Yokogawa released CENTUM CS 3000 R3 in 1998 as the first Windows-based production control system under our brand. For over 10 years of continuous developments and enhancements, CENTUM CS 3000 R3 is equipped with functions to make it a matured system. With over 7600 systems sold worldwide, it is a field-proven system with 99.99999% of availability.
CENTUM CS 3000 R3 features an open architecture, flexibility, and compatibility with existing systems. It can be seamlessly connected with the previous CENTUM systems, as well as it is easily upgraded into CENTUM VP system which was released in 2008.
Yokogawa guarantees the long-term support and supply of CENTUM CS 3000 R3 systems so that our customers will enjoy the optimized use of the asset.
CENTUM CS 3000 can be applied from a small to large scale production control systems. Since it was released in 1998, we kept adding and enhancing its functions continuously. CENTUM CS 3000 has established an absolute integrity with Yokogawa's ProSafe-RS safety instrumented systems released in February 2005, contributing to the plant safety.
HIS is a human machine interface for CENTUM CS 3000 R3 and it is available in enclosed display style, open display style, and desktop style.
Engineering station is a PC with engineering capabilities used for system configuration and system maintenance.
Field control station is the control unit for plant process control. Varying with the application capacities and application usages, there are several types of field control stations in the lineup.
Safety Control Station (SCS)
Safety control station is a controller of the ProSafe-RS TÜV SIL3 certified safety instrumented system and it can be configured on the same network with CENTUM CS 3000 enabling HIS to monitor status of ProSafe-RS.
Varieties of Fieldnetwork I/O (FIO) are available in compact sizes to convert process signals for FCS formats. The FIO first appeared in the market in 2001 and kept enhancing its functions and adding its varieties ever since. The same technology is inherited to CENTUM VP, the latest Yokogawa DCS. Remote I/O are for remote input and output that passes the field signals to FCS control unit via remote buses.
Bus converters are required if a system contains multiple domains or contains the legacy CENTUM project.
SIOS serves as a gateway for connecting CENTUM CS 3000 R3 system and the OPC server to the third-party PCS. It exchanges data, and acquires alarms and events through the OPC server.
A real-time control network for linking the stations such as FCS, HIS, and BCV. Click Vnet/IP for more information.
CENTUM CS 3000 R3 supports field digital protocols such as FOUNDATION™ fieldbus, HART, PROFIBUS, DeviceNet, Modbus, Modbus/TCP, EtherNet/IP and ISA100 wireless
Yokogawa controllers are designed for controlling and monitoring industrial plants which must keep running non-stop in stabilized status with high reliabilities.
A cabinet type and a rack-mount type of FCS are available from Yokogawa. Both Vnet/IP and V net control networks can be used for configuring the system networks. The dual-redundant design of the FCS processor modules, power supply, I/O modules, and I/O networks achieve high availability of 99.99999%. The pair & spare architecture is unique to Yokogawa that improves the stability of process control.
Process I/O Modules
Fieldnetwork I/O (FIO)
Yokogawa offers compact, cost-effective, and reliable I/O devices, targeted as the industrial standard.
In order to operate and monitor the subsystems of the auxiliary devices controlled by programmable logic controller (PLC), various types of analyzers and other instruments for the integrated plant automation, FCS subsystem communication capability enables connection with the subsystems, and also supports dual-redundant configuration.
The subsystems include Mitsubishi MELSEC, Allen Bradley PLC-5 and SLC500, Modbus compatible devices, Siemens SIMATIC, Omron SYSMAC, Yokogawa FA-M3, Darwin, and DAQSTATION and so on.
Achilles Level 1+ Robustness against Cyber Attack
Yokogawa has received Achilles Level 1 + certification for various Vnet/IP controllers.
What is Achilles Certification?
Achilles Certification Program is to provide a benchmark for the deployment of secure industrial devices. It is designed to assess the network robustness of industrial devices and certify that they meet a comprehensive set of requirements and conformance.
Operators access production control system via CENTUM CS 3000's human interface station (HIS) to make fast and intelligent decisions that maximize performance and minimize risks.
Based on the ergonomic design concept, the HIS can be selectable from desk top, open display style console, and enclosed display style console types. Multiple monitors can be set, and each one of the monitor displays multiple operation windows.
The operation keyboard is unique to Yokogawa. It consists of alphanumeric keys and special operation keys which are assembled with the dustproof and drip-proof flat keys. By assigning graphics to each button, operators can call up a graphic by one touch.
The data displayed on HIS are collected in the manner of event driven, i.e., HIS starts to collect the data only when the corresponding window is called up. Thus only the dynamic data in the currently displayed windows need to be refreshed. The load of HIS for data sampling is reduced and the one-second refresh rate for the dynamic data on the windows is guaranteed.
The HIS supports the use of multiple monitors, meaning that more windows can be displayed at the same time and enabling process variations and even alarms to be handled more promptly. This ability to display increased amounts of data at the operator console improves operation efficiency. CENTUM CS 3000 R3 supports up to four monitors which can be stacked vertically or positioned side by side and a mouse can move over those four screens. A large-size monitor can also be used.
Inheriting the same operation window designs from the legacy CENTUM systems, operators may feel familiar to the CENTUM CS 3000 operation windows from the first day they start using the system.
The Multiple-window mode like an office PC and the Full-screen mode like the legacy operator console are available for operation and monitoring environment.
The process control industry standard open interface OPC (OLE for Process Control, or open productivity & connectivity) is provided for collecting the process data, trend data and messages.
To prevent operation errors and other problems and ensure the safety of the system, such as prohibiting operations by unauthorized persons, limiting the ranges of operation and monitoring, and restricting operator actions to the system, extensive security functions are applied.
The AFCO project is a showcase of the good coordination between Yokogawa Middle East, Yokogawa Thailand, Yokogawa Singapore, and Yokogawa Electric Corporation. Yokogawa Middle East and Yokogawa headquarters both were involved in the project execution.
The Bahia de Bizkaia Plant is one of the most significant power projects to be carried out in this region. The project has been led and financed by Ente Vasco de la Energia, Repsol-YPF, British Petroleum, and Iberdrole S.A., with the total investment coming to approximately 600 million euros.
Eraring Power Station, located just north of Sydney, is one of the largest power stations in Australia, comprising four 660MW coal-fired units. The power station has operated reliably since 1981. To ensure continued reliability for the next few decades, Eraring Energy, the owner of the power plant, decided to replace the original hard-wired control equipment with a modern integrated control and monitoring system (ICMS).
Samsung Petrochemical Co. Ltd. (SPCL), a major Korean petrochemical company, produces 700,000 tons per year of purified terephthalic acid (PTA) at its Daesan plant. PTA, a white powder substance that is produced by oxidizing and refining para-xylene, is a precursor to polyethylene terephthalate (PET), a polyester material that has excellent thermal resistance and wear resistance and is widely used as a substitute for natural cotton fibers and in film packaging, beverage bottles, tire cords, paints, adhesives, and other applications.
At the age of approximately 30 years the plant underwent $A 72 million technology upgrade in 2001, to improve operating reliability and performance. Macquarie Generation, Yokogawa Australia and Ralph M Lee concluded an alliance agreement to supply and install the replacement control system at Liddell.
Thai Acrylic Fibre Co., Ltd. (TAF) was established in 1987 and is currently a leading acrylic fiber manufacturer in the ASEAN region with 450 employees. It produces a wide range of acrylic fiber productions with varied deniers and the annual production recorded 77,000 megatons in 2004 which is five times the production rate at the time of establishment.
Saudi Aramco's operations span the globe and the energy industry. The world leader in crude oil production, Saudi Aramco also owns and operates an extensive network of refining and distribution facilities, and is responsible for gas processing and transportation installations that fuel Saudi Arabia's industrial sector. An array of international subsidiaries and joint ventures deliver crude oil and refined products to customers worldwide.
PetroChina Guangxi Petrochemical Company has completed construction of a combined refinery and petrochemical production complex in Qinzhou, a port city in China's Guangxi Autonomous Region. With a 10 million ton per year capacity, the refinery is one of China's largest, and is truly world class, using a highly advanced hydrogenation process, with the main process technologies coming from the USA and France.
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.
The CENTUM CS 3000 / UOI was selected for this project. The control platform in the UOI is the GE Fanuc CIMPLICITY Human Machine Interface (HMI) system, which fully integrates the controls for the turbine and BOP auxiliaries and uses the same screens/formats at both the turbine and BOP HMI displays. The CIMPLICITY HMI used in the UOI is a SCADA based design that fully supports the customer's requirement for remote operation capability.
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.
The 2008 Frost & Sullivan Asia Pacific Company of the Year Award for Distributed Control System (DCS) market is presented to Yokogawa. Yokogawa is the market leader with a dominant market share in the Asia Pacific market.
The new CSPC (CNOOC and Shell Petrochemicals Company Limited) petrochemical complex at Daya Bay in southern China is one of the world's largest process industry projects (see box, Figure 1 and Table). It has a control system to match. Process Worldwide spoke to Johan Veerman, principal instrument and process control engineer at CSPC, about the challenges of managing such a huge job.
Predictive maintenance allows to schedule plant maintenance before a failure occurs only when it is necessary, greatly reducing unnecessary inspection and improving productivity. Yokogawa's Asset Excellence initiative helps its customers make their plant asset condition predictable and performance sustainable.
Recently, Reichhold, Inc. implemented an automated batch process system at its Azusa plant in California. The Azusa facility manufactures a broad range of unsaturated polyester resins. These thermosetting resins are used in a wide variety composite applications in the construction, marine, automotive and specialty segments including California surfboards.
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.
As a world's leading supplier of instruments and control systems for industrial process automation, Yokogawa has committed itself to the development of advanced solutions and products in three focused areas – measurement technologies, industrial automation and control, and information technologies.
Martin te Lintelo, Yokogawa Europe B.V., The Netherlands, discusses high level control system design for LNG receiving terminals. As demand for LNG increases worldwide, players face seemingly conflicting challenges. On one hand, they must expand capacity in different regions, make the business and production as agile and adaptive as possible, and improve operational efficiency.
A Yokogawa ProSafe-RS safety instrumentedsystem (SIS) will be the nucleus of a newfire and gas safety system at Shell's Clyde (NSW) refinery. The contract includes thecontrol system, system engineering andinstallation and supervision.
Environmental friendliness (E) must be assessed in today's product design in addition to the conventional design considerations of quality (Q), cost (C), and lead time (D). Hence, the product design system must be urgently restructured in order to minimize the environmental impact of a product throughout its life-cycle from purchase of the materials and parts, through manufacturing and distribution, to use and disposal.
There is growing recognition of the importance of preventing serious accidents in the process control field in view of the potential scale of impact on society. The IEC 61508 and IEC 61511 international standards call for the reduction of risk using safety instrumented systems (SIS) as well as the configuration of multiple protective layers in a process control system in order to prevent major accidents.
As plant operation becomes more intelligent and complex, the alarm system for safe and stable operation is becoming increasingly important. An alarm warns operators of an abnormal situation in a process and urges them to respond to it.
Recently, manufacturing industries are trying to slash the total cost of ownership (TCO). Batch processes are not exceptions. Until recently, in comparison to continuous processes, batch processes have generally not yet undergone systematization and standardization.
The manuals of control systems such as a DCS provide a vast amount of information depending on their multi-functionality and functional integration. A conventional large-scale control system our company offers comes with more than 10,000 pages of paper documents.
As industrial plant systems have increased in scale and their automatic control algorithms advanced, today's operators are required to have more advanced skills and knowledge of theplant systems and to learn the actions to be taken in response to any possible situations including emergencies.
One of Yokogawa's corporate philosophies is to contribute to society through broad-ranging activities in the areas of measurement, control, and information. To achieve this philosophy in the control industry, Yokogawa launched CENTUM, the world's first distributed control system (DCS), in 1975.
As the world's societies become more connected, market competition is becoming more ruthless and transactions are performed at ever increasing speeds. Deregulation has ignited global competition throughout the world. The proliferation of Information and Internet technologies have accelerated the growth of global competition, with life cycles for high tech products having lives measured in "dog years" (in each normal year they advance seven years).
The trend of open system architecture is becoming an important issue with distributed control systems (hereinafter abbreviated as DCSs). To meet this demand, the operation and monitoring functions, and the system generation functions of the CENTUM CS 3000 system are designed to support Windows NT and OLE for Process Control (OPC).
As a company that has strong relationship with nature and provides products using nature's blessings, Mercian Corporation is committed to the environment. Its environmental philosophy is "Mercian thanks nature's blessings and capability that sustain life, and seeks to balance environmental preservation with creating an affluent society."
Yokogawa Electric has been using Pair & Spare method as a reliability-enhancing technology for its line of distributed control systems (DCS) since the release of the CENTUM CS in 1993. As a result, the system has achieved an availability factor of seven 9's (99.99999%) for the record of operation to date.
As for a controller used in a distributed control system (DCS) shown in Figure 1, covering as many applications as possible with a single controller will bring cost reduction effects such as easy engineering and a small controller installation area. Therefore, the controller is required to process large amounts of data more quickly.
The power generation facility in a pulp and paper plant is comprised of units, each of which is composed of a boiler, a turbine, a generator, and auxiliary equipment, and these pieces of equipment were traditionally controlled on a unit/equipment basis. This paper presents an application of CENTUM, Yokogawa's distributed control system (DCS) that integrates the independent control systems of such power generation facilities to achieve labor saving through operations via CRT display and keyboard.
As more fieldbus devices are made practicable, demand is increasing for a distributed control system (DCS) which integrates fieldbus devices in its engineering, operation, and monitoring environments. Conventionally, control has been implemented by the dual-redundant CPUs and control bus within a DCS; however, sufficient reliability must be ensured even when it is distributed over field networks.
In recent years it has become increasingly common for plants to be provided not only with the control layer of a production control system (DCS, etc.), but also with the protection layer of a safety instrumented system (SIS) to reduce the risk of industrial accidents. The safety instrumented system is indispensable for avoiding risks to a plant failure.
The recent increase of devices enabled for a field network such as the FOUNDATION™ Fieldbus is phenomenal. This has been amplifying a requirement for distributed control systems (DCSs) to be capable of constituting a more pliant and efficient production control system by means of flexible connections to field networks in addition to traditional 4 to 20 mA signals.
The requirements for water supply and sewage services are becoming increasingly strict, such as consolidation of facilities, operational efficiency, lower cost, and information transparency due to stagnant demand. There is also demand for greater use of information technologies (IT), encouraged by the government's e-Japan strategy.
The environment surrounding process control systems has changed dramatically as the performance of personal computers improves and the Windows operating system advances, there has been a move towards the trend of open architecture. As we are already aware, in addition to the traditional high reliability level and the unique operability there has been an increase in demand for the interoperability of human- machine interfaces (HMI), which are responsible for the operation and monitoring of our distributed control system (DCS).
Yokogawa's business involvement in the pulp and paper industry started to grow in the 1970s after the in-house development and to establish the sales force for stand-alone Basis Weight Sensor with an analog recorder for a fixed point measurement. This involvement has expanded exponentially in the Asian region, particularly in the Japanese market over the past 35 years.
In process control it is not uncommon for systems to be affected by dead times, due to material transfer times. This is evident typically in pipelines. A fluid of density ρ and flow rate w in a section of pipe A the length of d takes the amount of time τ = ρAd/w to cover the whole distance (see Figure 1).
Industrial automation (IA) systems and products, which utilize measurement, control and information technologies, are used across the world as fundamental infrastructure for achieving safe, stable and highly efficient plant operation. In order to keep the systems and products effective throughout the plant lifecycle, customers need to periodically check their effectiveness and take prompt action if any problem is identified.
Global market pressures are causing businesses world wide to strive to lower manufacturing costs and to become more agile companies in order to quickly respond to changes in market demands and to fend off competitive threats. Yokogawa's customers in all industries and markets are responding to this pressure by working to more closely integrate their plant manufacturing systems with their enterprise wide business systems in a seamless manner.
In Japanese industries which grew rapidly until the early 1990's, solid production techniques for creating high-quality products supported the development of manufacturing industries. However, the economic environment has been changing rapidly and tough global competition has become unavoidable. Particularly, the manufacturing industry must adapt not only to changes in economic environments but also to changes in social conditions such as emphasis on health, safety, and environment (so called HSE).
For a coal fired power generation plant (hereafter referred to as "BTG facilities," in which "BTG" stands for boiler, steam turbine, and generator) supplying power to a large-scale production plant, the CO2 emissions from such facilities are a critical issue today.
Drastic changes in the economy of manufacturing industries, has led to increasing demand for plant operations to reduce personnel, improve efficiency, and increase the operation rate of facilities. On the other hand, for plants to operate safely, improvements in reliability and operational safety cannot be neglected.
The CENTUM CS 3000, a reliable distributed production control system, has been introduced worldwide with the objective of operating plants efficiently 24 hours a day, every day. The CS 3000 handles abnormal conditions in a plant appropriately and minimizes the chance of them developing into faults.
In this day and age, just simply buying a personal computer, taking it home and turning it on will enable you to be taken to the world of Internet. In such an era, communication connection capability and prospects is increasing in importance. DCSs are no exception for concern.
Due to emerging competitors from the rapidly growing countries such as India and China and the global economic downturn triggered by the Lehman shock, many companies in the process industries are struggling to survive the severe global competition.
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