yokogawa - distributed control system

Study Title • Executive Overview

Yokogawa

http://www.yokogawa.com

DCS OfferingsCentum, Stardom NCS

DCS BusinessYokogawa’s CENTUM system has always been at the core of the company’s DCS business. The latest version of Centum is Centum CS 3000 R3, which is the sixth generation since the introduction of the first CENTUM system in 1975. The company currently supports six versions of Centum. Many Centum V systems, for example, are still operational and supported by Yokogawa, who guarantees support of all its control systems for up to 10 years after sales of new systems are discontinued.

Centum CS 3000 R3 is a major upgrade over the R2 version, and integrates advances in information technology with the rapidly evolving needs of the modern manufacturing environment. Key features of Centum CS 3000 include Windows 2000 HMI, Fieldnetwork I/O, native Foundation Fieldbus (FF) functionality, and a series of advanced functions such as embedded advanced control and Plant Resource Manager (PRM). The R3 version is also backward-compatible with older CENTUM versions and is easily upgraded in phases or replaced with minimal investment.

Yokogawa’s Centum CS 3000 R3 field network I/O, developed in conjunction with Fuji Electric. The new I/O incorporates an Extended Serial Backboard (ESB) Bus with a speed of 128 MBPS. Centum CS 3000 R3 also incorporates a high-speed Ethernet-based control network. At the fieldbus level, CS 3000 R3 incorporates a Foundation Fieldbus H1 I/O card.

The advanced functions of CS 3000 R3, however, provide the true value add. The first of these is integrated Foundation Fieldbus engineering with Yokogawa’s Plant Resource Manager (PRM) software. PRM is Yokogawa’s plant asset management (PAM) solution. In ARC’s view, providing integrated PAM functionality is a key part of any effective Foundation Fieldbus Solution.

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CS 3000 R3 also includes a new control platform, called Advanced Process Control Station (APCS). Through Yokogawa’s alliance with Shell Global Solutions, Shell’s SMOC advanced process control software has been embedded in the CS 3000 control architecture.

Yokogawa’s answer to incorporating open networking technology in its systems comes with the release of the Vnet/IP control network, which is available in the latest major version release of the CENTUM CS 3000 control system. The first widely available DCS control network based on Gigabit Ethernet, Vnet/IP offers redundant communications and communications band partitioning over standard Ethernet, while providing the high reliability and deterministic response required for process automation. Vnet/IP offers ten times the throughput of Vnet, and routers are available

that can switch between Vnet and Vnet/IP.

The openness of Vnet/IP makes it easier for users to connect non-CENTUM components to the control network through Vnet/IP’s TCP/IP communications capabilities and enables their network configuration with commercially available network equipment. Data from third-party devices can be integrated with CENTUM CS 3000 through the GSGW process data server on Vnet/IP.

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Centum CS 3000 R3


Since Vnet/IP is Ethernet-based, users have the ability to choose from a wide range of hardware, and Yokogawa does not specify which hardware vendors are to be used. Yokogawa has, however, certified and tested Cisco and Dell hardware for Vnet/IP, which is consistent with the Ethernet-based offerings of many other DCS suppliers.

Yokogawa Stardom Network Control SystemYokogawa’s Stardom Network Control System (NCS) addresses the needs of applications where the combination of a PLC and HMI package are often used, but found to be inadequate. With the release of Stardom, Yokogawa is addressing the needs of markets that traditional DCSs have not yet met. Many of these, if automated at all, have used a variety of technologies ranging from PLCs to PCs that have required significant effort for system component connections. By leveraging the Internet and internet technologies, these types of applications can be addressed more effectively with fit-for-purpose configurations. Stardom NCS is the system that will fully realize Yokogawa’s e-RM vision for collaborative manufacturing.

Yokogawa Releases Enhanced Version of STARDOM Network-based Control System In April of 2008, Yokogawa released an enhanced version of the STARDOM Network-based Control System that complies with US gas industry standards and provides a new data-logging function for the FCN/FCJ autonomous controllers. These enhancements reduce costs by improving the efficiency of both operation and

maintenance. Yokogawa will use the release of this enhanced version to strengthen its sales targeting the oil and gas upstream processes.

The enhanced STARDOM version supports the American Gas Association's AGA3, AGA7, and AGA8 standards

used in North America, South America, and Asia. This ensures correct flow measurement as gas is transported between drilling


Stardom NCS


companies and distribution companies. STARDOM provides both gas metering and control functions.

The FCN/FCJ autonomous controllers have been enhanced with the introduction of a new data logging function. The controllers can now store control data and data from field instruments and facilities for access from distant locations via the Web, enabling efficient remote monitoring.

The STARDOM engineering tool has been enhanced with network templates that improve the reusability of applications. Yokogawa provides samples of these network templates. The engineering tools for STARDOM's FCN/FCJ autonomous controllers will also support Windows Vista.

Vigilance CampaignYokogawa has come a long way in making its message clear to the world of process automation. Several years ago, the company embarked on a full-scale global marketing campaign to make customers aware of Yokogawa’s focus on system reliability, security, dependability, and robustness.

Dubbed “Vigilance,” the campaign created a unified message for the company and greatly helped expand awareness of the Yokogawa brand and corporate philosophy. Vigilance is successfully increasing brand awareness and communicating Yokogawa’s message of reliability and quality to the worldwide market, particularly outside of Japan.

While the Vigilance campaign successfully expresses the company’s philosophy, articulating the value proposition of the company’s product, application, and services offering remains a key challenge for the company. Yokogawa, for example, has long been known for its control systems, field instrumentation, and fieldbus capabilities. Many customers, however, remain unaware of Yokogawa’s capabilities in production management, safety systems, alarm management, plant asset management (PAM), and many other areas. Yokogawa’s ongoing Vigilant-Plant campaign is designed to raise customer awareness of Yokogawa’s solution set and where it fits in the Vigilance scheme.



The VigilantPlant philosophy eliminates unplanned downtime and allows businesses to adapt and change quickly and with agility, to shifting market conditions and customer demands. This is consistent with ARC’s view that giving personnel access to the right information at the right time combined with the ability to take action is crucial for achieving OpX, and is the foundation of real-time performance management (RPM).

CENTUM Release 3.08Yokogawa announced CENTUM CS 3000 R3 Release 3.08 in October of 2007. Key features of the new version included enhanced gateway functions that provide enhanced connectivity with competitors' DCSs and PLCs and a Consolidated Alarm Management Software (CAMS) offering, which Yokogawa claims is the first true CAMS-based approach available in the industry.

Yokogawa's gateway functionality is embodied in the System Integration OPC Station (SIOS). Enhancements to the gateway mean that operators will be able to control and monitor both DCS and PLC systems from Yokogawa competitors with the same look and feel as CENTUM CS 3000. Data linkage to Yokogawa's STARDOM system has also been enhanced.

The CAMS alarm management package for the CENTUM CS 3000 Human Interface Station can integrate and control alarms from CENTUM CS 3000, the ProSafe-RS Safety Instrumented System, Plant Resource Manager (PRM), and STARDOM systems. CAMS for HIS collects alarms and events from each system, identifies expressions, and eclipses duplicate alarms. This package also provides value-added alarm information such as priority level, sorting identifier, root cause, and action to be taken. It helps reduce alarm flooding that may cause critical plant problems and relieves operators from cumbersome alarm acknowledgement tasks to let them concentrate on controlling and monitoring the process.

Yokogawa Unveils Centum VP CENTUM VP is the eighth generation of the CENTUM series, and succeeds the CENTUM CS 1000/CENTUM CS 3000. While securing clear backward compatibility and consistency with previous CENTUM systems, CENTUM VP redefines the role of a production



control system, commonly known as a DCS. Going beyond the traditional DCS function of controlling and monitoring a plant, CENTUM VP integrates plant information management, asset management, and operation support functions, achieving a unified operating environment. CENTUM VP provides a foundation for operational excellence by delivering information in context and allowing easy role-based access to all key information.

The first major component of the system, released in May of 2008, was the Centum VP HMI, which is one of the first HMI applications for automation to be available in Windows Vista and Windows XP. The new HMI incorporates a universal color scheme, greatly reducing the chance of an operator misinterpreting information due to color blindness, and increasing the overall visibility of the most important information to the end user. Yokogawa did a lot of research into this HMI to drive increased productivity and decrease the chance of operator error. Yokogawa claims that the new HMI "more than doubles the speed of operational decision making." The HMI also offers integrated alarm management capabilities, faceplates, trends, and history windows.

Centum VP Release R4.02.30The latest release of Centum VP supports integrated ISA 100 wireless functionality. These wireless products include an EJX-B series differential pressure and pressure transmitter, a YTA series temperature transmitter, and an integrated field wireless gateway for field sensor networks.

Yokogawa Releases Enhanced Version of STARDOM Network-based Control SystemYokogawa Electric introduced an enhanced version of the STARDOM Network-based Control System in 2010 with upgraded engineering functionality. The new engineering tool facilitates the construction of field digital communications networks that can reduce the cost of maintaining production equipment distributed over wide areas.

For this latest STARDOM version, Yokogawa has optimized its existing engineering tool that is used to configure large-scale SCADA systems based on Foundation Fieldbus. The new



Foundation Fieldbus Configurator enables a 60 percent reduction in engineering man-hours.

Improvements have also been made in STARDOM’s Logic Designer engineering tool for creating control applications. An enhanced Distributed Network Protocol 3 (DNP3) is also provided. All screens now have the same look and feel as that of other STARDOM engineering tools. An enhanced export and import function facilitates repeat engineering. Application downloading time to fieldbus devices have also been reduced substantially. Improvements have also been made to the Control Application Creation Tool (Logic Designer). New drag & drop, automatic rearrangement, automatic wiring mode switching, and other functions have been added that make this software easier to use.

Enhanced Functionality of DNP3 ProtocolDNP3 is a communication protocol used for controlling equipment distributed over a wide area, such as oil and gas field equipment. The protocol has been enhanced to support a wider range of SCADA applications.

Support of Modular Procedural AutomationAs a major supporter of Modular Procedural Automation and the procedural automation standard, Yokogawa already has a toolset that can support Modular Procedural Automation (MPA), from applications as small as scheduling sequences consisting of many sequential function charts (SFC) steps to more complex and integrated multiproduct solutions incorporating the Centum VP process automation system. SFC is the desirable means of defining the state relationships, concurrency, and transition conditions – otherwise known as the state model of the process – in the control system. With the application of additional procedural programming, the state model itself becomes the root of the control system.

The primary tool that Yokogawa has to implement MPA in the continuous process industries, however, is Exapilot– an automated procedural control solution now installed in over 1,000 plants around the world. Using Exapilot to describe steady state and non-steady-state operations by experienced operators as a graphical flow diagram of the sequence of actions, the operations



can be fully- or semi-automated. In addition to Exapilot, the Exaplog event analysis package helps to refine the controllability of a plant and identify parts of the plant operation that could be improved, by analyzing alarms and operator actions side by side. Combining Yokogawa’s consulting skills with products such as Exapilot allows users to integrate operator actions and the control system into a single unified environment for best practice plant operation. Some operators have a lot of knowledge, but are not familiar with computers or Exapilot, so someone has to put this knowledge into Exapilot. Yokogawa knowledge engineers specialize in capturing this knowledge from experienced workers and driving it into the system.

Key IndustriesWhile Yokogawa’ traditional strengths have been in the petrochemical, refining, oil and gas, and chemical industries, the company plays across all process industry segments, particularly in its native Japan. The company has also been making a strategic push into the power generation industry and was won several large power generation projects over the past year.


yokogawa - distributed control system

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