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 – auto –man 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
nterprise Technology & Solution Business (Top Management) Domain
Business Domain
Corporate Information systems Enterprise Resource Planning (ERP) Supply Chain Management (SCM)
Manufacturing Exec. System Domain Plant Information & Management System
MES Domain
(PIMS) Maintenance Management (MM)
Control Domain
Control Domain
Advanced Application Advanced Process Process Control Control (APC) Advance Operation Assistance (AOA) Plant Control Room/Factory Floor
DCS/PLC/PC/ESD/F&G
Field Domain
Field Domain Fieldbus and conventiona conventionall Field Instrumentation.
F i el e l d D o m a i n - for field instruments, control valves, Field bus instruments in this domain etc.. C o n t r o l d o m a i n - 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. st artup/shutdown. Ultimately AOA provides economic benefits as well as safe
M E S D o m a in i n - 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 understandin g of production economic economics. s.
Business (Top Management) Domain Corporate Information systems Enterprise Resource Planning (ERP) Supply Chain Management (SCM)
DCS Introduction CS 3000 – Integrated Control System Overview Advanced Advance d , Flexible Operator Functions Powerful Control Station Features Flexibility in Engineering Integrated Solutions – Extended Applications Unique Advantages leading to Lower TCO
’75~’78 ’79~’82 ’82~’88 ’84~’
’88~’
NEW MODEL
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
1. Enhanced Functions of OPS 2. Voice Output 3. Japanese Language Support 4. Sequence-oriented Control Station
(Function Key Development)
1. 2. 3. 4.
UNIX OS Advanced Control Open Net Work High Reliability
1. Function Assignment 2. Separation of Engneering 3. High Peroformance 5. Utilisation of Users’ Assets 4. Touch Operation 6. Easy Engineering 5. Window 6. Integration (Super Window) 7. Expanded Control Capacity
1. 2. 3. 4.
CS
XLAIS
EOPS ENGSComputer Station
HIS
ICS
10Mbps
V net
BCV
COPSV
FCS
COPS2
7DF
COPS
EFCS 1Mbps CFSS
7VP
HF-BUS
CFFS CFCS2
256Kbps CFCS
HF/F Converter Station
F-BUS 7FS
Control Loops Sequence Tables
32 20
32 20
40 40
40 200
CENTUM
CENTUM
CENTUM-V
COPS
WINDOWS-NT OS Client / Server Migration High Reliability
CS3000
CENTUM-XL
CTM-2
7DF
OPEN SYSTEM
INTEGRATED SYSTEM
EXCELLENT SYSTEM
USER ORIENTED OPERATION
’98~’
’92~’
80 200
4096 Blocks
Technology waves on Control Systems Windows 2000 Internet IT
NT and Microsoft
UNIX Micro processor
1st CENTUM
V
XL
CS
CS 3000
CS 3000 R3
June 1975
’82
’88
’93
’98
‘01
time
Integrated Plant Control System (IPCS)
Typical System Configuration Remote Business Domain
DCS
Ethernet Domain Closed-type HIS LCD-type HIS HIS/ENG APC
PIMS
AOA
MM ACG
Vnet APCS FCS With I/O
Mulcom
Incl. Fieldbus Engg.
I/O in the Remote Field
(ExaCoast) Prosafe-ESD
t e n r e h t E / 5 8 4 / 2 3 2 S R
BCV Migration bus converter CS/CS 1000/3000 CENTUM-XL/V/ µXL
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 Windows
Operation and Monitoring Support Functions
Graphic,Tuning, Trends, Alarms, Operator guidance
Process & Historical message reports, reports, Security ITV camera & CENTUM CENTUM desktop customization
Control Status Display Window Control Control drawing, Sequence table Logic chart window SEBOL & SFC windows
Common Operation and Monitoring Functions Window call-up, call-up, Window” or “Full screen”, System message, message, Window Window sizing, Window Window hierarchy hierarchy,, Navigator window…
Trend Functions Real time, Historical trends Long Long term data archive, External recorder, Expert trend viewer &Tuning trend
System Maintenance Functions System status, System alarm, HIS setting, set ting, Time Time setting dialog & Help dialog
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 Serial, Ethernet
To Field Device
FF-H1 4-20mA
・
・
FCS ・
・
PLC
New Remote I/O Bus (Ethernet)
(Subsystem)
Remote Node
FF-H1 To Field Devices
4-20mA (Conventional)
Fieldbus
FIO Features Small-sized (Compact) Two kinds kind s 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
FIO Node overview Up to 8 I/O modules
Remote I/O Interface (10Base2) Power supply
5 units (222.3mm) 写真挿入
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 Terminal Boards/marshaling)
I/O module Terminal Board & MIL Connector Cable
(Popular for low cost installations-Wiring of field devices via Terminal 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 Unit: Redundancy
Synchronous hot standby with fully redundant hardware and duplex functionality in design
Engineering Off line Engineering without Target Target Hardware by using Hardware Simulation Technology Off line Testing and Hardware Simulation
CAE Computer Aided Engineering
ENG Builder software
HIS
Concurrent Engineering
Order
Electronic Media Input
V net
FCS
Start-up
Engineering Engineering can start direct after ordering Engineering up to Configuration Testing can be done Off Line
Virtual Test Function Off line Testing
Virtual Testing
HIS
HIS HIS Function
l g a nFCS u i t r Simulator r i i V W
HIS Function
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
Each folder for each FCS
Drag&Drop enables Copy& paste
Each folder for each HIS
FB : Function Block
• Graphical configuration • FB in FCS and FF devices are handled in a same tool.
Flexible Field Wiring.
According to your plant, any I/O modules can be connected with direct connection or terminal board connection. 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 maintenanc maintenance. e.
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“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 maintenanc maintenance. e. No effect No effect
Control logic No effect
(1) R3 Controller is controlling the plant with its control logic.
No effect
(2) You You modify one of control loops. (or sequence logic etc.) Only this loop is stopped. Others are going on working.
No effect
(3) Modified item loop is retrieved online to actual control without any effect to other loops.
(4) In this term, CPU of controller never stops. Controller CPU
is Non-stop !
ooo
Controlling
No effect