examples: AUT: Control computation (PID) determines the instrument’s output. MAN:

No control computation and the instrument’s output is manually adjusted.

IMAN:

Displayed on the primary instrument of a cascade loop when the secondary instrument isn’t in CAS. Shows there is no control computation or output on this instrument.

CAS:

Setpoint control of this instrument comes from another (primary) instrument.

O/S:

Out of Service. All functions are non-operational.

The color of the pointers (SV and MV) on the tag faceplate also show the tag’s mode. The r ed pointer is in contr ol. If a tag is in AUT, the MV pointer will be yellow, and the SV pointer will be r ed. If a tag is in MAN, the MV pointer will be r ed, and the SV pointer will be yellow. If a tag is in CAS, the MV pointer and the SV pointer will be yellow.

MODE Changes Clicking on the text of the current mode makes the mode selection box appears. Click on the appropriate icon, then “Confir m”. If a tag is a cascade, then

will be shown on the faceplate.

Setpoint (SV) or MV Changes Click the

box under the tag.

A box will appear under the selected tag; type in the new value. MV appears in the box if the loop is in MAN, SV appears if the loop is in AUT. Clicking on the data item on the faceplate also displays this box. Use the mouse and select the SV or MV pointer (depending on the mode of the instrument) and a ramping window appears. The item can be adjusted by selecting the up or down arrows. On the operator keyboard, the SV or MV can be changed with the ramping keys been selected. To ramp quickly, select a tag, press the

after the loop has

button and then hold the ramping arrow.

Switch Instr uments Switch instruments are used to control ON/OFF devices like valves, motors, or pumps. A switch instrument has to be in MAN for the operator to make any changes in the output. To open or close a switch instrument, press the up or down ramping arrow click on the faceplate position you want.

for the selected tag or

The left-hand box on the faceplate shows the current output. The right-hand box on the faceplate shows the answer back (digital confir mation) from the field instrument.

29

CENTUM CS3000

CG0007

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CENTUM CS3000

2.4 Control Window The control window is an operation window using instrument faceplates to display the control status of each tag. Push the

key (or icon) to bring up the Control window.

Each control group window can show up to 16 tags. To bring up a specific window, select the NAME icon and type in the window name. The Faceplate window for that tag appears. Next, select the “Contr ol window” icon from the “Tool Bar ” or on the “Window Call Menu”. Operation Marks used as flags for the operator. Click on the X in the upper corner of any window to close it. Alar m color s: Gr een: Red: Yellow: Blue: White:

Normal operations Process alarm (IOP, HH, LL, OOP) Alarm has occurred (Deviation, Velocity, or Output limits) Alarm output disabled Tag without alarms (i.e.: internal switch)

Security Levels: Eight different access levels can be selected to specify the instrument’s operation, the mode selection key affects the security level assigned to an instrument. The chart shown below contains a simplified version of the different security levels. Specific security information can be found in the “Instruction Manuals”.

Monitoring

Level

S1 1 2 3 4 5 6 7 8

x x x

Can be executed

S2

x x

Operation S3

x

S1 **1 **2 x x x x x

S2

S3

x x x x

x x x

x Cannot be executed

**1 Only the alarm settings, SV, MV, and block mode can be changed. **2 Only the SV, MV, and block mode can be changed.

Tag Impor tance Mar ks One of the four different tag importance marks can be assigned to a function block. Important: The users must acknowledge SV and MV changes, and tag marks remains flashing after alarm recovers. General: No acknowledge SV and MV changes, but tag marks remains flashing after alarm recovers. Auxiliary 1: No acknowledge SV and MV changes, and tag marks stops flashing after alarm recovers. Auxiliary 2: No acknowledge SV and MV changes, and tag mark doesn’t flash before or after alarm.

31

CENTUM CS3000

HELP WINDOWS Help messages can be assigned to any operation window, with specific text created to aid the operator.

32

CENTUM CS3000

OV0001

Reactor

Boiler

Furnace

Sample Displays

CG0007

CG0002

CG0005

Logo

CG0008

CG0003

CG0006

Bit map

CG0004

3D type

TG0007

TG0001

TG0005

CUSTOM

01FRC-103 0.0L/M AUT NR

01LIC-601 5% AUT NR

01TIC-101 234DEGC CAS HI

16 Loops

01FIC-101 0.0L/M MAN NR

01PIC-101 100TNE/H AUT NR

01TIC-201 479DEGC CAS NR

Trend Group

Help

SEQ Table Status

Face Plate

System status

33

CENTUM CS3000

2.5 Overview Window The “Overview” window can be used for monitor ing the oper ation of a plant. Specifications: Number of display blocks: 32 per page Items that can be assigned to the overview blocks are: Function blocks (instruments), Windows (overview, control group, graphic), Comments Annunciators messages. Overview block selection: Mouse Cursor keys (on the keyboard). When a instrument is assigned to one of the 32 overview blocks, the alarm status of the assigned that tag or window is reflected as the color of the block. The display block changes color and flashes according to the alarm status. Alar m color s: (Same as on the Control Window) Normal operations Gr een: Process alarm (IOP, HH, LL, OOP) Red: Alarm has occurred (Deviation, Velocity, or Output limits) Yellow: Blue: Alarm output disabled White: Tag without alarms (i.e.: internal switch) Pressing the

key (or icon) will acknowledge (stops flashing status) all of the alarms on the displayed window.

{xe "**Empty**"} Scr een Hier ar chy Layout: The alarm statuses can be read from the lowest level window to the “Overview” window. Overview

Plant-A

Area-A

Plant-B Overview

Overview

Area-B

Area-A Graphic

Reactor-1

Overview

Reactor-2

Reactor-3

Reactor-4

34

Area-D

CENTUM CS3000

35

CENTUM CS3000

2.6 Tuning Window This window is used to display the parameters and tuning trend data for an instrument. The different types of function blocks will have items unique to their function. The Tuning Window can be displayed by typing in the tag name (to bring up the faceplate window) and selecting the icon on the “Tool Box” or “Window Call Menu”, or selecting this key on the optional keyboard.

Oper ation mar k assignment menu window Touching the “Operation mar k” icon displays the menu window, then select the desired text. To select items on this window: 1.

Only items with a “ = “ mark next to them can be changed.

Tr end data that can be displayed: Process variables (PV, CPV, or FV). Setpoint values (SV). Manipulated output values (MV). Switch positions (SW) Tr end display. The Tuning Trend starts displaying when the window is displayed. 48 minutes of data maximum. Selecting the “Reduce” or “Enlarge” time or data axis icon allows the modified for optimum viewing. Moving the scroll bar under the tuning trend allows viewing of past trend data. Selecting the “Reduce” or “Enlarge” data axis changes the vertical scale. Move the up or down arrow at the right- hand side of the trend to see the expanded data. (1, 2, 5, 10x) Selecting the “Stop/Resume” icon will pause the updating of the trend data. Selecting it again releases the pause. Touching the “Reser ve” icon allows the trend data to be recorded even when the Tuning Window isn’t being displayed. Up to 16 points can be reserved.

PG-L13 TUNING PANEL The PG-L13 is a 13 zone program set block. The user sets the time base in “Zones”, and the ramping to occur in during that time. Can be used to heat, cool, or cook products at a pre-defined rate. “AUT” allows the PG-L13 to run one time and then goes to “MAN”. “CAS” allows the PG-L13 to run continuously. “MAN” holds the output at the point it was put into that mode.

36

Pen assignment Stop/Resume display Enlarge time axis Reduce time axis Reduce data axis Enlarge data axis Pen numbers Display/delete reference Display initialize Save data Read data Stop/resume collection Start collection

37

CENTUM CS3000

TG0006

CENTUM CS3000

2.7 Trend Window There are 128 trend group windows (8 blocks with 16 trend group windows in each) on each HIS, each window can record up to 8 pens. Numeric data (like PV, SV, MV, and CPV) can be trended, including totalization. Blocks

Groups

Pens

1

1

1

2

2

2

3

3

3

4

4

4

5

5

5

6

6

6

7

7

7

8

8

8

9 10 11 12 13 14 15 16

Trend blocks can have different sampling periods. (2880 samples each): 1 second, (48 minutes) 10 seconds (8 hours) 1 minute (2 day) 2 minutes (4 days) 5 minutes (10 days) 10 minutes (20 days) There is a maximum of 1024 trend pens, with 256 pens for 1 and 10 second sampling.

Tr end display. Trends are displayed by typing in TGbbgg (bb=block #, gg=group # i.e. TG0101) Selecting the “Reduce” or “Enlar ge” time axis icon changes the displayed time scale. Moving the scroll bar under the tuning trend allows viewing of past trend data. Selecting the “Reduce” or “Enlar ge” data axis changes the vertical scale. Move the up or down arrow at the right- hand side of the trend to see the expanded data. (1, 2, 5, 10x). Selecting the “Stop/Resume” icon pauses the updating of the trend data. Selecting it again releases the pause. There is a blue (cyan) pointer at the top of the trend, the data shown at the right-hand side of the screen is the result of where the pointer is on the trend. To move the pointer, click where you want it to be. Trend data can be saved (maximum of 100) and read from a Windows file. Trend data can also be read from other HIS.

38

CENTUM CS3000 TREND POINT WINDOW Double clicking on the desired trend item displays a window that shows only that single items pen.

39

CENTUM CS3000

40

CENTUM CS3000

2.8 Graphic Window Each window can have: Up to 200 process data items 16 bit colors Up to 400 condition modifiers per graphic

Graphic items can be modified, depending upon the process state, to change color or blink. Each primitive (graphic item) can have up to 8 condition modifiers.

A graphic window can be a representation of a plant or a control system. Displaying the plant status graphically for intuitive operation and monitoring. The Over view and Contr ol windows ar e gr aphic windows also. The window can be built with: Process data displayed Touch targets assigned (so a loop can be controlled from this window) Links to other windows. Bit maps can be imported. Faceplate windows Overview primitives.

41

CENTUM CS3000

42

CENTUM CS3000

2.9 Process Alarm Window When a process alarm occurs in the FCS the notification is sent to the HIS and is shown in the “System Message Ar ea”. When the process alarm window is displayed, selecting the acknowledge key stops the alarm icon from flashing. The operator can select either all or just important alarms to be displayed. The process alarm window also has a filter icon which allows custom alarm searches. 18 alarms per window, 200 maximum displayed. Re-alar m: If the process doesn’t return to a normal state on a loop with a pr ior ity alar m, the HIS will re-generate the alarm at a specified time interval.

43

CENTUM CS3000

44

CENTUM CS3000

2.10 Operator Guide Message Window The operator guide message window (up to 70 characters) displays messages that are generated by a response to a specific condition. The messages are date and time stamped. The operator guide window has a filter for custom message source searching. 40 messages will be displayed.

45

CENTUM CS3000

Save window set Release window set Rotate windows M ake larger M ake smaller

Recall saved image

46

CENTUM CS3000

2.11 Navigation The Navigator window displays a list of HIS window like Windows Explorer. Clicking on the panel name will display that panel. USER displays all of the operation windows in the HIS. Clicking on a graphic panel with a “+” in front displays the assigned panel hierarchy. SYSTEM displays all of the message and system level windows in the HIS.

SAVE / RELEASE WINDOW SET When multiple windows are displayed on the HIS, they can be saved and displayed again by calling up the window they were overlaying when the save was made. Up to 30 window sets can be defined.

MAKE LARGER / SMALLER A window’s size can be changed by using these icons.

HELP WINDOWS Help windows can be created for special help situations. A help window (up to 70 characters and 21 lines) can be attached to any of the graphic operations windows and is displayed when the "HELP" button is pressed.

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3 System Maintenance Windows OBJ ECTIVES OF THIS CHAPTER Explain and view the following system maintenance items: 1.

System overview window.

2.

System alarm message window.

3.

Control station display window.

4.

Define HIS setup items.

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3.1 System Overview Window The System Overview window shows the hardware statuses of the stations. Up to 32 stations are shown on this window. The HIS that this panel is displayed on is back-lit.

Alar m conditions: Green:

Normal.

Red:

Failure (Duplex stations will also show processor failures).

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CENTUM CS3000 SYSTEM ALARM MESSAGES The system alarm message window is used to display the system alarms in order of occurrence, beginning with the most recent. System alarms can be acknowledged by selecting the

button.

The message marks will stop blinking when the alarms have been acknowledged.

3.2 System Alarm Window System alarms can be displayed, as a smaller window, on any operations screen by selecting the “System Alar m” icon in the System Message Area.

HELP icon displays an on-line help message for the system message with the cursor positioned in front. Filter icon allows for custom system alarm searching either by FCS, HIS (current) or All stations.

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3.3 CS3000 Control Station Status Display Window Clicking on the FCS block on the SYSTEM window displays this status window. The control station status display shows: The module configuration of the FCS. The status of the card is shown by the color. CPU loading. Clicking on the box beneath the FCS will display the Node Interface Unit and I/O module statuses.

“IOM Load” reloads a selected I/O module’s database. Save Tuning Parameter s icon saves the contents of the FCS setup file for control parameters like P, I and D.

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HIS Setting

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3.4 HIS Setup Display This window is used to show the status information for the operator station.

Selecting HIS Setting icon on the System Overview window will bring up this display. Station displays the setup information when the HIS was defined. Printer defines the Windows printer to use for specific message types. Buzzer allows the changing of alarm tones and volumes. Display defines the screen mode (full screen or window) and the length of the tag name to be displayed. Window switching allows the changing of the size or type of display when the process alarm window, system alarm window, Operator Guide, or process alarms are selected. Vnet shows the status of the Vnet. Alar m allows definition of the alarm types to be displayed on the HIS. Preset Menu is used to configure the “Preset Window Menu” which allows quick access to important or often used operation windows. Equalize used to equalize the database files. A message will appear when this is necessary. Function key shows the current definition of the programmable function keys on the operator keyboard. The keys can be re-assigned on this display by using drop down menus. Example Display pre-defined operation screens.

O CG0001

Start and stop trends.

T TG0001 STOP

Execute system function

K HDCP

Most of these are existing Keyboard, Tool Box, or System Message Window functions.

Light LED (FLASH, ON, or OFF)

E 10 F

Run programs

F C:\file\program

Run multimedia files

X PLAY1 filename.avi

NOTE: The multimedia files must be in file: C:\CS1000/3000\his\Media\User

A function key’s LED can be defined to show the alarm status of an operation window.

Oper ation Mar k allows the creation and customization of the operation marks text and color.

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4 Process and Historical Reports OBJ ECTIVES OF THIS CHAPTER

Learn the functions of the “Pr ocess” report and “Histor ical” report pages: 1.

Search for specific tags.

2.

Display past alarm occurrences.

3.

Define a search for specific date and time.

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Tag Search Tag Search Dialog

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4.1 Process Report Window Selecting the Pr ocess Repor t icon displays this window. “Tag Sear ch Dialog” icon allows the user to conduct custom searches for: A range of FCS or control drawings. Specific tags Specific elements with tag names assigned. Specific alarm states. “Arbitrary Character” can be used to search for a “Tag Comment” “Tag Sear ch” icon searches for the parameters defined on the selected Sheet.

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I/O Search

I/O Search Dialog

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4.2 I/O Searches Under the Pr ocess Repor t a user can search for digital elements. I/O Sear ch Dialog icon allows the user to display screens showing: Which annunciator messages are active. The state of Common switches. Which digital inputs and outputs are active. The status of communication bits to subsystems (PLC). I/O Sear ch icon searches for the parameters defined on the I/O Search Dialog icon..

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4.3 Historical Report Window Select the HISTORY icon to display this window. The historical message window is used to search the operation records and process alarms that are stored on the HIS hard drive, and displays up to 3500 previously generated messages. Date allows searching for a specific date and time. Message type displays: Process Alarm: Displays the process alarm messages. Status Changed: Shows mode changes (AUT, MAN CAS, O/S). Operation Guide Messages. Sequence Messages. Maintenance: Displays the system operation and file loading messages. Operation Message: Shows operation messages like setpoint and mode changes. System Alarm: Shows the system alarm messages. Specific Number: Allows the user to look for up to four (4) specific alarm numbers. Occur r ence Sour ce: Station: Select the station name by using the down arrow. Hierarchy Name: Search for a specific drawing. TAG: Allows for a search to be conducted for a specific tag. An ”*” can be used as a search wildcard. Batch ID: When batches are run (using the batch software), a specific ID is assigned. Searches can be made from this number. User search conditions: This allows searching of system activities when a specific user was logged on. MESSAGE MONITOR WINDOW This icon displays up to 100 items that are also found in the "Historical Search" such as: Process Alarms System Alarms Operation messages Sequence messages

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5

Control System Design

5.1 Architecture

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5.2 I/O Module Arrangement

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6 Control Concept 6.1 Tag naming standards In all system is created one tag standard and programming standard. This standard will include PCS and also SCS controllers. I/O tag name should consist of the following figures and characters:

XXX-YYZZZS Description of tag creation:

Position

Description

XXX – Unit number

102, 107

YY – Type of signal

TI, TO, etc.

First letter Y means

A - Analysis F - Flow L - Level P - Pressure Q - Gas detector T - Temperature X - Motor/driver, push button Z - Valve

Second letter Y means

I - Input signal O - Output signal X - Signal from panel controller T - Temperature transmitter C - PID regulator Y - SW element A - Alarm

ZZZ – Number of loop

001, 002, etc.

S (suffix)

A, B, C … O - Open C - Close R - Run F - Failure

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6.2 Tag alarms standards Alarm functions shall be implemented using the data acquisition and shared processing equipment of the control system. All alarms shall be visually and audibly indicated and shall be connected to event logging facilities.

Standar ds Each tag in control system can have alarm detection option. For analog tag signals we can use L alarm, LL alarm, H alrm, HH alarm and Open loop alarm. Optionally we can use also deviation alarm. For digital tag signals we can use Status alarm and Change of state alarm. Tag alarming will be applied according process design requirements. We will use three levels of alarms: High Alarm (Critical alarms) Low alarm Log alarm Each alarm level gives its importance. High alarm is most critical alarm for the technology and in control system will have separate critical alarm display. Low alarm has lowest priority. Log alarm will not be represented on alarm screen, but will be written to alarm history file. By these alarm levels we can optimally manage our alarm strategy. Also each alarm will have audible and graphical representation. Each alarm will have graphical representation on the process screen and on alarm summary screen. Alarm Representation for analog signals: Bad Measure – High Alarm HH – High Alarm H – Low Alarm L – Low Alarm LL – High Alarm Bad Measure – include open loop, out of the measure range and other, according the control system capabilities. On the alarm summary screen we can clearly distinguish importance of the incoming alarms: Not acknowledge alarm – Blinking Acknowledge alarm remaining – Remain current alarm colour without blinking

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7 Process screens standards 7.1 Colors of medium

7.2 Colors of device states Run / Open state Stop / Close state

-

Green White

Uncertain state (Failure)

-

Red

Starting / Opening Stopping / Closing

-

Green blinking White blinking

7.3 Colors of electrical failures Failure

-

Red

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7.4 Basic types of equipment (shapes)

7.4.1 Pump, fan

Stop - White

Run - Green

Failure - Red

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7.4.2 Solenoid Valve (ON/OFF)

Close - White

Open - Green

Failure - Red

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7.4.3 Regulation valve

Manual

Close - White

Auto

Feedback of the setpoint

Cascade

Open - Green

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7.4.4 Analog measurement

Alarm

- Number of decimal places shall be designed by technological requirements. - Engineering units shall be always visible.

7.4.5 Regulator Set point value Measurement value Output value

Alarm

Measurement value: Green if measurement value is in operational limits. Red if measurement value reaches LO or HI limits or LL or HH limits.

7.4.6 Faceplates - Faceplates shall be designed according technological requirements and possibilities of selected control system.

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