Yokogawa Distributed Control System (dcs) Centum Cs3000 R3: Technology Of Automatic Control

Distributed Control System Technology of Automatic Control

Yokogawa Distributed Control System (DCS) Centum CS3000 R3

Hannan Akhtar

Objective  Learning Industrial Automation & DCS in general  Yokogawa DCS  Typical Control Loop  DCS Hardware  DCS in FFC-MM  DCS Software Engineering & Test Function  Future plan of upgrade

Industrial Automation

 Use of control systems and information technologies to reduce the need for human work in the production of goods and services.  A control system is a device, or set of devices, that manages, commands, directs or regulates the behavior of other devices or systems. Industrial control systems are used for controlling equipment or machines.  Control Systems are used in various industries such as electrical, water, oil, gas and chemical.

Distributed Control System (DCS)  A distributed control system (DCS) refers to a control system usually of a manufacturing system, process or any kind of dynamic system.  In DCS the controller elements are not central in location (like the brain) but are distributed throughout the system with each

component sub-system controlled by one or more controllers.  The entire system of controllers is connected by networks for communication and monitoring.

 A DCS typically uses custom designed processors as controllers and uses both proprietary interconnections and communications protocol for communication.

Distributed Control System (DCS)  A typical DCS consists of functionally and/or geographically distributed digital controllers capable of executing multiple

regulatory control loops in one control box.  The input/output devices (I/O) can be integral with the controller or located remotely via a field network.

 Today’s controllers have extensive computational capabilities and, in addition to proportional, integral, and derivative (PID) control, can generally perform complex algorithms.

 DCSs may employ one or more workstations and can be configured at the workstation or by an off-line personal computer.

Comparison with PLC  PLC stand for programmable logic Controllers  Used for batch processes; fixed desired operation at fixed input

 Sequencers and Logic based interlocking are easily implemented  ESD system is based on PLC(Honeywell Failsafe FSC)

Comparison with PLC

Qualities

PLC

• Response Time

• Fast

• Scalability

• Few hundred I/O

DCS • Slower in comparison • Thousands of I/O

• Redundancy

• Redundant Robust Schemes

• Standard/Redund ant schemes

• Complexity

• Simpler and easier to Program

• Complex and proprietary Programming

• Process Changes

• Suitable for Less Process Changes

• Suitable for online changes

Yokogawa DCS at FFC-MM  Yokogawa Centum CS3000 R3  System covers Ammonia, Urea, Utilities and Water Treatment Plants  Seven FCS Controllers (DCS Systems) & 15 HIS Computers (Operator Screens) are installed # DCS System

Installation / Commissioning Year

1 Utilities & TGs

TA-2006

2 Ammonia & Urea Plants

TA-2007

3 WTCR

Year 2013/14

Typical Control Loop

RACK ROOM

FIELD

INPUT MODULE Barrier

(FTA) 4-20mA

4-20mA

TRANSMITTER

CONTROL PROCESSOR OUTPUT MODULE Barrier (FTA) 4-20mA

CONTROL VALVE

4-20mA

CCR HMI

Yokogawa DCS HIS V-NET

DATA PACKETS FCU

RIO BUS

DATA PACKETS

NIU FCS

IOM 4 – 20 mA

Control Valve

4 – 20 mA Transmitters

DCS Control Station - FCS

FCU

NIU

IOM

Power Supply

REDUNDANCY OF THE SYSTEM V net

Processor card

Main Memory (with ECC)

Processor card V net I/F

V net I/F

CPU 1

CPU 1

Collator

Power Supply

Collator

CPU 2

RIO bus card

FCU

Main Memory (with ECC)

CPU 2

RIO bus card

Power Supply

V netBUS BUS RIO

R I/O bus Com. Card

Com. Card

Redundant Link between control processor & HMI I/O system PROCESSOR Bus type networkCARD I/O SYSTEM CPU SPEED = 133 MHz Token Passing technology Speed = 2 Mbps Input Module Memory = 16 MBytes Speed = 10 Mbps Twisted pair cable Output 640 handling capacity Coaxial cable Module MaxI/Os distance = 750 m

Field Control Unit

RIO POWER BACKUP BUS RIO BATTERY POWER DISTRIBUTION VNET COUPLER FAN CPU UNITS SUPPLY COUPLER INTERFACE (72 CARD HOURS) UNITS UNITS

Input / Output Modules

RIO INTERFACE POWER SUPPLIES I/O MODULE NEST NODE I/O CARDS

Typical DCS Inputs / Outputs Modules

• • • • • •

Inputs

Process Transmitters Process Sensing Switches Temperature Sensors Tachometers Limit switches Operator commands and push buttons • Inputs from MCC / Electrical Substations • Inputs from other systems like Vibration Monitoring System, Electronic Governing System, ESD DCS and ELMS, etc. • Communication Inputs

Outputs

• Control Valves • MOVs (Opening & Closing) • Solenoid Operated Valves (SOV)

– Open / Close Shutdown Valves – Start / Stop turbines and machines

• Start / Stop commands to motor starters through electrical substations • Indications, lamps, Hooters etc. • Special interface signals to other control systems like ESD, antisurge controllers, speed governors and Gas Turbine • Communication Outputs

Input / Output Modules  I/O modules transfer field signal to field control stations and vice versa  I/O modules can be categorized into the following main types: Types

Analog

Digital Communication

Model

Name

AAM10

Current/Voltage Input Module (Single Channel)

AAM11

Current/voltage Input module

AAM21

mV, Thermocouple, RTD Input Module

APM11

Pulse Input Module (Frequency)

AAM50

Current Output Module (Single Channel)

AAM51

Current/Voltage Output Module

ADM12T

Contact Input Module (32-Point)

ADM52T

Contact Output Module (32-Point)

ACM12

RS-422/RS-485 Communication Module

DCS Architecture • In Yokogawa DCS, there are two networks: – Control Network (Vnet)

• Real time data from field devices etc

– Data Network (Enet) • Data Equalization.

• There is no central server station, every computer on Vnet directly communicates with FCS. • Following different O&M groups are configured: • • • • • •

Urea Ammonia Front-End Ammonia Back-End Boardman Utilities Power Generation WTCR (Not linked with main CCR)

• HMI/EWS : OS Windows XP SP-2

Human Interface Station (HIS) HIS is a computer where operating & monitoring software is

used by plant operators These are standard computers with special communication

cards used for interfacing with FCS (DCS Controllers). Yokogawa

supply

standard

license

for

operation

and

monitoring software. Engineering Station computers have additional license of DCS configuration software

FFC – MM Main DCS Architecture

UTILITIES

GCR

COORD

TGs CONTROL

AMMONIA UREA

E-NET

V NET

300 Meters

Power Generation 02 FCS Units

01 FCS Unit

ENGINEERING STATIONS

Note: WTCR DCS is equivalent to Utilities DCS System

FRONT END

BACK END

02 FCS Unit

01 FCS Unit

Control Room

DCS Network Architecture

Types of Networks • Vnet – – – – –

All stations are connected to each other through Vnet Used to fetch process data from FCS to HIS Used to send operator commands/action from HIS to FCS Used to exchange process data between FCSes Redundant

• Ethernet – All HIS PCs (including EWS) are connected to each other through Ethernet – Based on standard LAN adapter – No connection with DCS controller (FCS) – Used to equalize/synchronize engineering data from EWS to HIS – Used to exchange trend data between HIS – Non-redundant

Functional Distribution 06 Field Control Stations (FCS) FCS0101

TG-701A

FCS0102

TG-701B

FCS0103

Utilities

FCS0104

Ammonia Front-End

FCS0105

Ammonia Back-End

FCS0106

Urea

13 Human Interface Stations (HIS) HIS0131, HIS0132, HIS0133

Urea

HIS0141, HIS0142

Ammonia Front-End

HIS0143, HIS0144

Ammonia Back-End

HIS0161, HIS0162

Utilities

HIS0160

Coordination Engineer

HIS0159*, HIS0163

Power Generation (read-only)

HIS0145

Engineering Workstation

*HIS0159 is read-only HIS placed in G

HIS – Operation and Monitoring  Number of Tags = 100000

 Operation and monitoring windows  Graphic Window

 Control Loop Face-Plate

 8 – Control Loop Display  16 – Control Loop Display  Trend Window

 Tuning Window  Process Alarm Window

HIS – Operation and Monitoring  System Maintenance Functions  System Alarm Window  System Status Overview Display  FCS Status Display  NIU Status display

 Electronic Sounds for annunciation  Seven different sounds are produced

 Reporting Package  Generate reports periodically and on demand

Graphic Window

Graphical Window 400 Data points per window 200 Data Modifiers (Flashing, Color change)

Graphic Window

LOOP IMPORTANCE

PROCESS CONDITIONS OF LOOP LOOP OUTPUT

LOOP TAG

LOOP DESCRIPTION

MODE OF OPERATION

PROCESS VARIABLE

SET POINT

Distributed Control System

SYSTEM ALARMING

NORMAL STATE

Technology of Automatic Control

ALARM STATE

8- Loop Display

16 – Loop Display

Trend Window 06-TIC-101

Trend Window 6400 trends can be archived Minimum time resolution = 1 sec

Trend point window

Sample Time of Trends Following sampling times are available: – – – – – –

1 second 10 second 1 minute 2 minute 5 minute 10 minute

• Sample time is assigned at Trend Block level • High-speed trends (1s, 10s) generate more network traffic and require more storage space • Maximum of 02 high-speed trends can be configured per HIS

Trend Data Storage • Trend data is stored in files • One file stores 2880 process samples. – For 1 second trend: 2880 seconds = 48 minutes – For 1 minute trend, 2880 minutes = 2 days • By default, HIS saves only current file and discards older ones • If the HIS has “Long-Term Data Archive Package”, it does not discard older files and stores trend data for extended periods. • Space requirement for storing trend data: – 1 second trend block: 2.5 GB/month (approx.) – 1 minute trend block: 42 MB/month (approx.) • Long-Term storage is available on HIS0131, HIS0141, HIS0144 and HIS0163. • We are retaining 3 months of trend data in these HISes

Tuning Window

Tuning Window Set point, PV, MV limits Alarms Settings Vary PID control tuning parameters Add / Remove Operation Mark Monitor real time trend (SP, PV, MV)

Process Alarm Window

Process Alarm Alarm will be logged in chronological order

System Alarm Window

System Alarm Alarm will be logged in chronological order

FCS Status Window

FCS STATUS

NIU STATUS

System Status Overview VNET STATUS

FCS STATUS

HIS STATUS

Distributed Control System

Technology of Automatic Control

NIU STATUS

COMM. MODULE STATUS I/O MODULE

POWER SUPPLY STATUS

Operator Keyboard

System Message Window 1. Main Toolbar

2. Message Display Area: Display alarms and system messages

3. Date/Time Display: Displays Current Date and Time 4. Icon Display Area: Indicates various states of the HIS Database Equalization Required

Extended Toolbox

Window Call Menu

Preset Window Menu

Engineering and Configuration • All engineering and configuration functions are performed from the engineering work station machine. • Steps are involved in engineering of the system. – Defining System Architecture • FCS Controllers • I/O Cards & Channels • HIS Stations • Project Common (Alarm Processing etc) – I/O & Loop Configuration • Defining all tag names and data points which will be exchanged between field and system • Configuring loops using function block library – Developing Graphics • Developing graphics of plant data • Linking live data (tag names and data points) with effects on graphics

Engineering and Configuration • Operation & Monitoring is managed through security level, configuring access level and alarm priorities. • HIS Security: – Off User – Operation & Monitoring of plant (If Privileged) – On User – O&M with configuring tuning & other settings – Eng User – O&M, additional functions for managing specific functions of HIS settings

• Access level is configured through HIS configuration from EWS

Alarm Management • Common Alarms of Process Indicator – PLL, PL, PH, PHH, VH, IOP

• Configuration of individual type of alarm is done through two tables: – Alarm Priority Table • Define priorities High, Low, Medium & Logging.

– Alarm Processing Table • Different User Levels (1-8), these user definer the alarm priority & color alarm state for each type of alarm.

• Individual loops are tagged with user level for alarm processing.

Alarm Management • Alarm Priority Table Priority

HMI Printer History

Action

High

Y

Y

Y

Lock Type

Medium

Y

Y

Y

Lock Type

Low

Y

Y

Y

Non Lock Type

Logging

N

Y

Y

Self Ack. Type

• Alarm Processing Table User

PLL

PL

S5

L

Yellow

L

Yellow

S6

M

Orange

M

Orange

S7

H

Red

M

Orange

Communication with Sub-Systems • Data is fetched from various devices through communication link and displayed on DCS HMI. • DCS initiates all data transactions, therefore, DCS is called Master and the devices are called Slaves or “Sub-Systems” • Sub-System communication allows transfer of process parameters from various systems to DCS with minimum hardware wiring • Over 20 devices are communicating with DCS currently. – Communication Interface: RS-485 – Communication Protocol: Modbus RTU

Sub-Systems connected with DCS Sub-System Description

Related Equipment

Bently Nevada 3500 Systems

TK-421 / TK-431 / TK-441 / MK-212 TK-101 / P-102 / TG-701A / TG-701B

Woodward Governors

TK-601 / TK-101 / TG-701A

CCC Vanguard / Guardian System

TK-421 / TK-441

GE Antisurge Controllers (CMS)

TK-431 / TK-101

Honeywell FailSafe Control (FSC)

F-202 BMS

TurboMach Gas Turbine

GT-703

GE PAC 8000

B-603 (HRSG) BMS

GE-Fanuc PLC

F-501 BMS

Red Lion PLC

MK-800A-H (Fan Vibration)

GE-Fanuc PLC

Urea Cooling Tower (Wireless)

Future Plans • Existing HIS computers are based on Windows XP, running on old machines (about 8 years old), which are no more available for purchasing. • Its software and PC up gradation with Windows 10 will be proposed in CAPEX-2017.

• Architecture of the new system will be similar to the existing system except the Control network. New network will be Vnet/IP. • With this upgrade, we can also add PIMs (Plant Information Management System).

Thank you