yokogawa -integrated production control system solution for petrochemcial industries
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http://www.yokogawa.com/dcs/
Bulletin 33J01A10-01EN
The core platform for Yokogawa’s VigilantPlant® Solutions
CENTUM VPIntegrated Production Control System Overview
F-BUS (250 Kbps)
HF-BUS (1 Mbps)
V net (10 Mbps)
CENTUM1975
CENTUMCS
1993CENTUMCS 3000
CENTUMVP
1998CENTUM
CS 3000 R3
2001
2005 2008CENTUM
VP R5
2011
CENTUM V1983
CENTUM-XL1988
Vnet/IP (1 Gbps)2014
CENTUM VP R6
Nearly 40 years and still countingCENTUM history
Yokogawa has maintained exclusive ownership of CENTUM development throughout the history of this product series. The upgrade path for each legacy system is always taken into consideration before a new version is released.
Yokogawa's commitment
VigilantPlant is Yokogawa's vision for the ideal plant. Our vision is for a plant to be a place where people can be watchful and attentive, while the business responds quickly and effectively to change. Non-stop production is assured as the plant's personnel con�dently expand their capabilities. In such a well managed plant, it is possible to plan for the future and make the kind of changes needed to optimize every aspect of its operations. It keeps evolving in response to changing needs.
Yokogawa’s system platforms combined with its proven execution experience provide the highest quality and the most innovative solutions for secure and optimized process automation and management. Yokogawa’s global customer centric focus together with strong local support reduces users’ business risks and provides the lowest total cost of ownership. With a long history of progressive compatibility, Yokogawa is your dependable automation partner.
Is your plant silent and boring?“A well managed plant is silent and boring.”- Peter. F. Drucker
02 03
CENTUM VP ushers in an operating environment that keeps everyonefully aware, well informed, and ready to face the next challenge.
The Automation Design Suite, Yokogawa's new engineering environment, is designed for faster and more �exible engineering. This radical innovation ensures a standardized and consistent engineering framework, thereby maintaining data integrity and facilitating management of change. It streamlines engineering work�ow, eliminates redundant work and increases reusability.
A common interface for control, safety, and asset intelligence provides operators with all the relevant information to aid in decision-making. This together with embedded mechanisms such as our Consolidated Alarm Management Software (CAMS) prevents information overload and ensures safe and uni�ed plant operation.
Versatile and Efficient Engineering
Intuitive and Integrated Operation
N-IO (Network I/O), the next-generation software con�gurable smart I/O, reduces footprint, lowers marshalling costs and allows �exible I/O binding. Matched with the FieldMate Validator, our commissioning tool, this allows for signi�cantly faster project completion and reduced costs without compromising on quality.
Improved Project Execution and Reduced Cost
High Performance and Dependable Control
Yokogawa provides a comprehensive and systematic approach to plant lifecycle management. With online upgrades and modi�cations, step-by-step migration paths, in-depth security solutions and a wide array of lifecycle services, we make sure that our customers get the most out of their investment.
Continuous Evolution and Long-term Investment Protection
99.99999% availability is a CENTUM hallmark that provides unmatched reliability for plant control. The powerful Field Control Station (FCS) coupled with the Vnet/IP high-speed network not only ensures high-capacity processing but also secure and reliable communication.
Advantages04 05
True Integration of Production Excellence,Safety Excellence and Asset ExcellenceCENTUM VP achieves the Operational Excellence that is the focus of Yokogawa’s Production Excellence, Safety Excellence and Asset Excellence initiatives. It offers integrated viewing and data handling functions. For example, alarms from the ProSafe-RS Safety Instrumented System and Plant Resource Manager, Yokogawa’s Asset Management product, can be seen and handled seamlessly in the Human Interface Station (HIS).
Easy to operate with clear visibility
Dedicated Operation Keyboard
Software Suites
Consolidated Alarm Management
Plant Asset Management
System message banner
Yokogawa offers an intuitive and easy-to-understand HMI environment for plant operation and monitoring, which is the result of
vast experience with CENTUM systems in operation. Flexibility in displaying operation windows and monitors helps in adapting to
various aspects of operation needs. CENTUM VP provides easy-to understand graphics based on the ergonomics and knowledge
engineering. For instance, data displays are provided with high visibility that enables intuitive awareness of the situation. The use
of colors considers the best contrast and environments of the central control room and the con�guration of the displays integrates
the knowhow of experienced operators. With all these functions, CENTUM VP enables operators to make quick and accurate
decisions during operations and contributes to improve operation ef�ciency.Consolidated Alarm Management Software (CAMS) helps customers avoid safety and environmental incidents that can
be caused by alarm �ooding. It also enables customers to improve operational ef�ciency under normal conditions,
freeing operators from having to perform tedious repetitive tasks and allowing them to focus on true process concerns.
CAMS supports Six Sigma DMAIC (De�ne, Measure, Analyze, Improve, Control) for alarm management based on the
latest EEMUA #191 alarm management guideline. It provides additional useful tools such as graphical historical data
analysis and automatic alarm reduction. Sequence of event management functions are also included.
With PRM (Plant Resource Manager) and intelligent �eld devices, operators and maintenance personnel can monitor
the condition of plant assets remotely. Plant Resource Manager's diagnostic functions detect early signs of
performance deterioration such as valve sticking and impulse line blocking. By helping curtail excessive preventive
maintenance and enabling higher level predictive and proactive maintenance, Plant Resource Manager opens the way
to asset predictability.
Optimized allocations of the function keys and buttons enable operators to call up or
switch graphics and control loops by pressing a single key. Two types, a single-loop
and an eight-loop simultaneous operation keyboards, are provided giving users the
ability to react quickly to process conditions.
Cont inuous ly d isp lays the la test a la rm messages, keeping operators up to date on process conditions.
Browser barContains navigation tools for the convenience of operators, frequently-used icons can be grouped in a My Favorites folder.
Window historyLists the previous operat ional displays. Operators can quickly call up previously-used graphics windows.
AOG SolutionThe AOG (Advanced Operating Graphics) solution is a
consulting service provided to help design PCS
(Process Control System) graphics based on human
factors engineering and knowledge engineering. AOG
provides intuitive situation awareness through
ergonomic design, looking at factors such as color
selection, layout, and visual function. Certi�ed
consultants conduct a task analysis of plant
operations and the result is re�ected in the graphics
des ign . The GUIs can enhance sa fe ty and
productivity by early detection of abnormal situations,
quicker decision making, reduction of errors,
less-stressed operators, and translating operator
skills into explicit knowledge.
All plant process data and device data arehandled by CENTUM VP.
CENTUM VP's versatile architecture covers not only continuous and batch process control but alsomanufacturing operations management.
A wider variety of software suites for automation solutions is available.
Operation06 07
Control network
I/O network I/O network
Yokogawa’s CENTUM series achieves high availability thanks to a dual-redundant design, online maintenance capability, and other advanced features. The FCS processor module, power supply, I/O modules, and I/O networks are all dual redundant. Active and stand-by processor modules work in synchronization: even if a failure occurs, control switches over seamlessly to the stand-by module and the FCS continues running. Failed modules can be replaced online, ensuring that not even a hardware failure will interfere with plant operation.
Ensuring the Highest Availability and Reliability
The CENTUM series employs a pair & spare architecture
that improves the stabil ity of process control. Each
processor module has redundant CPUs that execute the
same computations simultaneously. Their outputs are
constantly compared and a bump-less switchover to the
stand-by processor module is initiated if any anomalies
caused by electronic noise or other phenomena are
detected. This minimizes the likelihood that CPU hardware
faults will have any impact on process control.
The HIS runs on Microsoft Windows operating systems
platforms and offers customers the convenience of using
commercial-off-the-shelf hardware. Although the reliability of a
PC is relatively low, it does not affect the total reliability of the
process operator function. As the HIS is not server-client
dependent, multiple HISs provide independent backup such
that there is no single point of failure.
Through an online maintenance function, FCS applications can be modi�ed without shutting down the FCSs. It means, you can change
logics and parameters without interrupting the process control. This is useful for expansion or modi�cation of the plant in operation.
Yokogawa has a long history of delivering stable and high quality
CENTUM systems. The CENTUM VP controller features outstanding
processing performance and a large application storage capacity, yet
inherits the same quality and stability that are the hallmark of the
CENTUM series. It has been optimized to take full advantage of
advances in �eld digital technology that will help plants operate with
increased ef�ciency and stability.
The state-of-the-art Field Control Station (FCS)
Designed for Stable Control
Online Maintenance
The CENTUM VP provides functional blocks for monitoring, control, manipulations, calculations, logic functions, and sequences. Not
only continuous control but also advanced control, complicated sequence control, and batch control are all executed in a redundant,
secure, and reliable controller environment. Plant systems can be �exibly designed, ranging from small-to-large-scale, through the
combination of these control blocks.
Yokogawa's Vnet/IP provides open, rel iable, and real-t ime
broadband communications, which enables the use of commercial
off-the-shelf technology that help reduce costs. The open
c o m m u n i c a t i o n d o e s n o t a f f e c t p r o c e s s c o n t r o l d a t a
communications nor does it impact the performance and security
aspect of the control communications. The Yokogawa system
guarantees data updates every second in the HIS, regardless of
project size or complexity.
Wide variety of Function Blocks
N-IO (Network I/O) : Ultimate flexibility
1 Gbit, World’s Fastest Open Control Network
No Single Point of Failure
Baseplate
Universal I/O Module
• 16 Channels I/O
• Signal: AI/AO/DI/DO
• Software Configurable
• HART 7 Support
• Full Redundancy
Adapter
• Built-in Signal Conditioner
• Single point integrity
• Through, Pulse, Multi
types of DI and DO, etc.
Termination Block
N-IO reduces footprint, lowers marshalling costs and allows �exible I/O assignment.
Universal I/O and Software MarshallingN-IO has AI/AO/DI/DO in each I/O channel. Each I/O channel
can be changed to other I/O types by software programming.
Adapter (Built-in Signal Conditioner)N-IO implements a wide variety of built-in signal conditioners on
its baseplate. In most cases, there is no need to prepare external
signal conditioning or the additional space this requires.
RedundancyThe same N-IO baseplate supports both single and dual
redundant formations, eliminating the need for multiple
hardware/software vendors when implementing redundancy.
I.S. BarriersThe N-IO baseplate supports Intrinsically Safe I/O barriers.
CENTUM : the DCS solution with an incredibly high 99.99999% availability!
I/O Network
Control08 09
Yokogawa accelerates plant startup and Ensures sustainable performance
The Automation Design Suite - Improving Quality, Reducing Complexity and Enhancing Productivity
Yokogawa paves way for a new engineering paradigm for the next-generation. It is not uncommon for a project to experience backsliding and significant rework, all of which affects the TCO (Total Cost of Ownership). Yokogawa's engineering prevents these inefficiencies and ensures our customers reap all these benefits throughout a plant’s lifecycle.
Yokogawa provides smart engineering thanks to three innovative products.● Automation Design Suite, Yokogawa’s engineering environment● N-IO (The Network I/O), Yokogawa’s software con�gurable smart I/O● FieldMate Validator, Yokogawa’s commissioning tool for N-IO
The Automation Design Suite adopts a Modular approach to
automation design and execution, where process loops, alarm
design philosophy, graphics and more are deployed as design
patterns: downloaded, shared and re-used as standards across the
enterprise, saving time and resources.
Yokogawa leverages its long history and vast expertise in process
automation, with standardized, industry proven engineering
modules available that span a broad range of processes and
functions for production, safety and asset excellence.
After the DCS is sent to a site, design changes often happen due to physical restrictions of implementation or inadvertent
miscalculations and these changes can signi�cantly affect the project schedule. And shortening the term of a project is an everpresent
challenge. Flexible I/O binding, Yokogawa’s improved late I/O binding solution, helps overcome these customer challenges.
The Automation Design Suite, Yokogawa's new engineering environment, retains the entire engineering history of your plant from
design phase, through commissioning and live operation; which ensures up-to-date plant knowledge with every expansion, or
hardware and software change throughout your lifecycle.
The �exible I/O binding facilitates simple and hassle-free I/O binding. This is made possible by software marshaling
and the N-IO’s universal channels. The type of I/O and the interconnection between the I/O module and the controller
can be modi�ed remotely which signi�cantly absorbs the impact of last-minute I/O changes. Furthermore, the �exible
I/O binding achieves early delivery of I/O cabinets to the site, and problems can be found and �xed on-site at a very
early stage.
Flexible I/O Binding – ensuring project execution excellence
Reducing the Risks to Scheduled Project Delivery
The �exible I/O binding shortens duration of a project. After I/O design is �xed, application engineering and hardware
engineering can progress independently and parallel. This is made possible by System Independent Loop
Commissioning. System Independent Loop Commissioning project capability utilizes Yokogawa's FieldMate
Validator, an innovative tool allowing the �eld testing and validation of N-IO without requiring a deployed system.
Early Start-up
Module Based Engineering
The Automation Design Suite is more than the ‘As built’ speci�cation of your plant… It provides dynamic management of
design, investment and project effectiveness by auditing and versioning engineering changes, and facilitating effective
engineering through ModPacks (Modi�cation Packages).
Management of Change and Resources
Design SATCon�guration Application & HW FAT
Ship & Install
Fieldwiring
Early Start-up
Reducing risksto scheduled project delivery
Improving quality,Reducing complexity andEnhancing productivity
ConventionalEngineering
Yokogawa’sEngineering
Dependency Analyze Authorization Recording changes through out the plant lifecycle
Control
Alarm Design
HW/SW Con�g
Documents Control
Alarm Design
HW/SW Con�g
Documents
Check-in
ApproveValidate
Change
Check-out
Modi�cation Package Modi�cation PackageDatabase
Design SATCon�guration
Manufacturing& HW FAT
ApplicationFAT
Ship & wiring
LoopValidation
Automation Design Suite effects
N-IO effects FieldMate Validator effects
This serves to maintain project schedules by
reducing the delays and the engineering impact
of late design changes or scope changes. The
Automation Design Suite also auto-documents
and checks inconsistencies in project activity
and software resources, removing the pain
from project management, and signi�cantly
reducing project risk.
Yokogawa’s vast and in-depth engineering experience coupled with CENTUM’s rich history guaranteesunparalleled project execution.
Engineering10 11
Yokogawa is committed to sustaining your businessWith vast experience in maintenance technology and an extensive support structure, Yokogawa maintains the reliability and availability of the control system throughout a plant's lifecycle.
Yokogawa’s services for plants lifecycleYokogawa provides operational solutions and optimization of the maintenance plan as well as overall cost through our three introductory
steps that include Opportunity Identi�cation Services, Solution Implementation Services and Lifecycle Effectiveness Services.
Step1
Step2
Opportunity Identi�cation Services TM
Solution Implementation Services TM
Security
Robust Cyber-Security
Endpoint Security Service
We are in a new age of controlling security risks. The spread of malware and a rise in increasingly sophisticated cyber attacks
are causing even more serious damage. The threat of cyber-security risks extends beyond information technology systems and
into control systems. The use of information technology systems has advanced control systems and helped reduce costs and
provide more functions. However, we now need to tackle the associated security risks.
Yokogawa provides an effective security service in response to the customer’s
requests and operational conditions. USB Port Lock Service, Unauthorized
Program Countermeasure Service, Security Information Service, etc. are
available. The Anti-virus software and the white listing software are provided by
Yokogawa.
Yokogawa evaluates the effectiveness of a customer’s system with periodical inspection,
environmental diagnosis, deterioration diagnosis and maintenance histories and identi�es
issues that require improvement to avoid risks. Based on objective data, Yokogawa
proposes optimum lifecycle maintenance plans and conducts measures based on the
plan. Also, we analyze system utilizations such as controllability, alarm, HMI etc.
quantitatively and identify new opportunities for improvement.
Preventive Maintenance to sustain high availability
Prompt Recovery in case of emergency
Yokogawa provides maintenance operations based on the plant lifecycle plan for the
purpose of sustaining the system’s functions and overall effectiveness.
Provide periodical inspections and parts replacement, improve system reliability and
availability. (MTBF Improvement)
Yokogawa Global Response Center and our worldwide network provides prompt
recovery 24/7 with the effective utilization of remote maintenance technology.
(MTTR Reduction)
Yokogawa prevents data corruption and inconsistency by providing software
backup services. Also, our security service protects the customer system from
virus infection and data tampering.
Yokogawa advocates the concept of Advanced Decision Support (ADS) which
enabling operators quick and accurate decision making in plant operation and
improving plant safety and productivity. The following services are provided based on
the international standards under the ADS concept.
* ISA-18.2 based design consulting for alarm management
* ISA-101 based design consulting for HMI
* ISA-106 based design consulting for procedure automation
Integrity / Security sustainment
Operation Optimization
Step3 Lifecycle Effectiveness Services TM
Yokogawa periodically reviews the customer lifecycle plan and veri�es
the effectiveness of maintenance and improvements.
CENTUM VP has obtained theISASecure® Embedded Device SecurityAssurance (EDSA) certi�cation.
ISASecure EDSA 2010.1 Level 1 TMCerti�cation number : CSSC-C00001CENTUM VP R5.03.00 / Vnet/IP Firmware R18
CENTUM VP �eld control unit has obtained the ISASecure® Embedded Device
Security Assurance (EDSA) certi�cation from the ISA Security Compliance
Institute (ISCI). The certi�cation was obtained through a process that involved an
examination by the CSSC (Control System Security Center) Certi�cation Labora-
tory. It ensures that CENTUM is equipped with the cyber security features to be
used in the industries such as oil, petrochemical, power and many others.
S t e p
S t e p
S t e p
Three Introductory Steps
MigrationNot satis�ed with another vendor’s control systems? Consider migrating it to CENTUM VP. We have successfully migrated over
350 non-Yokogawa systems so far and the number is steadily growing. To name a few: Bailey INFI90, Foxboro I/A, Emerson
RS3/PROVOX/DeltaV, Eurotherm, Hartman & Brown ContronicP, Hitachi, Honeywell TDC2000/TDC3000/PKS, Siemens
SIMATIC, Taylor MODCELL, Toshiba, Allen-Bradley PLC.
UpgradingUpgrading is simple and quick: it takes just one click of a mouse to execute an FCS upgrade. All of Yokogawa's legacy CENTUM
systems can be controlled and monitored from a newer CENTUM system. Via a control network, CENTUM VP can control and
monitor operations at a plant that relies on a CENTUM V, CENTUM-XL, CENTUM CS, or CENTUM CS 3000 system. The latest
CENTUM VP can also communicate with both the N-IO and the more traditional FIO and Yokogawa will continue to sell and
provide long-term support to both types of I/O. Thus, by allowing its customers to utilize their existing assets wherever possible,
Yokogawa offers them a cost-effective way to upgrade their production control systems.
Yokogawa maintains the reliability and availability of the control system throughout a plant's lifecycle.
Lifecycle management12 13
System architectureScalable and interoperable architecture CENTUM VP has a simple & common architecture consisting of human machine interfaces, field control stations, and a control network.
Human Interface Station (HIS)Windows based operating system, commercial-off-the-shelf PC
hardware, and optional specialized operator keyboard for a large
variety of operator consoles.
Engineering Station (ENG)With the same PC features mentioned above, this includes a
comprehensive engineering package for all the CENTUM VP
components and applications.
Field Control Station (FCS)100% Yokogawa manufactured. This is the core of CENTUM VP’s
high availability/reliability, continuing the CENTUM heritage.
UGS/GSGWUni�ed Gateway Station (UGS) serves as a gateway to interface
CENTUM VP with STARDOM or the third-party subsystems.
Generic Subsystem Gateway (GSGW) is a controller for operating
and monitoring subsystems connected to CENTUM VP.
Bus Converter (BCV)Interface hardware that connects multiple control network domains.
It also connects previous CENTUM series systems to CENTUM VP.
Control Network (Vnet/IP)Vnet/IP, an IEEE802.3 Ethernet compliant redundant network
operating at 1 Gbps, incorporates Yokogawa’s technology,
achieving deterministic, reliable, and secure communications.
Multiple System Connection
Wide Area Network Connection
Customers are demanding different sites to be linked together so that bi-directional operation can be made more ef�cient.
Yokogawa provides a multiple system connection function to connect several CENTUM VP sites together and link older CENTUM sites.
True InteroperabilityInteroperability of Yokogawa CENTUM systems with the “outside world” begins with OPC. CENTUM VP utilizes an OPC server that meets the
demands of information �ow, advanced control, and alarm/event management. Our customers enjoy solid performance and wide �exibility of our
OPC server for their integration projects. Yokogawa maintains interoperability with all intelligent instrumentation and deployed �eldbuses.
Subsystem Integration and Digital Fieldnetworks SupportTo meet the growing need for communication with manufacturing equipment including
variable speed drives, PLCs, and “smart” motor protection relays for operation and
monitoring, as well as with analyzers, weighing machines, smart instruments, and other
instruments used for product inspection, CENTUM VP supports a wide variety of
communication interfaces and digital �eldnetworks such as FOUNDATIONTM �eldbus,
PROFIBUS-DP, Modbus RTU, Modbus TCP/IP, and DeviceNet.
CENTUM VP can expand its control network by connecting with a wide area network.
System integration and monitoring of remote or isolated locations are enabled using a
public or satellite network, with no loss in reliability or security.
Digital FieldnetworksCENTUM VP supports FOUNDATIONTM �eldbus, HART, PROFIBUS-DP,
DeviceNet, Modbus, Modbus/TCP, and EtherNet/IP.
Safety Control Station (SCS) - ProSafe-RSThis is Yokogawa’s TÜV SIL3 certi�ed premier safety instrumented
system. It incorporates Yokogawa’s own Pair & Spare and Vnet/IP
technologies and offers unprecedented synergy with CENTUM VP.
Network-based Control System - STARDOMYokogawa’s intelligent-hybrid remote telecommunication
controllers are ideal for the oil and gas upstream market. They
can be seamlessly integrated, via the UGS, to CENTUM VP.
Operational Excellence Software SuiteA software suite for the Windows platform that supports plant
operations and maintenance improvement, such as plant safety,
plant asset management, production management, and optimization.
FCS
Wirelessaccess point
Wireless access point
Field wireless managementstation
Wirelesstransmitter
Wirelesstransmitter
FCS
FIO
FCS
N-IO
PLC
FCN FCN-RTU
UGSSCS
FCJPLC
ENG(Automation Design Suite) HIS HIS TSE
PRM(Asset management)
14 15
Business domain
Control network
FieldbusWirelessFieldbus
Firewall
CENTUM, Lifecycle Effectiveness Services, Opportunity Identification Services, ProSafe, Solution Implementation Services, STARDOM, FieldMate, VigilantPlant,VigilantPlant Services and Vnet/IP are either trademarks or registered trademarks of Yokogawa Electric Corporation.All other company brand or product names in this bulletin are trademarks or registered trademarks of their respective holders.
[Ed:02/b] Printed in Japan, 412(KP)
2014
http://www.yokogawa.com/dcs/
With the release of the world’s first DCS nearly four decades ago, Yokogawa helped empower an entire generation of plant operators. With our focus on creating a sustainable future, we are committed in our efforts to support a new generation of plant operators.
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