centum vp system introduction

CENTUM VP System Overview Specification Document

ISD-MASP-S07009

ISD-MASP-S07009 Feb 4, 2008

■ General CENTUM VP is the next evolutionary step of Yokogawa control system with better information visibility, performance foresight, and operational agility. This document covers the specification of the system overall, components, and network of the CENTUM VP system. For detail of each, please contact the nearest Yokogawa office.

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■ History Yokogawa has released the CENTUM system as the world first DCS in 1975. Then we continuously providing the new DCS products based on the latest technologies and customer’s feedback with keeping the compatibility with former Yokogawa system not to bother our customers. Based on our 30-year DCS experience, Yokogawa is proud to introduce the new CENTUM VP system.

■ Project Experience As of September 2007, Yokogawa has almost 20,000 project experiences for various industries application such as oil & gas upstream/downstream, chemical, petrochemical, pulp & paper, iron, metal, power, pharmaceutical, food & beverage, etc. all over the world.

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■ System Architecture ■ Component

HIS (Human Interface Station) An HIS serves as a human interface for operation and monitoring. The HIS works on an IBM PC/AT-compatible PC (hereinafter referred to as a general purpose PC), or in a console HIS (*6) consisting of a general-purpose PC and Open Display Style Console Assembly, implement the respective functions. The HIS software achieves the secured, safe, and intuitive operation environment, and it enables all the plant operators to execute the required actions in real time without being bothered by the nuisance information or by lack or delay of the plant information.

FCS (Field Control Station) An FCS performs process control. High availability is achieved by the unique redundancy architecture called Pair & Spare technology. Various types of signals can be handled as the process input and as the process output, and also various types of communication can be managed with the subsystems such as PLC, MCC. Handling of process signals and communication signals are achieved by the hardware called I/O modules inserted on the FCS rack, and also on the expansion I/O nodes connected to the FCS rack via the redundant I/O bus. (ESB bus and ER bus) Regulatory control logics, Sequence logics, and various kinds of functions achieve the stabile process control for many types of application easily.

HIS HIS/ENG

Exaopc Server

Terminal Server

SIOS/GSGW

Subsystems (PLC, MCC, etc.)

Modbus, CIP, etc.

OPC Server of other PCSs or subsystems. (PLC, MCC, etc) Ethernet

1Gbps Redundant Control LAN (Vnet/IP)

FCS

Expansion I/O nodes

ESB bus

ER bus

PIMS, Historian etc.

Plant LAN or Corporate LAN

APCS

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ENG (Engineering station) All the configuration work for a CENTUM VP system is executed on the ENG station. The engineering software called Builder function is installed in general purpose PC, and most of the configuration is available with drag & drop, list selection, or fill in the blanks manner. The Builder function can be installed in the same PC as HIS. On the ENG station with HIS function, engineers can do the debug work before connecting the actual process by using the test function, and it shortens the process shutdown time for engineering. Exaopc Server OPC server function of the CENTUM VP system and achieves the bi-directional communication between CENTUM VP system and the OPC client software such as historian or business domain systems. SIOS, GSGW To integrate the subsystem data into the CENTUM VP, 2 methods are available. One method is to communicate with FCS and the subsystem by using the communication modules such as Modbus, CIP, etc. If the subsystem has its own OPC server, SIOS and GSGW can be the OPC client of that OPC server and work as the FCS on the Control LAN. SIOS and GSGW manage the data translation between the subsystem and the CENTUM VP system and make the data integration easily. GSGW (General Subsystem Gateway) has the 4000 data points and function blocks, and it fits to connect the small subsystems such as PLC. SIOS (Subsystem Integration OPC Station) has 20000 data points and can handle DA and A&E, and it fit to connect other process control systems such as competitors’ DCS.

Terminal Server There is the increasing needs to monitor the plant operation remotely through WAN. Terminal Server achieves the remote monitor and operation from the PCs which are remote from the Control LAN and FCSs. The client side no special software is needed. Control LAN 1 Gbps redundant Ethernet called Vnet/IP is the control LAN of the CENTUM VP system. PCs connected to the Vnet/IP such as HIS, ENG requires the dedicated network card VI701 on the PCI bus. FCSs and other Yokogawa hardware have the dedicated Vnet/IP interface on it. Vnet/IP secures the real-time process data communication among the components on it with high data integrity, and high availability network with redundancy architecture. It is possible to use the control bus of former Yokogawa control system called Vnet, 10Mbps Ethernet network as the CENTUM VP. All the FCSs and other Yokogawa hardware which have the Vnet interface can be used in the CENTUM VP system. Bus converters Yokogawa keeps the connectivity of the latest control system and the former Yokogawa control system. The control networks of those are different and the bus converters enable to connect those different networks in seamless. The HISs of CENTUM VP can operate the controllers of CENTUM CS 3000, CENTUM CS 1000, CENTUM CS, CENTUM-XL, CENTUM V and Micro-XL

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■ System Specification System overall Up to 256 stations can be in one CENTUM VP system. One CENTUM VP system can be divided into up to 16 Vnet/IP domains and one Vnet/IP domain can have up to 64 stations. Station here includes HIS, ENG, FCS and other components which connected on the Vnet/IP network. The PCs or other hardware which use only the open communication area of the Vnet/IP is not included. Tag name can be assigned on each function block or on other elements, and up to 1,000,000 tag-names can be used in one CENTUM VP system. HIS Graphic One HIS can have up to 4,000 graphics. Each graphic can have 800 process data on it, and 1 second data refresh is available. One HIS can have up to 4 monitors, and up to 10 graphics can be displayed at the same time with regardless the number of monitors. Frequently used combination of the graphics and other display components can be pasted on a frame, and the set of those can be call up quickly. Trend 50 trend gathering block are in one HIS, and one trend gathering block has 16 trend group. The data gathering period can be defined for each block, and the choice is 1 second, 10-second, 1-minute, 2-minute, 5-minute, and 10-minute. Operator can easily paste the trend graph of any defined trend data pen on the trend graph display with drag & drop with regardless of the data gathering period. Alarm & Event Only the messages which require the immediate action should be notified only to the concerned operator, or work overload for operators respectively reduce the plant operation efficiency. The Alarm & Event window of CENTUM VP has the capability of filtering, suppression, and shelving designed based on the alarm policy of each plant, and it enables safer and more efficient

plant operation than before. FCS Single CPU type or Duplexed CPU type can be selected. In case of duplex type, when the abnormality of the control module is detected, switching-over to the stand-by one happened within mille-seconds not to affect the plant operation. Each CPU module has 2 CPU chips whose the calculation results are always checked. If the result of the control module unmatched, the control right is switched to stand-by one even no hardware abnormality is detected. This is called pair & spare technology to achieve high plant operation availability. One FCS has 8 slots for I/O module, and you can install any types of I/O modules there. Additionally it is possible to connect up to 14 expansion I/O nodes on one FCS. One I/O node has 8 slots for I/O modules. 2 types of I/O network are available to connect the expansion I/O nodes. One is ESB bus, 128 Mbps with Yokogawa dedicated hardware. The other is called ER bus, which is Ethernet based hardware, and the network distance is extendable by using the COTS Ethernet repeaters. Both of I/O networks can be redundant. We have various types of I/O modules. Analog input (1-5V, 0-10V, 4-20mA, RTD, T/C, Pulse), Analog output (1-5V, 0-10V, 4-20mA), Digital input and output, Foundation Fieldbus, PROFIBUS-DP, Serial communication and Ethernet communication. Ethernet communication includes CIP and Modbus/TCP. Analog input and output

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modules have the capability of HART protocol. All of the I/O modules can be redundant.

In case of redundant configuration, hot swapping of the abnormal hardware is available without affecting other portion for CPU modules, I/O modules, I/O bus network cables etc. The engineers can do the online modification of the configuration of the controllers and that of the HISs are available without affecting others.

Network (Vnet/IP) The Vnet/IP is a real-time process control LAN used to connect system components. The Vnet/IP contains two types of communications process control communications and open communications. Process Control communication is the one among CENTUM VP components such as HISs and FCSs, and the real time high data agility communication is mandatory. The Vnet/IP is always dual redundant. Open communication is not the communication of CENTUM VP, but the generic Ethernet communication with Non CENTUM VP components such as PLCs. Usually, control communications are carried out via LAN 1. Open communications are carried out via

LAN 2. If a control communications error occurs at the LAN1 side, control bus communications will be carried out via LAN 2. The Vnet/IP uses general-purpose communications devices for network connection. The communication bandwidth for control communication and for open communication is fully segregated in LAN 2, and the load of open communication does not affect the control communication at all. The components which use the control communication in a domain are connected to the 1Gbps Ethernet Layer 2 switch as one broadcast domain. Multiple domains are connected via Ethernet Layer 3 switch. The Vnet/IP domains can be in hierarchy configuration.

ESB bus Interface modules

ESB bus

Expansion I/O nodes

FCS

Optical fiber

ER bus

FCS

ER bus Interface modules

Expansion I/O nodes

(a) Expansion I/O nodes with ESB bus

(b) Expansion I/O nodes with ER bus

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■ Operation Environment HIS, ENG, APCS, SIOS, and GSGW work on Windows XP or on Windows Vista Business. Windows 2003 server is also available. For detail requirement, please contact the nearest Yokogawa office. Expanded I/O nodes can be in the temperature between -20 - 70 deg C. Any other Yokogawa hardware such as FCS, Bus converters can be installed between 0 – 50 deg C. The available power supply is 100-120 V AC, 220 – 240 V AC, or 24 V DC.

■ Regulatory Compliance Safety Standards (*1) [CSA]

CSA C22.2 No. 1010.1 (for 100 to 120 V AC and 24V DC

power supply)

[CE Mark] Low Voltage Directive

EN 61010-1 (for 220-240 V AC and 24 V DC power supply) (*8)

EMC Conformity Standards (*1) [CE Mark] EMC Directive

EN 55011 Group 1 Class A (for 220-240 V AC and24 V DC

power supply) (*9)

EN 61000-6-2 (for 220-240 V AC and 24 V DC power supply)

(*2)

EN 61000-3-2 (for 220-240 V AC power supply) (*3)

EN 61000-3-3 (for 220-240 V AC power supply) (*4)

[C-Tick Mark]

AS/NZS 2064 (for 220-240 V AC and 24 V DC power supply) Standards for Hazardous Location Equipment [CSA Non-Incendive] (*5)

Class I, Division 2, Groups A, B, C and D Temperature code T4

CSA Standard C22.2 No. 157-92

CSA Standard C22.2 No. 213-M1987

ISA Standard ISA-S12.12 1994

(For 100-120 V AC and 24 V DC power supply)

[FM Non-Incendive] (*6)

Class I, Division 2, Groups A, B, C and D Temperature code T4

FM Class Number 3600: 1998



(For 100-120 V AC, 220-240 V AC and 24 V DC power supply)

[Type n] (*7)

EN 60079-15: 2003

IEC 60079-0: 1998

IEC 60079-11: 1999

(For 24 VDC power supply)

[Intrinsic Safety]

EN 50014 1997 +A1 +A2

EN 50020 1994

EN 50021 1999 *1: To conform to safety standards and EMC conformity standards, install

19-inch rack-mounted devices in a keyed metallic cabinet.

*2: A lightning arrestor or the like is required to meet this surge immunity

standard.

*3: An external device such as a power unit with harmonic current

neutralizer and an active harmonics

Conditioner must be connected to meet this harmonic current emission

standard.

*4: The specified limits of voltage drops across wiring must be satisfied to

meet this standard.

*5: To meet the standard for hazardous location equipment, 19-inch

rack-mounted devices must be installed in a keyed metallic cabinet

approved by CSA or non-incendive regulator in your area.

*6: To meet the standard for hazardous location equipment, 19-inch

rack-mounted devices must be installed in a keyed metallic cabinet

approved by FM or non-incendive regulator in your area.

*7: To be compatible with Type n, the specification requirements of EN

61010 and EN 60079-15 must be met, and a keyed metallic cabinet,

whose degree of protection is IP 54 or above, prescribed by IEC 60529

must be used for housing.

*8: The analog input side of this equipment is measurement category 1.

For details, see CENTUM CS 3000 Installation Guidance (TI

33Q01J10-01E).

*9: A Class A hardware device is designed for use in the industrial

environment. Please use this device in the industrial environment only.

Note: According to the New Approach Directive, the manufacturer and the

representative office in EU are indicated below:

Manufacturer: YOKOGAWA Electric Corporation

(2-9-32 Nakacho, Musashino-shi, Tokyo 180-8750, Japan).

Representative office in EU Community:

Yokogawa Europe B.V. (Databankweg 20, 3821 AL Amesfoort, The

Netherlands).

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■ Trademark • CENTUM, Vnet/IP, DARWIN, DAQSTATION ProSafe

and Exaopc are registered trademarks of Yokogawa Electric Corporation.

• Exaplog and Exapilot are trademarks of Yokogawa Electric Corporation.

• Windows is a registered trademark of Microsoft Corporation in the United States and/or other countries.

• Ethernet is a registered trademark of XEROX Corporation.

• Modbus is a registered trademark of Schneider Electric and/or such related companies.

• PLC, PLC-5 and SLC500 are trademarks or registered trademarks of Rockwell Automation, Inc.

• MELSEC and MELSEC-A are registered trademarks of Mitsubishi Electric Corporation.

• SYSMAC is a registered trademark of Omron Corporation.

• “FOUNDATION” of “FOUNDATION fieldbus” is a registered trademark of Fieldbus Foundation.

• Other product and company names appearing in this document are trademarks or registered trademarks of their respective holders.

centum vp system introduction

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