Yokogawa Indonesia ＜ Document Number> Copyright © 2004, Yokogawa Indonesia Continuous Solution...

Yokogawa Indonesia

＜ Document Number>Copyright © 2004, Yokogawa Indonesia<date/time>

Continuous Solution Support for Centum XLCentum XL Migration to CS3000

Presentation to:

PT. CALTEX PACIFIC INDONESIA

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<Document Number>Copyright © 2004, Yokogawa Indonesia<date/time>

Why You Need Continuous Support ?

1. OEM (original equipment manufacturer) stops production of low demand spare parts

2. Some component parts are no more available in the market

3. Spare part price increases due to special order to OEM in small quantity

4. Maintenance cost increases for old system – not cost effective to maintain

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Continuous Support Schedule of Centum-XL

30 Sept. 2013

• Continuous supply for SC cards & panel related components

2000 2005 2010

End Of Support (EOS)

30 Sept. 2010

2013

Step-1 & Step-2 migration period Step-3 migration period

• Special Maintenance Contract (yearly renewal)

• Continuous supply for consumable, SC cards & panel related components

• Spare Parts except SC cards supply are stop

• Repair of faulty cards is supported, but replacement of cards except SC cards depend on availability of stocks

End Of Parts Supply

• Maintenance & Engineering Supports are available

• Only Control Unit and related spare part order available.

• MMI & other parts available by special request

30 Sept. 2000

End of Order

30 Sept. 2005

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Phased Migration (1 of 3)

Control bus

Controllers

EOPS

Field devices

Existing CENTUM-XL

Use of general-purpose platforms and Ethernet enhances network functionality.

Completes transformation to a network system.

First Step: Replacement of HMI’s

APC AOA

EnterprisenetworkSCM / ERP

Internet

PIMS / MES

ABC

HIS

EthernetCS3000

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Control bus

Controllers

Field devices

Adds new functions and increases capacity.

No change to the existing I/Os or field wiring!

I/O points can be increased as the

production lines are changed.


Second Step: Upgrade of FCSs’ CPUs

HIS

Enterprisenetwork

APC

SCM / ERP

PIMS / MES

AOA

Internet

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Controllers

Field devices

Migration is completed!

No Need to Change Field wiring !


Third Step: Replacement of FCSs’ I/O

HIS

Ethernet

Enterprisenetwork

APC AOA

SCM / ERP

Internet

PIMS / MES

Yokogawa Indonesia


Benefits of CS3000 after Migration

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Production Control System for Small and Medium Scale Application based on Windows 2000/XP

Integrated Production Control System for Medium to Large Scale Application based on Windows 2000/XP

Integrated Production Control System for Small to Large Scale Application based on UNIX

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Enterprise Technology Solution (ETS) Connection Ready

from:CorporatePlanning

Automation

acrossthe

Enterprise

to:Real Time

ControlLevel

SERVICES

Your Production Facilities

Your Enterprise Objectives

PRODUCTS

from:CorporatePlanning

Automation

acrossthe

Enterprise

to:Real Time

ControlLevel

Real Time Production Control Level

Real Time Production

Management Level

SOLUTIONS

EnterpriseManagement

Level

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Positioning of CS 3000 R3

CENTUM CS 3000 R3

PIMS

AOA

Field Network

Existing SystemsCENTUM-XLCENTUM V

APC

Migration FCS

HMINew migration path supplies open architecture with existing systems.

Rich interface by new I/O.

FOUNDATION™ Fieldbus

Featuring cutting-edge “open” technologies

Well-balanced open architecture and reliability

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CS3000 System Specifications

• Scale

– (16 domains, 64 stations/domain, 256 stations/system)

– 100.000 Tags

• Domain Structure

– CS 3000 multiple domain

– For Existing Yokogawa DCS connection (CS/ -XL/ -micro XL) or Future Expansion, Bus converter can be connected

• Control Bus

– High Speed (10Mbps) real time network (V-net)

Page.12


FCN

CS3000 System Architecture (1/2)

Fieldbus Devices

Device Maintenance Management

Control System

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CS3000 System Architecture (2/2)

VnetVnet

ooo

Large FCS

Remote I/O

FF-H1

EthernetEthernet

Small FCS(FIO Based)

PLCs

SystemsOther

SubsystemGateway

FCJ/FCN

PROFIBUS-DPV1

servers

OPC

HIS

Safety systems

Ethernet

DeviceNet

GSGW

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Centum CS3000 Control Processing

• Field control station

• Large capacity(logic, control loops, I/O)

• Types of FCSMedium-Small and Large

FFCS

KFCS

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......

FieldbusPLC

(Subsystem)Exiting I/Os (HART)

Field Bus-H1RS,Ethernet

4-20mA(Hybrid)

New Remote I/O Bus (Redundant HSE)

Conventional I/Os

Analog SignalsContact Signals

I/O Node Units

New Direct I/O Bus (Redundant)

Field Control

Unit

Human Interface (HIS & ENG)

Redundant Vnet Bus

Total No. of Node / FCU : 10 NodesTotal No. of Node / FCU : 10 Nodes

FIO: Sample of System Configuration

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KFCS (Direct connection to FCU type)

RB301

CP345

LFCS(for RIO)Front Rear

KFCS（ for FIO）

FIO

FIO

FIO

FIO

FIO

SB301

CP345

TB

TB

TB

TB

TB

FIO

FIO

FIO

FIO

FIO

SB301

CP345

FIO

FIO

FIO

FIO

FIO

RIO bus

Same configuration and functions except bus I/F card

Please note that CP345 is still used !

( 2 Mbps )

ESB bus( 128 Mbps )( 10m max. )

Capacity in 1 LFCS: e.g. 432 x AI(AAM11)

(e.g.1200 AI need 3 LFCS)

Capacity in 1 KFCS: e.g. 640 x AI(AAI 135)

(e.g. 1200 AI need 2 KFCS)

Front Rear Front Rear

ESB: Extended Serial Backboard

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KFCS (Remote I/O type)

FIO

FIO

FIO

FIO

FIO

SB301

CP345

TB

TB

TB

TB

TB

Front Rear

KFCS

<CCR>

FIO

FIO

TB

TB

Front Rear

<Field>

Generic cabinetsLocal I/O (In KFCS)

Quick responsiveness

I/O in Field

close to site

ESB bus

ERbus ： Enhanced Remote BUS

128 Mbps

ER bus10Mbps 185 m-YCB 141(10Base2), 500m-10Base52Kms- with Ethernet Repeater

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Ethernet

Vnet

H1 Fieldbus segment

Terminator

Fieldbus devices

HIS

ALF111 in service

KFCS

Legacy field devices

Redundant ALF111

World-first dual-redundant Fieldbus ports; up to 4 ports

HIS-ENGLFS2610 FOUNDATION Fieldbus Communication Package

Bus power supply

Foundation Fieldbus Configuration

YIN-CMK<Document Number>Copyright © 2004, Yokogawa Indonesia<date/time>

Pair and Spare Redundancy CPU

Applied to Standard Type Field Control StationBumpless TransferIndependent Memory + ECC

V net I/F V net I/F

CPU1

RI/O BusI/F

RI/O BusI/F

Collator

Collator

ECCMemory

ECCMemory

Right Processor CardLeft Processor Card

RI/O Bus

V net

CPU2

CPU1

CPU2

Control Stand by

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Human Interface Station (HIS) of CS3000

Page.21


HIS Basic Features

• Fully independent MMI (multiple redundancy)

• 1 sec refresh• Large capacity

(over 100,000 tags)• Operator friendly• Native Windows Application running

on 2000/XP Kernel

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Types of Operator Station

Open Console Full Console Desktop

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Full Console HIS

Side-by-side installation with the existing console (i.e. CXL Console)

Generic PC in a market is installed inside, but the functions to be much more reliable are added.

Touch panel is available.

Operation Keyboard is available.

Track ball is available.

The 2’nd LCD can be stacked.

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Fully utilize Windows 2000/XP for easy and safety operation - Concentration of all Yokogawa’s know-how and experiences - Multi window operation mode / Full screen operation mode Efficient engineering function - Optimized for CS 3000 database structure - Virtual test function - Self-Documentation function Highly reliable control function - High functionality and reliability same as CENTUM CS - Open architecture to fields - redundant PLC comm., Fieldbus, etc. Easy and quick maintenance - Not depend on the 3rd vendor’s support.

Fully utilize Windows 2000/XP for easy and safety operation - Concentration of all Yokogawa’s know-how and experiences - Multi window operation mode / Full screen operation mode Efficient engineering function - Optimized for CS 3000 database structure - Virtual test function - Self-Documentation function Highly reliable control function - High functionality and reliability same as CENTUM CS - Open architecture to fields - redundant PLC comm., Fieldbus, etc. Easy and quick maintenance - Not depend on the 3rd vendor’s support.

All software packages are developed by YOKOGAWA - GuaranteedAll software packages are developed by YOKOGAWA - Guaranteed

High reliability, High Efficiency, High Functionality, Supreme TCOHigh reliability, High Efficiency, High Functionality, Supreme TCO

Software

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Operation Windows

Faceplate Faceplate windowwindow

Control Control group group windowwindow

Last 5 Last 5 alarms alarms windowwindow

Navigator Navigator windowwindow

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Intuitive Navigation

Easy to Easy to learn learn screen screen navigator navigator

Graphical Graphical Function keysFunction keys

Alarm window Alarm window remains on remains on toptop

Tool box helps Tool box helps screen call-upscreen call-up

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CONTROL 0007PVSVPVSVPVSV

PVSV

PVSV

PVSV

PVSV

PVSV

PVSVFIC001

Check user name

Check user name

Check operation and monitoring scope

Check operation and monitoring scope

Check operation and monitoring authority

Check operation and monitoring authority

• Function block operation and monitoring

• Windows operation and monitoring

• Receipt of messages

• Function block operation and monitoring

• Windows operation and monitoring

• Receipt of messages

User in

Security

User Group User Permission

Operation History

Tag Basis

Important Tag

Ordinary Tag

Auxiliary Tag1

Auxiliary Tag2

(Major Alarm)

(Medium Alarm)

(Minor Alarm)

(Logging Alarm)

Operation Mark

Key Access

Windows 2000 user security

Pass Word

ID Card

Finger Print

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Fig. : Virtual Test function

Operation &Monitoring

FCSEmulator

Virtual Test Function No FCS Possible to generation and test by using only note PC!

Virtual Test Function No FCS Possible to generation and test by using only note PC!

Engineering function

Virtual Test Function

Virtual Test Function

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YOKOGAWACS3000

HIS Operation

YOKOGAWACS3000

HIS Operation

YOKOGAWACS3000

HIS Operation

YOKOGAWACS3000

HIS Operation

Electric documents (IMs) - CD-ROM based documents - On line documents - Paper based IMs are also available

Product Documents


Open data interface

Windows PC

ACG Text mode / Frame mode

OPC/DDE server

Process DB

OPC/DDE server can play a role of Firewallfor FCS and process database

OPC/DDE server can play a role of Firewallfor FCS and process database

PIM/MES/ERP

OPC/DDE I/F

OPC/DDE client

HIS

FCS

Ethernet

V-Net

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Remote Functions

Web based MonitoringRemote Operation / EngineeringOpen Remote I/OWide Area Operation & Monitoring

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Ethernet

HIS

FCS

V net

Plant LAN/WAN

General-purpose PC

HIS graphic/trend windows are converted into HTML files and Java Applets

Web Server

Dial-up Internet Connection

General-purpose PC

Graphic windows, trend windows, and ITV windows

Plant monitoring on a business trip, at home, at maintenance office, etc. using Web Browser

Web based monitoring

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Remote Operation / Engineering.

Vnet

Public n

etwork

Remote Monitoring

Remote Engineering

Remote Operation

Dial-up

Unmanned sites

Ethernet

Operation/Engineering is available without going in front of PC’s connected on Vnet.

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V net

Remote I/O

FoundationFieldbus

Remote Area

Reduction of TCO・ Operation and Monitoring from Control Center・ Remote I/O Configuration Change by Engineering Tools・ Device Management of Field Devices by PRM (Plant Resource Management) Software Package・ Online Configuration Change

3rd Party Solution

... ...Field Control

Unit

Field Bus-H1

Example of

Open Remote I/O Solution

Field Device Management by PRM (Plant Resource Management) Package

Open Remote I/O Bus

HIS / EWS

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V net

Ethernet Router

Router

ACG

HIS ENG

FCS

Router

Router HIS ENG

FCS

V net

Ethernet

ACG

Satellite link orOptical Fiber

1MBps

MIS

SFCS

Added benefit:

Added benefit:

Operate UNMANNED

platform from On-shore

Seamless system Integration through Public or RadioNetworks

use with ExaQuantum MIS

to gather information from

various REMOTE PLANTS

Wide Area Operation & Monitoring


REMOTE MAINTENANCE SUPPORT (RMS)

Detailed Maintenance Information Acquisition & Analyzing by Service Center Specialists

Hardware and Software Revision Management

Initiation of Test Programs

Remote Analysis, Support and Advise

• Customer• Local Service Engineer• Etc.

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Yokogawa Indonesia


Yokogawa Indonesia ＜ Document Number> Copyright © 2004, Yokogawa Indonesia Continuous Solution...

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