Process Control PLC/RTU

What's new

18th Apr. 2018: Release of a new module, “E2 bus interface module” for I/O expansion.

20th Nov. 2017: Press release of a new unit extension module, "E2 bus interface module."

Process Control PLC/RTU: STARDOM

Smart control systems are key components for smart manufacturing plants. By quickly and easily responding to business and production dynamics, they enable users to meet changing market demands. With STARDOM control systems, processes are no longer interrupted thanks to redundant configurations and reliable hardware. And end-to-end digital communication optimizes asset management by transmitting asset information together with more accurate digital process data, both vertically (from field devices to SCADA and MES systems) and horizontally (across utilities and field devices). STARDOM controllers help you maximize operational excellence​.

  • High reliability and high speed are essential for the systems that control your critical processes. The dual redundant model of the field control node (FCN) autonomous controller ensures that these processes continue without interruption even when a module is replaced.

  • The low power consumption model of the field control node (FCN) autonomous controller meets the demanding requirements at inhospitable remote locations which lack power.

  • Versatile Data Server Software (VDS) is Web-based HMI/data server software that adds advanced architecture to the conventional HMI/SCADA functionality.

Overview:
  • World's first offshore regasification terminal relies on Yokogawa ICSS (CENTUM CS 3000, ProSafe-RS).
  • LNG carrier scheduling, unloading, tank storage, and vaporizing are all procedure based operations.
Overview:

When Rangitata Diversion Race (RDR) Management took steps to improve visibility and performance for their historic irrigation scheme in New Zealand’s South Island, they selected a Yokogawa solution comprising FAST/TOOLS SCADA and Stardom RTU’s as platforms upon which operational excellence for future could be established.

 

New Zealand has been considered an agricultural country since the 19th century, when the introduction of refrigerated transport allowed its sheep and dairy industries to expand providing meat, wool, butter, and other agricultural products both locally and overseas. Throughout the 20th and into the 21st century agricultural imports have remained important to the New Zealand economy, contributing about two-thirds of exported goods.

 

Image 1: Aerial of Canterbury Plains, South Island, New Zealand.

 

​​​The Canterbury Plains region of New Zealand’s South Island is an area of braided rivers and pastoral perfection between the Southern Alps and the Pacific Ocean. Almost as flat as a billiard table, the plains are a patchwork of agricultural activity and produces more than 80% of New Zealand’s grains, crops and seeds.

 

With a growing population and increasing international demand for produce, New Zealand’s Public Works Department initiated a project in 1937 to divert water from the Rangitata River on to the Rakaia River crossing the Canterbury Plains. This was a dream come true for the regions pioneering farmers who had struggled with water management and drought for decades.

 

When officially opened in 1945, the 67km long Race (Race meaning an occurrence where a fast-moving tide moves through a constriction) provided water to over 600 farms via a canal network and would improve their production five or six-fold. Taking water from three rivers (Rangitata, Rakaia and Ashburton), the system is gravity fed with an average fall of around 200mm per km across the entire distance of the Race. Although the land from the Rangitata river is fairly flat, there is a mountainous section from the Rakaia river which requires water to be pumped uphill to link into the Race. This is the only non-gravity fed section, with around 28 MW of power provided for pumping and other use in the region by two hydropower stations which are part of the overall scheme.

 

Taking 20 years to reach full capacity it has since transformed farming in the district and is now considered their most important piece of infrastructure. Since its initial implementation it has continued to grow, now covering more than 110,000 square hectares (around 1,100 square kilometres).

 

Managing growth of the Race

 

Image 2: Water offtake point, Rangitata river, New Zealand.

 

RDR Management Ltd are a user-owned limited company consisting of five core shareholders. It is responsible for the effective operations and maintenance of the Race including environmental management, forecasting and future planning and development activities.

 

RDR Management Ltd are a lean and highly effective organisation managing all the operational and maintenance requirements of the Race with a team of only five employees. This is quite an achievement considering the wide geographical dispersion of the Race. It also places greater significance on the operational effectiveness and reliability of the control and visualisation tools they employ.

 

As a consequence, when reviewing their future requirements for control and visualisation in the late 2000’s, after an extensive and detailed evaluation process they selected Yokogawa’s FAST/TOOLS SCADA and Stardom RTU’s implemented by their partner Industrial Controls South Canterbury Ltd.

 

“The Race was going through a period of evolution as we prepared for growth, adapting to the changing requirements of farmers while also remaining environmentally sensitive” according to RDR Management’s Chief Executive Ben Curry.

 

“We needed a platform which not only provided us with accurate and reliable real-time operational information, but one which was simple to use and highly intuitive. Although our operations and maintenance team are highly skilled, running lean requires tools to support their activities in the most efficient way”.

 

RDR Management Ltd were also conscious of the remoteness of their application and the need to ensure continuous operation. Their choice of FAST/TOOLS and Stardom was not solely based on technological advantage for wide area operations, but also considered their vision for future and local support requirements. Yokogawa are one of a limited number of control and automation vendors to maintain an ongoing presence on the South Island, celebrating their 20th anniversary in the region during 2019. Location also being a prime consideration in the selection of Industrial Controls to integrate the Yokogawa solution, whose locality and reputation for engineering excellence made them an ideal partner.

 

Image 3: Stardom RTU panel at the river offtake station.

 

The Race comprises over six-hundred farm and twenty-five main gates and take-off’s, connected via a radio network back to the FAST/TOOLS central monitoring station at Ashburton. Covering an area of over 110,000 square hectares, this is an undertaking of enormous proportions and an area which is prone to extremes of weather (with temperatures dropping as low as -10 in winter).

 

With the scheme in operation all year round (more for power generation in winter) it is imperative that any equipment deployed must maintain the highest levels of reliability at all times and in all conditions. This is something the Stardom RTU’s are renowned for, providing not only high levels of availability, but also advanced functionality allowing local web services for in-field activities as well as connectivity back to the FAST/TOOLS operations centre for overall performance monitoring.

 

Delivering an adaptable solution for the Race

 

Image 4: Rangitata River South Island, New Zealand.

 

Industrial Controls specialises in industrial electrical automation systems, providing control solutions for industry. Founded in 1996 it is one of the South Islands foremost providers of industrial electrical and automation solutions. Having worked with Yokogawa for around twenty years, they have developed a strong and mutually beneficial partnership. When it came to selecting a FAST/TOOLS and Stardom solution for RDR, both parties knew the eventual outcome would be a highly effective and reliable control and visualisation solution.

 

According to Jeph Burns, Principal Automation Engineer at Industrial Controls, “When RDR’s upgrade requirements for wide area SCADA and RTU’s were issued, it was a clear choice which platform was most suited. We saw that RDR was looking for quality local support and FAST/TOOLS plus Stardom were the perfect fit for all parties, but more specifically RDR. The support process is much more straight-forward when you have reliable SCADA and RTU platforms designed to operate in-line with industry standards. This allows you to focus on optimising and improving the performance of the overall system rather than trouble-shooting a solution which was not designed for this type of application. With FAST/TOOLS both flexible and straight forward to configure, with well documented software, creating an operations environment which is intuitive and easy to use has long-term benefits to the client.”

 

When developing and implementing such a geographically dispersed project, Industrial Controls used their experience in manufacturing industries to advantage.

 

“We didn’t have the same mindset as other integrators working in telemetry” says Jeph. “Instead we combined our familiarity with real-time operations with our multi-disciplined team and a desire to provide the best technologies to our clients. This provided RDR with a real-time operations system that continues to meet their needs. Our approach led us to a wireless ethernet networking solution, made possible by the proximity of RDRs system to the mid-Canterbury foothills. We also engineered mobile based software solutions to account for the SCADA system not being manned 24/7 with the RDR lean approach, something FAST/TOOLS enabled through its integration API’s.”

 

Stardom RTU’s proved to be particularly well suited to the application, not only due to their ruggedness, but also their low power consumption and tight integration with FAST/TOOLS for ‘store and forward’ of data. This complimented the wireless networking approach, providing data security for when the network was unavailable.

 

The web HMI client provided by FAST/TOOLS reduced the administrative overhead of maintaining client software within RDR’s operations team, with its graphics system allowing the finishing touch of a modern interface that was eye catching and intuitive.

 

Responsible management of the environment

 

RDR Management Ltd also understand that they play an increasingly important and proactive role in managing the environment within which they operate. Managing fish and sediment related issues in the Race are part of their day to day operational challenges, as is carefully monitoring the amount of water they draw from the river.

 

Ben Curry comments; “The eco-system in this part of the South Island is particularly sensitive. Draw off too much water from the rivers to feed the farms via the Race and this can lead to unacceptable consequences down river. We have strict upper and lower thresholds of water that we are allowed to draw from the river network and we ensure we strictly abide by these. In times of drought this can be particularly challenging when river flow drops. Although the farmers are less than pleased when offtakes and supply to their farms fall, they understand the same way we do that environmental management is the responsibility of us all”.

 

As part of their long-term goals for improving their already high standards of environmental management, RDR are working on a number of initiatives to bolster the system to the benefit of all. The Race is currently just a ‘Run of River’ system and lacks storage. This presents issues during summer when river flows fall leading to challenges for the farmers.

 

 

As such, RDR have plans to build storage reservoirs at select locations along the Race which when completed will hold up to 53 million cubic metres of water. This will provide a higher degree of resilience and reduce dependency on the river during low flow periods. They are also working with farmers to reduce leakage levels, with pipe systems become far more prevalent and reducing leakage by around 40%.

 

Balancing for the long term

 

Managing growth expectations, operational effectiveness and environmental requirements can be a daunting balancing act, especially in one of the most naturally beautiful regions on the planet. Doing so with a highly skilled but small team on an application which covers 110,000 square hectares is even more so.

 

Yet this challenge is accepted and delivered on by the dedicated team at RDR Management Ltd, supported by a highly reliable Yokogawa solution and engineering excellence from Industrial Controls. This three-way partnership has helped deliver water to the farmers of the Canterbury Plains for over ten years and continues to adapt with the recently installed R10.4 version of FAST/TOOLS. This further increases web client support providing additional functions for operational and maintenance activities. With a system which continues to grow and evolve to meet evolutionary needs of the Rangitata Diversion Race, FAST/TOOLS and Stardom continues to be one constant upon which firm foundations for operations and maintenance can be built upon.

 

Image 5: Large centre pivot irrigation system running on a farm in Canterbury, New Zealand.

Overview:
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Overview:

As the demand for food is increasing worldwide, fertilizers are playing an essential role in improving agricultural productivity. OCI Nitrogen (hereinafter OCI) is a leading producer of mineral fertilizers and the world's largest producer of melamine, which is used to make adhesives and resins for a wide range of applications, such as furniture panels, laminate flooring, coatings, paints, and plastics.

Overview:
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  • Fast and controllable integration cycle
  • High speed hybrid compressor control solution
  • Reduced OPEX for the compressor operation by replacing old and obsolete PLCs with a modern hybrid control platform
Industries:
Overview:

Granite Power is a geothermal company that has developed GRANEX®, a patented direct supercritical fluid heat transfer technology for the efficient, eco- nomic, and zero carbon emission generation of electricity from low grade geothermal sources using the Organic Rankine Cycle (ORC).

Industries:
Overview:
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  • The STARDOM FCJ controllers achieved an accurate water loss management system while keeping the running costs to a minimum.
Overview:

The STARDOM™ network-based control system is composed of highly independent components that are based on the latest network technologies.

Overview:
  • Easy set point definition for all plant power generation operations
  • Stable electric power generation
  • Power plant optimization
  • Control of electric power generation based on net performance
Industries:
Overview:
  • Reduced cabling costs by using a commodity GPRS network infrastructure
  • Additional reduction in system cost by making full use of existing components
  • Reduction in cost of software by using all web-based technology
  • Long-term service contract — no need to worry about a suspension of maintenance services
Industries:
Overview:
  • STARDOM and FAST/TOOLS integrated SCADA solution for Indian Oil Corporation's multiproduct oil pipeline.
  • STARDOM facilitates the total visualization of data needed for safe and reliable pipeline operations.
Overview:
  • Reduced risk through distributed installation
  • In-house engineering to ensure ability to perform maintenance and modification
  • Time-efficient replacement using the five IEC61131-3 languages
  • Ease of connecting with display panels and MES
Industries:
Overview:
  • Uninterrupted Medical Oxygen Production with FAST/TOOLS Monitoring.
  • Audits are performed periodically, requiring traceability and the keeping of historical records for all batch production activities.
Industries:
Overview:
  • Reliable monitoring and control system of the world's first, 16" seawater reverse osmosis (SWRO) membrane desalination plant.
  • Accurate measurements of the SWRO parameters with Yokogawa conductivity meters, pH meters, and magnetic flow meters contribute to a longer SWRO membrane life and reduce Total Cost of Ownership.
Overview:
  • Yokogawa provides STARDOM and FAST/TOOLS for biomass pilot plant.
  • FAST/TOOLS is an "all in one" SCADA solution that functionsa a data historian.
Industries:
Overview:
  • Scalable, flexible configuration with functions distributed to multiple controllers on a facility basis
  • Redundant architecture optimally designed for requirements of entire plant
  • General-purpose communications network used for control bus
  • Integrated operation environment through web-based human-machine interface (HMI)
Overview:

The Nanjing Municipal Environment Monitoring Center (NMEMC) was looking for a better system that could be adopted for use in online pollution monitoring. For the following reasons, Yokogawa STARDOM autonomous controllers with embedded Web servers were selected for this air emissions and waste water surveillance data collection and transmission system:

Industries:
Overview:
  • The aging DCS system was replaced with an integrated control system for all processes at the Siheung water treatment plant.
  • Powerful Modbus communication function of STARDOM enables integration with the existing HMI via the OPC gateway.
Overview:

Taiyo Nippon Sanso Corp. was looking for a system that could be easily adopted to its plant architecture. For the following reasons, Yokogawa's STARDOM system with the FCN autonomous controller and the VDS Web-based SCADA software was selected as their control system for a Water-18O plant and other facilities.

Overview:

The municipal water system of Oviedo, Florida provides high quality water to more than 30,000 area residents from its West Mitchell Hammock and A.M. Jones water treatment facilities. The West Mitchell Hammock facility is designed to provide an average daily flow of 10 million gallons per day (MGD), with an ultimate design flow of 16 MGD. 

Overview:

Many different types of gases are consumed in industries as varied as chemicals, food & beverages, and medical. These gases are normally delivered in liquid form by trucks and dispensed at the customer site. Although the flow volume of cryogenic liquefied gas is used for billing purposes, it is not easy to accurately measure this because the gas is always at saturation temperatures.

Overview:

STARDOM FCJ/FCN can be used as an electronic flow measurement system described in API MPMS Chapter 21.1. The flow computer calculations are performed in order to provide a high performance flow metering for Natural Gas. FCJ/FCN can perform both normal control and flow computer function at the same time.  Utilizing STARDOM and Yokogawa Multivariable Transmitter EJX (HART or Foundation Fieldbus field transmitter), the advanced flow measurement can be realized.

Overview:

An automatic custody transfer system for unmanned LNG gas stations that embeds PC oriented functions such as e-mail, FTP, and the Java runtime environment in a robust hybrid controller.

Overview:

STARDOM field control node (FCN) autonomous controllers allow both Modbus master and slave functions to run simultaneously.

Overview:

Yokogawa ensures a reliable heat and CO2 transfer system by using the standard GPRS protocol. The exclusive use of webbased technology enables the market gardeners to go online to order heat and CO2 and view information.

Industries:
Overview:

Yokogawa provides controller embedded flow calculation library based on AGA (American Gas Association) reports.

Overview:

To make the most of the advantages of GPRS, Yokogawa's STARDOM FCN/FCJ intelligent RTUs and FAST/TOOLS SCADA package have several functions that reduce the number of packets that must be sent. This dramatically lowers communication fees.

Overview:

Gas flow data calculated by an RTU can be sent back to a transmitter using the two-way communications capability of FOUNDATION fieldbus.

Overview:

The discharge of improperly treated industrial chemicals and fuel gas can have a major impact on the environment, posing a serious threat to public health. Concurrent with the global growth of manufacturing operations to keep pace with market trends, many countries are taking measures to deal with environmental problems.

Overview:

Recently, several ARC Advisory Group analysts and management team members had a chance to sit down with the new Yokogawa President and COO, Mr. Takashi Nishijima, and several other top Yokogawa executives to discuss the company's burgeoning presence in the worldwide upstream and midstream oil & gas industry.

Industries:
Overview:

For the liquefied natural gas (LNG) industry, which has witnessed healthy growth and large project investments over the last few years, Asia is right at the center of the action. Whenever any sector booms in the economy, as is the case with the liquefied natural gas (LNG) production-transport-gasification distribution network the world over, there is a concomitant growth in the demand for automation solutions.

Overview:

LNG Industry, Summer 2012

Martin te Lintelo, Yokogawa, The Netherlands, discusses the need for better automation, measurement and control instruments to cope with the rising popularity of LNG.

Yokogawa Technical Report
STARDOM Wireless I/O
(rd-te-n06002-004)
999 KB
Overview:

Recently, there is an increasing demand for operation and monitoring of all the various controllers distributed in the field on the same screens to improve plant operation efficiency. The purpose of the Unified Gateway Station (UGS) is to connect external controllers, such as the STARDOM's FCN/FCJ autonomous controllers and other vendors' controllers, to the CENTUM VP integrated production control system and to operate and monitor those external controllers on the Human Interface Station (HIS) screens, the operation and monitoring screens for the CENTUM VP.

Yokogawa Technical Report
Overview:

Due to the rising energy demand in emerging countries in recent years, the amount of oil and gas production has been increasing, thus investment in the development of new oil and gas fields and replacement of old facilities has been booming.

Overview:

Laser interferometers and linear scales are used for measurement of the moved distance or positioning on the stage of precision machining equipment such as manufacturing equipment for semiconductors. The laser interferometer, in particular, features high accuracy, non-contact measurement and easy installation.

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Instruction Manuals
General Specifications
Software
Technical Information

Product Overviews

    Overview:

    On April 18th 2018, YOKOGAWA has released the new unit extension module: “E2 bus interface module” for the STARDOM autonomous controller “FCN-500”. Excellent Scalability and Excellent Reliability, FCN-500 has evolved with “Excellence × 2”.

    Overview:

    Providing an introduction to the features of STARDOM autonomous controller ‘FCN’. “Faster, Stronger, Smarter”, the FCN-500 STARDOM controller strengthens your core competencies with field proven reliability.

    Overview:

    Yokogawa presents a demonstration of how the combination of Stardom FCN-RTU and FAST/TOOLS SCADA can be combined to provide a powerful control and data collection system where in the event of a network disconnection or computer outage - Stardom internally buffers data that would otherwise be lost and on reconnection or restoration of the SCADA Server FAST/TOOLS is able to back-fill missing data in its trend.

    Overview:

    New CPU module for the STARDOM autonomous controller 'FCN' is unveiled. “Faster, Stronger, Smarter” controller will strengthen your competencies.

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