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Why we use control system?

Control system is reducing the operation cost by reducing man power. Control system is improving the product quality and reducing the waste time by reducing the error factor and high responding to the errors.

Pressure control loop

Block diagram for control loop

PID control loop


Proportion Integral Derivative

The controller calculate the integral & derivative of the errors between the process variable and set point then generate a control effort by adding these two quantities to the error it self.

PID advantage
PID is the most widely control system in the projects. Simple configuration. High stability. High reliability. Simple operation.

PID controller with auto man mode

PID controller response

CASCADE CONTROL

Simply the Cascade control loop consist of two control loops interact together the output of the first controller(master controller) is the set point for the control device, and the second loop is slave loop.

CACADE CONTROLO LOOP

Enterprise Technology & Solution


Business (Top Management) Domain
Corporate Information systems Enterprise Resource Planning (ERP) Supply Chain Management (SCM)

Business Domain

Manufacturing Exec. System Domain


Plant Information & Management System

MES Domain

(PIMS) Maintenance Management (MM)

Control Domain
Control Domain
Advanced Application Advanced Process Control (APC) Advance Operation Assistance (AOA) Plant Control Room/Factory Floor

DCS/PLC/PC/ESD/F&G

Field Domain

Field Domain

Fieldbus and conventional Field Instrumentation.

Field Domain - for field instruments, control valves,


Field bus instruments in this domain etc..

Control domain - DCS/PLC/PC/ESD etc as major


equipment in this domain. DCS is mainly carrying out Basic Regulatory Control (BRC) and Enhanced Regulatory Control (ERC) i.e. combination of calculation and other blocks to provide final control. APC add value on top of BRC/ERC to provide yield improvement, precise product quality control, Economic optimization of energy consumption (steam, power). Ultimately APC provides economics benefits. DCS and other systems, besides control and automation function provides major plant operation. When plant in a normal operating condition, Automatic control and APC are in action. To further enhance the plant operation and carry out automatic and guided operation e.g. automatic startup/shutdown etc. AOA is our solution which helps in faster and safe startup/shutdown. Ultimately AOA provides economic benefits as well as safe operation.

MES Domain - Our MES and solutions practically fulfills


all needs of production & maintenance staffs all process and equipment related historical and real time information. Further it bridges the information gap between Control domain and Business domain. e.g. Material balance calculations at MES level provides information on efficient working of process to production management. At the same time at Business domain material balance information is used by Finance management for understanding of production economics.

Business (Top Management) Domain


Corporate Information systems Enterprise Resource Planning (ERP) Supply Chain Management (SCM)

DCS Introduction

CS 3000 Integrated Control System Overview Advanced , Flexible Operator Functions Powerful Control Station Features Flexibility in Engineering Integrated Solutions Extended Applications Unique Advantages leading to Lower TCO

7578 7982 8288 84

88
EXCELLENT SYSTEM
1. Function Assignment 2. Separation of Engneering 3. High Peroformance 4. Touch Operation 5. Window 6. Integration (Super Window) 7. Expanded Control Capacity 1. 2. 3. 4. 5. 6.

92
INTEGRATED SYSTEM
UNIX OS Advanced Control Open Net Work High Reliability Utilisation of Users Assets Easy Engineering 1. 2. 3. 4.

98
OPEN SYSTEM
WINDOWS-NT OS Client / Server Migration High Reliability

USER ORIENTED OPERATION


NEW MODEL
1. Enhanced Functions of OPS 2. Voice Output 3. Japanese Language Support 4. Sequence-oriented Control Station

THE FIRST DCS SYSTEM IN THE WORLD 1. Distribution of Control 2. FIF

1. Unified Operator Stations 2. Redundant Control Stations

1. High Speed Comunication Bus 2. Adoption of HDD 3. CMOS Memory 4. One-Touch Operation
(Function Key Development)

CENTUM ENTUM

CENTUM-XL CENTUM-V
XLAIS EOPS ENGS Computer Station 10Mbps BCV

ICS

HIS

V net

- 7DF
COPS 7DF 256Kbps CFCS 7VP 1Mbps CFSS CFFS CFCS2 HF/F Converter Station HF-BUS COPS2

COPSV

FCS

EFCS

F-BUS
7FS

Control Loops Sequence Tables

32 20

32 20

40 40

40 200

80 200

4096 Blocks

Technology waves on Control Systems


Windows 2000 Internet IT

NT and Microsoft
UNIX Micro processor

1st CENTUM June 1975

V 82

XL 88

CS 93

CS 3000 98

CS 3000 R3 01

time

Integrated Plant Control System (IPCS)

Typical System Configuration Remote


Business Domain Ethernet Domain Closed-type HIS LCD-type HIS HIS/ENG APC PIMS MM ACG AOA

DCS

Vnet
APCS Mulcom FCS With I/O

Incl. Fieldbus Engg.

BCV Migration bus converter CS/CS 1000/3000 CENTUM-XL/V/ XL

I/O in the Remote Field


RS-232/485/Ethernet

(ExaCoast)
Prosafe-ESD

H1 Fieldbus

Field Devices

PLC / Remote I/O /

System Scalable
Min. Configuration Single Domain Configuration Expanded. System Configuration

Controller

One Process Unit


Max. No. of Tags Max. No. of Stations

Whole Complex

: 100,000 per HIS : 64 Expanded System Max. No. of Domains Max. No. of Stations

: 16 : 256

Operation and Monitoring


Standard Operation and Monitoring Windows
Graphic,Tuning, Trends, Alarms, Operator guidance

Operation and Monitoring Support Functions


Process & Historical message reports, Security ITV camera & CENTUM desktop customization

Control Status Display Window


Control drawing, Sequence table Logic chart window SEBOL & SFC windows

Trend Functions
Real time, Historical trends Long term data archive, External recorder, Expert trend viewer &Tuning trend

System Maintenance Functions


System status, System alarm, HIS setting, Time setting dialog & Help dialog

Common Operation and Monitoring Functions


Window call-up, Window or Full screen, System message, Window sizing, Window hierarchy, Navigator window

Lets have a look at some samples

Operation and Monitoring Windows


Navigator Window

Control Group Window

Tuning Window

Overview Window

Trend Window

Control

Input Output

Field Control Station and FIO feature


..
Vnet

Direct Node
To Field Device

Serial, Ethernet
FCS

FF-H1 4-20mA

PLC

(Subsystem)

New Remote I/O Bus (Ethernet)

Remote Node

FF-H1
To Field Devices

FIO Features Small-sized (Compact) Two kinds of connection Direct Node Remote Node Dual redundant I/O Module are possible (for all type) Field Network RS:2 ports FF-H1 : 4 segments Profibus-DP

4-20mA (Conventional)

Fieldbus

FIO Node overview


Up to 8 I/O modules
Remote I/O Interface (10Base2) Power supply

5 units (222.3mm)

19 inches

Rich Flexibility: Field connections


Field wiring method according to the application & budget
Pressure Clamp Terminal block (Direct wiring for field devices)

Yokogawa Terminal Board, Cable & I/O adapter


(Wiring of field devices via Terminal Boards/marshaling)

I/O module Terminal Board & MIL Connector Cable


(Popular for low cost installations-Wiring of field devices via Terminal Board/Marshaling)

Remote I/O installation


Explosive sites Explosive sites

Corrosive sites Corrosive sites FCU

ooo

CCR (Central Control Room)

Separated sites Separated sites

Field Control Unit: Redundancy

Synchronous hot standby with fully redundant hardware and duplex functionality in design

Engineering
Off line Engineering without Target Hardware by using Hardware Simulation Technology
Off line Testing and Hardware Simulation CAE
Computer Aided Engineering

HIS

ENG Builder software

Concurrent Engineering

Electronic Media Input

V net

FCS

Order
Engineering

Start-up

can start direct after ordering Engineering up to Configuration Testing can be done Off Line

Virtual Test Function


Virtual Testing HIS HIS Function Off line Testing

HIS

HIS Function

FCS Simulator

Virtual Wiring

FCS Simulator

Exatif Communication Interface


Plant Simulator Plant Model

- Off Line Virtual Testing using only one PC - Connection with Plant Simulator using the FCS Simulator

Unified configuration with LOOK&FEEL.


Project Detail configuration (Each plant)
for each

Graphical configuration FB in FCS and FF devices are handled in a same tool.

Each folder for each FCS

Drag&Drop enables Copy& paste

Each folder for each HIS

FB : Function Block

Example : Control logic

Flexible Field Wiring.

According to your plant, any I/O modules can be connected with


direct connection or terminal board connection.

Even in case of field bus, you can choose either type. Change the front blocks, you can change how to connect the field wiring.

Dedicated cable

Field wiring

Terminal board
Field wiring

Flexible Field Wiring.


For dual

For single
Dedicated cable

Terminal board

On-line maintenance.

In your plant operation, sometimes you would like to modify or to add/remove your control logic or graphics.
It is quite difficult (nearly impossible) to stop your controller frequently. You usually configured several control loops. While modifying one of loops, you do not want to effect the control of any other loops.

R3 provides the On-line maintenance function to meet your above requirement.


You need not stop your controller when you modify small parts of control logic, graphics, etc. Any other parts of control logic are effected by this modification, so the influence for your plant control is minimum.

On-line maintenance.
No effect No effect Control logic No effect

(1) R3 Controller is controlling the plant with its control logic.


(2) You modify one of control loops. (or sequence logic etc.) Only this loop is stopped. Others are going on working. (3) Modified item loop is retrieved online to actual control without any effect to other loops.

No effect

No effect

(4) In this term, CPU of controller never stops. Controller CPU

ooo

is Non-stop !

Controlling

No effect

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