Yokogawa ICSS Overview.pdf
Short Description
This document details about the system architecture, Key components, benefits and other concepts related to yokogawa'...
Description
Topics
Introduction ICSS Concept & Features ICSS Key Components Conclusion
Copyright © Yokogawa Electric Corporation
-2-
ICSS System Architecture CCR
Instrument Room
Vnet /IP Network
Vnet/IP Network
DCS
Safety
DCS
Safety
SAR2-SS1 Vnet/IP Network
Vnet/IP Network
DCS
DCS
Safety
RDS
RDS Vnet/IP Network
Vnet /IP Network DCS
Safety
Vnet /IP Network Safety
DCS
Well heads Copyright © Yokogawa Electric Corporation
Well heads -3-
Vnet /IP Network DCS
Safety
Safety
CENTUM VP System Configuration – Major components Client PC
Operator Station (HIS) Asset management station
PRM
Enclosed Display Style Console HIS
Dual Redundant Vnet/IP Real-time Control Network
Open Display Style Console Desktop type HIS HIS
FCS
3rd party wireless gateway
Ethernet TSE server an/or ENG
ProSafe-RS SENG
Safety Instrumented System Controller
ExaQuantum ExaOPC (PIMS) (OPC server)
Sub system gateway
ESD / F&G Field Network ProSafe-RS SCS
Unified Gateway Station (UGS) RTU/PLC
Copyright © Yokogawa Electric Corporation
• Single Window Operation • Integrated • Scalable • Reliable • Open -4-
Yokogawa and the Digital Oil Field Single Window Operation
True integration of safety system with DCS – Common architecture simplifies engineering – Common HMI improves operational efficiency
Alarm integration Operational integration
ProSafe-RS Integrated Safety System safeguards your plant and operations Copyright © Yokogawa Electric Corporation
-5-
Proven Experience
Network Fault Tolerant
Cyber Certification
Reliable
Lost data was recovered
Digitally Enabled
Programming Languages
Intelligent Controller
Commns. Independent
In all Process Plants & pipelines
Application Portfolio
DNA 99.99999%
Copyright © Yokogawa Electric Corporation
-6-
Unified Gateway Station
New Approach
Central Processing Facility Simplified architecture for all subsystems - Unified interface engineering - Facilitate easier change management - Various Interface available • MODBUS TCP, MODBUS RTU • EtherNet/IP • OPC DA and OPC AE - STARDOM controller without OPC server - ADL is available between FCS and UGS - Redundant configuration
Controller
OPC Server
3rd Party PLC
Modbus
3rd Party PLC
Copyright © YMA
UNIFIED GATEWAY (UGS)
EtherNet/IP
OPC Server
3rd Party PLC
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AB PLC
STARDOM
Yokogawa and the Digital Oil Field Scalable System CENTUM VP is available from small to large scale DCS System Sizing Total number of stations (FCS + HIS) per domain Maximum number of domains Total tag capacity per system
Min. Configuration
Max. Domain Configuration
Max. No. of Tags Max. No. of Stations
: 64 stations (Total 1024 /system) : 31 domains : 1,000,000 tags
Max. System Configuration
: 100,000 per HIS : 64
Max. No. of Domains: 31 Copyright © Yokogawa Electric Corporation
-8-
Pair & Spare CPU Architecture Both CPU modules are processing independently, so CENTUM achieves real bumpless switchover (For Redundancy purpose) A pair of CPU chips is on each CPU module
Vnet/IP
Power card
Vnet/IP I/F
CPU 1
CPU 1
CPU 2
CPU 2
Comparator
Main memory with ECC
Comparator
CPU module
Vnet/IP I/F
– Each CPU is processing independently
PIO I/F
PIO I/F
PIO I/F
PIO I/F
IO bus I/F
IO bus I/F
Coupler
Coupler
Copyright © Yokogawa Electric Corporation
CPU module Main memory with ECC
Power card
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 -9-
Versatile Redundant Options - VMR
Redundancy for Enhanced Availability with no SIL Degradation.
SIL3
Input
CPU
Output
Circuit, MPU
MPU, memory
Circuit, MPU
Circuit, MPU
MPU, memory
Circuit, MPU
Circuit, MPU
MPU, memory
Circuit, MPU
Circuit, MPU
MPU, memory
Circuit, MPU
Copyright © Yokogawa Electric Corporation
- 10 -
Oil & Gas References User
Loc
Scope
Hard I/Os
Value
KHURAIS CPF
KSA
ICSS-PCS
30,000
20M+
ADCO ASAB
UAE
ICSS
20,000
12M+
HAWIYAH GAS PLANT
KSA
ICSS BROWNFIELD EPIC
35,000
30M+
PS2, PS3
QATAR
ICSS BROWNFIELD EPIC
5,000
17M+
PDO KAUTHER
OMAN
ICSS
7,000
5M+
ALGERIA
ICSS SCADA
28,000
10M+
ADMA OPCO SARB/ULFFD/A NSFFD
UAE
ICSS MAC
65,000
50M+
ZADCO UZ750K
UAE
ICSS MAC
45,000
30M+
EL MERK
Copyright © Yokogawa Electric Corporation
- 11 -
Real time Control network (Vnet/IP)
Copyright © Yokogawa Electric Corporation
- 12 -
Evolution of CENTUM - 39 years of Heritage 2011
2008 CENTUM VP
2001 2005 CENTUM CS 3000
1998 1993
10 MBPS Dual Redundant Token Pass V net
HF-Bus 1MBPS Dual Redundant Token Pass
1983
1988
CENTUM V
CENTUM-XL
COPS2 COPSV
CENTUM CS
CENTUM CS 3000
ICS
HIS Vnet/IP
1Gbps Dual Redundant
1Gbps Dual Redundant
FCS ABC
ENGS
PFCS LFCSKFCS
EOPS
CFCS EFCD
F-Bus 250 KBPS Dual Redundant Token Pass
FFCS
Vnet/IP
FCS
1975 CFCS2 CFCD2 CFFS
AVR
HIS
CENTUM COPS
HIS HIS
PICS
EWS
UGS
R3
CFCS CFCD Copyright © Yokogawa Electric Corporation
- 13 -
FFCS
350MHz, 128MB New ESB modules 14 Nodes, 50 KM
Control Network (Vnet/IP)
Open
Client PC
Reliable
Realtime
Operator Station (HIS) Asset management station
PRM
Enclosed Display Style Console HIS
Dual Redundant Vnet/IP Real-time Control Network
Open Display Style Console Desktop type HIS HIS
FCS
3rd party wireless gateway
Ethernet TSE server an/or ENG
ProSafe-RS SENG
Safety Instrumented System Controller
ExaQuantum ExaOPC (PIMS) (OPC server)
Sub system gateway
ESD / F&G Field Network ProSafe-RS SCS
Unified Gateway Station (UGS) Subsystems
Copyright © Yokogawa Electric Corporation
-Vnet/IP: Real-time Control Network -Ethernet: Information Network -Exaopc: OPC Server -Exaquantum : Plant information management system - 14 -
ICSS System Architecture – Domain Structure
Multiple-domain configuration for Vnet /IP ENG HIS SENG IP Vnet/IP
Domain 1
HIS
HIS
L3 switch
HIS/ENG
HIS
HIS/ENG
Vnet/IP
Domain 2
Vnet/IP
Domain 4
Domain 3 Copyright © Yokogawa Electric Corporation
Vnet/IP
- 15 -
HIS
Field Control Station (FCS)
Copyright © Yokogawa Electric Corporation
- 16 -
Field Control Station (FCS) Client PC
Operator Station (HIS) Asset management station
PRM
Enclosed Display Style Console HIS
Dual Redundant Vnet/IP Real-time Control Network
Open Display Style Console Desktop type HIS HIS
FCS
3rd party wireless gateway
Ethernet TSE server an/or ENG
ProSafe-RS SENG
Safety Instrumented System Controller
ExaQuantum ExaOPC (PIMS) (OPC server)
Sub system gateway
ESD / F&G Field Network ProSafe-RS SCS
Unified Gateway Station (UGS) Subsystems
Copyright © Yokogawa Electric Corporation
-Vnet/IP: Real-time Control Network -Ethernet: Information Network -Exaopc: OPC Server -Exaquantum : Plant information management system - 17 -
Yokogawa DCS Solutions –System Architecture L2 Router
Bus 1 Open
Bus 2 Vnet/IP Data Highway – 1 Gbps
Reliable
Field Control Unit (FCU)
Realtime
Remote I/O Bus – 50 km max
Redundant Controllers & Vnet/IP Communications
Local FIO Node (FIO)
Maximum FIO Nodes / FCU 14 (includes the FCU node) Maximum FIO Nodes / FCU 14 (includes the FCU node) Maximum Local FIO Nodes 10 Maximum Local FIO Nodes 10 Maximum Remote FIO Nodes 13/FCURemote - 8/remote line Maximum FIObus Nodes 13/FCU - 8/remote bus line
Redundant Node Interface Units
Local I/O Bus – 128 Mbps Remote I/O Bus – 128 Mbps
Local FIO Node (FIO)
Redundant Power Supplies
Copyright © Yokogawa Electric Corporation
- 18 -
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 available – 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
Copyright © Yokogawa Electric Corporation
- 19 -
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 as 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.
Copyright © Yokogawa Electric Corporation
- 20 -
Pair & Spare CPU Architecture Both CPU modules are processing independently, so CENTUM achieves real bumpless switchover (For Redundancy purpose) A pair of CPU chips is on each CPU module
Vnet/IP
Power card
Vnet/IP I/F
CPU 1
CPU 1
CPU 2
CPU 2
Comparator
Main memory with ECC
Comparator
CPU module
Vnet/IP I/F
– Each CPU is processing independently
PIO I/F
PIO I/F
PIO I/F
PIO I/F
IO bus I/F
IO bus I/F
Coupler
Coupler
Copyright © Yokogawa Electric Corporation
CPU module Main memory with ECC
Power card
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 - 21 -
Field Digital Communication Protocols ALE111 Ethernet Communications Module •EtherNet/IP (CIP) •Modbus TCP •PLC-5/SLC500 Ethernet Communication
ALP111 PROFIBUS-DP Module
CIP
• Redundant Configuration is available.
Control Logix
PROFIBUS-DP Linking Device
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
PLC-5
HART I/O
Copyright © Yokogawa Electric Corporation
- 22 -
4-20mA
SLC500
ProSafe-RS
Copyright © Yokogawa Electric Corporation
- 23 -
Field Control Station (FCS) Client PC
Operator Station (HIS) Asset management station
PRM
Enclosed Display Style Console HIS
Dual Redundant Vnet/IP Real-time Control Network
Open Display Style Console Desktop type HIS HIS
FCS
3rd party wireless gateway
Ethernet TSE server an/or ENG
ProSafe-RS SENG
Safety Instrumented System Controller
ExaQuantum ExaOPC (PIMS) (OPC server)
Sub system gateway
ESD / F&G Field Network ProSafe-RS SCS
Unified Gateway Station (UGS) Subsystems
Copyright © Yokogawa Electric Corporation
-Vnet/IP: Real-time Control Network -Ethernet: Information Network -Exaopc: OPC Server -Exaquantum : Plant information management system - 24 -
Topics
ProSafe-RS Positioning Certification Key Components Safety Architectures & Redundancy Diagnostics Advanced Features Conclusion.
Copyright © Yokogawa Electric Corporation
- 25 -
Safety Product Positioning
No SIL
SIL 1
SIL 2
SIL 3
SIL 4
Control
Asset Protection
PSD F&G
ESD PSD F&G
HIPPS sub sea nuclear
Copyright © Yokogawa Electric Corporation
- 26 -
TÜV Certification
First certified for SIL3 applications by TÜV Rheinland on 10th March, 2005.
Visit TÜV homepage
http://www.tuvasi.com/ Copyright © Yokogawa Electric Corporation
- 27 -
Certified Applications
ESD, PSD, BMS and F&G included. Copyright © Yokogawa Electric Corporation
- 28 -
Logic Solver Components SCS (Safety Control Station) comprises – –
one SCU (Safety Control Unit) SNUs (Safety Node Units)
110 I/O modules can be mounted – –
More than 1500 I/O points per SCS Redundant 800 points /100mS scan
Safety communication can be established between different SCS via V net, V net/IP –
Safety communication data is protected by CRC, Seq.No, time stamp, SRC/DST add.
Transferring the safety I/O data between CPU module and I/O modules via ESB/SB Bus (Safety I/O Bus) Communication data between CPU and I/O is also protected.
Copyright © Yokogawa Electric Corporation
- 29 -
Versatile Modular Redundancy Multiple redundant configuration are available
Fully Redundant
– – –
Fully single Fully redundant Partially redundant
– – –
Power supply module V net interface unit I/O Bus (SB-Bus) interface module are always in redundant.
Redundant switch over is controlled by each redundant pair, not controlled by processor module. (partial switch over)
Partially Redundant
Copyright © Yokogawa Electric Corporation
Fully Single
- 30 -
Remote IO
Distance up to 50km – only for Vnet/IP SCS
V-net/IP
CPU node (SSC50□)
0-5Km
5-50Km
Master
SNT401
SNT411
Slave
SNT501
SNT511
ESBbus
IO node (SNB10D)
Optical fiber max 50km x 4 (2 pairs) Max 50km, 9xSNB10D IO node (SNB10D) ESBbus
IO node (SNB10D)
Copyright © Yokogawa Electric Corporation
- 31 -
Highly Scalable Architecture
Distribution on Vnet 64 stations in a domain – 100 thousand tags
V net/IP
1000 I/O per CPU rack plus I/O racks
Total 14 racks
50 I/O per CPU rack . Copyright © Yokogawa Electric Corporation
- 32 -
Single SIL3
SIL3 with single Input-CPU-Output modules – Internal redundancy inside module using proven “Pair & Spare” concept from Centum DCS Single CPU module
Single Input module Single Output module Input
Circuit, MPU
CPU
Circuit, MPU
Copyright © Yokogawa Electric Corporation
MPU, memory
MPU, memory
- 33 -
Output
Circuit, MPU
Circuit, MPU
Increased Availability With No SIL Degradation
High availability via redundant CPU & I/O module – Proven redundant technology from Centum DCS – Redundant options are selectable part by part! Redundant CPU module
Redundant Input module Input
Circuit, MPU
Redundant Output module CPU
MPU, memory
Circuit, MPU
Input
Circuit, MPU
MPU, memory
CPU
Circuit, MPU Copyright © Yokogawa Electric Corporation
MPU, memory
MPU, memory
- 34 -
Output
Circuit, MPU
Circuit, MPU
Output
Circuit, MPU
Circuit, MPU
Versatile Redundant Options
Redundancy for Enhanced Availability with no SIL Degradation.
SIL3
Input
CPU
Output
Circuit, MPU
MPU, memory
Circuit, MPU
Circuit, MPU
MPU, memory
Circuit, MPU
Circuit, MPU
MPU, memory
Circuit, MPU
Circuit, MPU
MPU, memory
Circuit, MPU
Copyright © Yokogawa Electric Corporation
- 35 -
Integrated Control & Safety
DCS and SIS share the Vnet DCS and SIS are integrated physically, segregated logically. Vnet/IP Domain A
Safety ENG
Vnet/IP Domain C ENG
HIS/ENG
HIS
SENG
L3 Switch
L3 Switch Repeater
FCS
Safety Controller
Optical Repeater
Safety Controller
FCS
FCS
FCS L3 Switch
Optical Repeater
Vnet/IP Domain B SENG
Safety Controller
FCS
Copyright © Yokogawa Electric Corporation
Safety Safety Controller Controller - 36 -
Safety Controller
Communication on Vnet/IP Centum VP HIS
Vnet/IP Safety Comm.
Vnet comm.
Safety Controller (SCS)
S. Data
Centum VP FCS
S. Data N. Data
Safety Layer
N. Data
Safety Layer
7 2 1
7 2 1
Copyright © Yokogawa Electric Corporation
- 37 -
N. Data
7 2 1
Advanced Features Plant Resource Manager
from PST package
SIL3 AIO with HART
AIO with FF/HART
PST
Control Valves
Safety Valves
Diagnostic information of field equipments by FF/HART
Copyright © Yokogawa Electric Corporation
- 38 -
Integration with other systems
Copyright © Yokogawa Electric Corporation
- 39 -
Field Control Station (FCS) Client PC
Operator Station (HIS) Asset management station
PRM
Enclosed Display Style Console HIS
Dual Redundant Vnet/IP Real-time Control Network
Open Display Style Console Desktop type HIS HIS
FCS
3rd party wireless gateway
Ethernet TSE server an/or ENG
ProSafe-RS SENG
Safety Instrumented System Controller
ExaQuantum ExaOPC (PIMS) (OPC server)
Sub system gateway
ESD / F&G Field Network ProSafe-RS SCS
Unified Gateway Station (UGS) Subsystems
Copyright © Yokogawa Electric Corporation
- 40 -
Challenges for multiple sub-systems integration Central Processing Facility
- Complex architecture depending on subsystem - Complex engineering - Cumbersome change management
Traditional Approach
OPC Client
Controller
Modbus RTU
3rd Party PLC
Modbus TCP
3rd Party PLC
Copyright © Yokogawa Electric Corporation
OPC Server
3rd Party PLC
- 41 -
OPC Client
OPC Client
OPC Server
AB PLC
OPC Server
STARDOM
Unified Gateway Station
New Approach
Central Processing Facility Simplified architecture for all subsystems - Unified interface engineering - Facilitate easier change management - Various Interface available • MODBUS TCP, MODBUS RTU • EtherNet/IP • OPC DA and OPC AE - STARDOM controller without OPC server - ADL is available between FCS and UGS - Redundant configuration
Controller
OPC Server
3rd Party PLC
Modbus
UNIFIED GATEWAY (UGS)
EtherNet/IP
3rd Party PLC
Copyright © Yokogawa Electric Corporation
3rd Party PLC
- 42 -
OPC Server
AB PLC
STARDOM
Field Digital Communication Protocols ALE111 Ethernet Communications Module •EtherNet/IP (CIP) •Modbus TCP •PLC-5/SLC500 Ethernet Communication
ALP111 PROFIBUS-DP Module
CIP
• Redundant Configuration is available.
Control Logix
PROFIBUS-DP Linking Device
DeviceNet
Modbus/TCP
Copyright © Yokogawa Electric Corporation
PLC-5
- 43 -
SLC500
Operation and Monitoring
Copyright © Yokogawa Electric Corporation
- 46 -
CENTUM VP System Configuration – major components Client PC
Operator Station (HIS) Asset management station
PRM
Enclosed Display Style Console HIS
Dual Redundant Vnet/IP Real-time Control Network
Open Display Style Console Desktop type HIS HIS
FCS
3rd party wireless gateway
Ethernet TSE server an/or ENG
ProSafe-RS SENG
Safety Instrumented System Controller
ExaQuantum ExaOPC (PIMS) (OPC server)
Sub system gateway
ESD / F&G Field Network ProSafe-RS SCS
Unified Gateway Station (UGS) Subsystems
Copyright © Yokogawa Electric Corporation
-Vnet/IP: Real-time Control Network -Ethernet: Information Network -Exaopc: OPC Server -Exaquantum : Plant information management system - 47 -
Features of HIS (Operation Station) Large Capacity ( No License )
– Max. No. of Tags: 1,000,000 per system – Max. Graphic Displays: 4,000 per HIS – Real-time trend Points: 3,328 per HIS
Operation environment
– Single, dual, Quad LCD. – Desktop, Solid Style Console, and Open Style Console – Latest Microsoft Windows OS platform
Performance and function for achieving real-time plant operation – – – – – –
1 second graphic call up 1 second screen refresh Real-time trend time based at Controller 1 msec SOE at IO level Frame display Window History function
Real-time Alarm Management View Copyright © Yokogawa Electric Corporation
- 48 -
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
Copyright © Yokogawa Electric Corporation
- 49 -
Alarm Handling Real-time Alarm View (CAMS) – Both process alarm and system alarm are covered – Alarms from the ProSafe-RS safety system and from the PRM Plant Asset Management system are also covered – A single operation is required to call up the related dialogs – The functions to reduce the operators’ overload to avoid overlook of important alarms are available • Filtering, Eclipsing, Suppression, Shelving – Alarm engineering is available in the standard engineering function
Alarm Set-point Management
– The set-points are managed in a master database • Master database is initiated in the alarm design phase • Master database can be downloaded to the HIS, FCS • The function to show the deviations clearly between the master and the current alarm set-points is available on the HIS • Import function to reflect the current set-points to the master database is available for process improvement purpose
Copyright © Yokogawa Electric Corporation
- 50 -
Real-time Alarm View (CAMS) The latest three alarms are always shown
Click blinking icons to open the CAMS View
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. Copyright © Yokogawa Electric Corporation
- 51 -
Alarm list is shown here
Trend Graph Display Example Trend line Assignment
Index
– Drag & Drop to assign the data points from any trend blocks on a trend view
– Up to three indexes can be displayed – Data values on the trend graphs can be checked
Faceplate Display
Legend Area – Assigned data points and the current data are shown – Check/Uncheck to show/hide trend line Copyright © Yokogawa Electric Corporation
- 52 -
– Click the Legend Area, then the Faceplate is shown next to the trend graph view
Engineering Function
Copyright © Yokogawa Electric Corporation
- 53 -
Quick & High-quality Engineering Minimized shutdown time or reconstruction – The longer time links the larger financial disadvantage
CENTUM VP provides the following configuration environment – – – – –
Total Project management. Reuse of configuration data Multiple Engineers can work simultaneously. On-line maintenance. DCS Tag equalization for Historian
Copyright © Yokogawa Electric Corporation
- 54 -
Advanced Debugging for Project Database Virtual test – – – –
Normal operation is available.
Check simple entry mistakes. Try new control logic. Check graphic work Operator training
HIS
Memory in PC FCS FCS FCS FCS Simulator
Target test – Check actual FCS CPU performance – Check the actual relationship among each station.
DCS and ESD Integrated simulation OTS platform readily available Minimum check at Start up ! Copyright © Yokogawa Electric Corporation
- 55 -
oo oo oo ooo
Virtual input is Virtual input is created from the created from the output from FCS output from FCS simulator.
For HIS, this pretends FCS
FCS memory
Field devices devices Field
Auto Auto wiring wiring
For FCS For FCS, this simulator, this pretends the pretends the actual plant. actual plant.
Start plant) Targetup test Virtual test! (Actual Actual plant
Safety Integration Integrated Monitoring
DCS and SIS are ’truly integrated’ – SIS and DCS data are within the same window – SIS data can be used in the FCS – Integrated SIS & DCS Sequence of Event (SOE) data CENTUM VP
Time shared on the same network
FCS
Vnet/IP
SIS data can be used in FCS ProSafe-RS SCS
SCS and FCS Faceplates
-
Faceplate Trend Graphic System status Alarm SOE
System status
SCS
SCS
FCS
SOE Viewer FCS and SCS information integrated
CENTUM VP FCS
Copyright © Yokogawa Electric Corporation
- 56 -
Yokogawa’s PRM (Asset Management)
Copyright © Yokogawa Electric Corporation
- 57 -
Field Devices – Data flow to PRM
Copyright © Yokogawa Electric Corporation
- 58 -
Color Status for Field Devices in Maintenance Alarm
Status icon display in Navigator windows Plant View
Network View
Icon
Detail
(Green)
Healthy by Device Patrol
(Red)
Maintenance alarming by Device patrol
(Yellow)
Maintenance Warning By Device patrol
New
(Gray)
Communication failure
(White)
Status not yet confirmed Alarm Off
(Background Gray) Un-confirmed alarm
Copyright © Yokogawa Electric Corporation
- 59 -
NAMUR Recommendation NE107 (FF-912)
There are four alarm categories defined as per the NE107 specification, Failed (Failure), Off-Specification (Out of Specification), Maintenance (Maintenance Required), and Check function (Check Function).
Copyright © Yokogawa Electric Corporation
- 60 -
System 1 Event Messages
View System 1 event messages as PRM maintenance alarms in PRM
Copyright © Yokogawa Electric Corporation
- 61 -
Integration with GE Energy’s System 1 Call Detail panel of System1
PRM navigator panel displays status of System1.
Machinery condition monitoring
PRM monitors asset conditions
Copyright © Yokogawa Electric Corporation
- 62 -
Plant Asset Data Integration Device information can be called-up
Device status
Help
Device diagnostic information
Result of device Diagnosis Copyright © Yokogawa Electric Corporation
- 63 -
Multi Valve Vendor PST Scheduler Multi-vendor ESD Valves Grouped per Process area Time scale from minutes to a year
Calendar based Scheduling
Results & Coming Schedule
Copyright © Yokogawa Electric Corporation
- 64 -
PST Notification
Maintenance Alarm Message in PRM Operation Guidance Message in CENTUM HIS
Copyright © Yokogawa Electric Corporation
- 65 -
Yokogawa FF Solutions
Copyright © Yokogawa Electric Corporation
- 66 -
Foundation Fieldbus on CENTUM VP Integrated DCS with Fieldbus
Ethernet HIS
•Operation •Engineering
PRM
HIS-ENG
V net
FCS
•Control •FF Block
•Device Monitoring •Maintenance Management •Advanced Diagnosis •Link Master (LAS) •Redundancy •4 ports supported
ALF111 (master) ALF111 (slave) Power Supply
IO Module for FF_H1
4-20 mA
H1 Fieldbus Fieldbus Equipment
Conventional Equipment
Copyright © Yokogawa Electric Corporation
- 67 -
Signal Flow (Analog FF loop)
12 Devices
12 Devices Copyright © Yokogawa Electric Corporation
- 68 -
Evolution by Fieldbus : Operations and Maintenance Maintenance Cost reduction： Realize of Predictive maintenance Fieldbus System 4~20mA Digital communication (PRM) Plant Operation
Remote maintenance： -Parameter change -Device alarm event -Device detail display -Advanced diagnosis
Analog PV PV
Diagnosis status Device Alarm
MV
AI
etc
PID
AI
AO Maintenance work in site： -Parameter change -Periodical patrol -Confirmation on site
Intelligent Device Diagnosis etc
Copyright © Yokogawa Electric Corporation
- 69 -
Salient Features of Centum VP (DCS) Features
Benefits to Users
Simple and Common Architecture
Ease in Operation, Monitoring and Maintenance
Globally Distributed Database
No Server required. No loss of Data on HMI failure
Unique Pair and Spare architecture.
Bumpless transfer without process upset.
V-Net/IP, 1 Gbps Network. World’s Fastest
Smooth Operator interaction with process
Open Architecture and Interoperability
Easier integration with third party system, field devices
Tag License per Operator station (100,0001,000,000 Tags)
No tag limitation. No cost during project expansion
Test Function : Simulator
Faster Installation and Commissioning
Easy Software Upgrade and Various Migration Tools Easy upgradation, expansion with less time and cost
Final Benefit : Total Cost of Ownership (TCO) is the lowest in Industry Copyright © Yokogawa Electric Corporation
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Salient Features of ProSafe RS Features
Benefits to Users
Versatile Modular Redundancy - VMR
Minimal Failures - Fault Tolerant - High Availability
Each modules from Input to Processor to Output are equipped with Dual CPUs and Dual Circuits
No Time Restriction in degraded mode as SIL 3 Certified with Single Modules.
No Emergency operator and spare inventory required to keep continuous operation.
On-Line addition of IO modules / IO Node On-Line Scan time change
Easy future add-ons / expansions : Lower overhead cost as no shutdown needed No manual intervention and shutdown. Large IOs can be added
Analogue cards are HART compatible
No HART Mux/panels required. Less Hardware. Less Foot Print. Less Power Consumption. Comprehensive Integrated AMS on single DCS PRM
Corrosive Coating up to ‘G3’ Level is a standard feature.
High physical strength : Long Life of Components and System
Temperature withstand up to 70Deg
Suitable for Outdoor application : Low Cost
Copyright © Yokogawa Electric Corporation
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Salient Features of ProSafe RS Features
Benefits to Users
DO Module with 2 Amp is available for High Current
No relay needed so less intermediate components and (e.g. Horns and Beacons). Line Monitoring achievable.
Line Monitoring for IO Modules
Easy Diagnostics and Maintenance - Short and Open Circuit detection
1 ms Real time SOE In-Built Standard Feature
Accurate post incident analysis. Pin point the root cause.
ONE Network, ONE Window
No additional gateway required. No Engineering. Less Hardware, Less failures, Less Foot Print and above all very efficient due to single window
CPU Memory Flash Memory High capacity Memory 32 MB. Battery Backed RAM Copyright © Yokogawa Electric Corporation
Smooth handling of large database. Instantaneous start and protect logics in case of Power Failure. Safety Ensured.
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BENEFITS OF INTEGRATED DCS SYSTEMS Yokogawa Solution
Non Yokogawa Solution
Attributor
Vnet I/P
MODBUS/OPC or loosely connected
Integration Level
Integrated Same as existing DCS network
Separated Via OPC server
SOE Resolution
1msec Real Time
OPC A&E based
Alarm Detection
1 Sec
3 to 5 Sec
SOE Screen (Operator Station)
Integrated in DCS Alarm display
Separate
Time Synchronization
1 msec
Based on SNTP server resolution.
Complex to achieve as DCS ‐ Same as DCS. No configuration required. Color discrimination for DCS and SIS is available. Extensive configuration required. No direct faceplate block available in FCS. Control Network is loaded.
Faceplate
Tag Mapping
Fully integrated – instantaneous
OPC Mapping
Diagnostics
Through integrated System display page
Depend upon ability of the DCS system (via graphics page)
Data Transfer
Deterministic
Non‐Deterministic
Trend Limitation
No limitations. Trends at one‐second intervals can be displayed.
Trends at one‐second intervals cannot be displayed.
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BENEFITS OF INTEGRATED DCS SYSTEMS Yokogawa Solution
Non Yokogawa Solution
Attributor
ProSafe RS
MODBUS/OPC or loosely connected
Shared Maintenance Procedure
Lower Maintenance Overhead
Dual maintenance Overhead
Redundancy
Secured, Fully, Reliable
Switch Over time
Instantaneous (less than 1ms)
Loosely redundant, engineering solution 10‐15sec
Redundancy Software
Not required. Seamlessly integrated.
Required.
Reboot of Gateway during data changes.
Not Applicable
Reboot of OPC server is necessary for changes.
Engineering
Easy, seamless
Complex.
FCS cannot access to Gateway
Not Applicable, seamless.
Not Possible.
Asset Management
Integrated (through HART Pass Through, using DCS & Separate (Via HART multiplexers & ESD Communication infrastructure) Separate Network required)
Attributor
ProSafe RS
OPC Interface
Shared Maintenance Procedure
Lower Maintenance Overhead
Dual maintenance Overhead
Copyright © Yokogawa Electric Corporation
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Conclusion - ProSafe-RS
ProSafe-RS provides Best In Class Combination of Safety, DCS Integration and Asset Management Flexible architectures without SIL compromise Advanced diagnostics for maximum process availability High environmental robustness for remote mounting.
Copyright © Yokogawa Electric Corporation
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Conclusion - Centum VP
Stable System Architecture Solutions-Oriented Approach Strong Production Management & Optimization Solutions Broad Product, Application & Service Offering Open Communication Infrastructure Comprehensive Lifecycle Support
Copyright © Yokogawa Electric Corporation
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