CENTUM VP

CENTUM VP has a simple & common architecture consisting of human machine interfaces, field control stations, and a control network.  It supports not only continuous and batch process control but also manufacturing operations management.

CENTUM VP Overview

Yokogawa released its CENTUM distributed control system (DCS) in 1975, a world first. CENTUM VP is the ninth generation in the CENTUM series. Known for their rugged performance, CENTUM systems set high standards for engineering and technology excellence while ensuring backwards compatibility with previous system versions and support of the latest technology applications. Knowledge-driven engineering lies at the heart of CENTUM, a Yokogawa flagship product that has been proudly serving the process industry, over the past 40+ years.


Yokogawa Releases CENTUM® VP R6.05 Integrated Production Control System
– With a new processor module and an enhanced engineering function –

This release also features an improved engineering function that speeds up project execution by achieving savings in configuration and installation time. These enhancements cover the entire control system lifecycle, from installation and start-up to end of service.

Enhancement

  1. CP471 processor module with Yokogawa-developed system LSI
    For the CENTUM VP field control unit (FCU), Yokogawa has developed the CP471 processor module. The new CP471 processor module has a new system LSI of Yokogawa’s own design. Application of a Yokogawa product eliminates the possibility of disruptions due to the modification or discontinuation of a commercially available product. This shall ensure the long-term availability of this key component.

  2. Reduced test time for the AD Suite integrated engineering environment
    Yokogawa developed the Automation Design Suite (AD Suite) engineering environment by leveraging its wealth of project engineering knowhow, and released it as part of CENTUM VP R6.01. AD Suite is a powerful yet flexible engineering environment that helps engineers produce quality work and improves efficiency over the entire project lifecycle.

Field Control Station (FCS)

FCS

For over 40 years, Yokogawa has been developing and delivering stable, high quality CENTUM systems. All the CENTUM series field control stations (FCSs), both software and hardware, have been developed by Yokogawa. CENTUM VP can be flexibly designed ranging from small- to large-scale.

The CENTUM VP controller is capable of handling a massive amount of field data at comfortable speeds that fully satisfies the needs in the field digital era.

Both the controllers and I/O node units can be placed in remote, classified locations (IEC Zone 2/Class I Div. 2) which saves installation cost.

We know single bit of software and hardware to maintain a 99.99999% availability service record.

Reliable Controller

Reliable Controller

The CENTUM VP controller features outstanding processing performance and a large application storage capacity, yet inherits the same quality and stability that are the hallmark of the CENTUM series. Processor modules, power supplies, I/O modules, and communication buses all support redundant configuration.

The latest release of the controller has been optimized to take full advantage of advancements in field digital technology that will help plants operate with increased efficiency and stability. A high speed remote I/O unit enables connecting controllers over remote site up to 50 kilometers via optical fiber cables.

Digital Field Network Support

CENTUM VP supports a wide variety of communication interfaces and digital field networks such as FOUNDATION™ fieldbus, PROFIBUS-DP, Modbus RTU, Modbus CP/IP, and DeviceNet. Device diagnosis communication and SOE functions are enhanced. Changes in the mechanism to access device data have contributed to reduce loading to the main processors and improves the performance of the plant asset management software, Plant Resource Manager (PRM).

Pair and Spare Architecture

This is a unique feature of the CENTUM series that improves the stability of process control. Each processor module has redundant CPUs that execute the same computations simultaneously. Their outputs are constantly compared and a bump-less switchover to the stand-by processor module is initiated if any anomalies caused by electronic noise or other phenomena are detected. This minimizes the likelihood that errors will have any impact on process control. Our pair & spare technology is the key to achieve the 99.99999% of availability.

N-IO (Network I/O)

N-IO (Network I/O)N-IO (Network I/O), the next-generation software configurable smart I/O, reduces footprint, lowers marshalling costs and allows flexible I/O binding. Matched with the FieldMate Validator, our commissioning tool, this allows for significantly faster project completion and reduced costs without compromising on quality.

Universal I/O and Software Marshalling

N-IO has AI/AO/DI/DO in each I/O channel. Each I/O channel can be changed to other I/O types by software programming.

Adapter (Built-in Signal Conditioner)

N-IO implements a wide variety of built-in signal conditioners on its baseplate. In most cases, there is no need to prepare external signal conditioning or the additional space this requires.

Redundancy

The same N-IO baseplate supports both single and dual redundant formations, eliminating the need for multiple hardware/software vendors when implementing redundancy.

Intrinsically Safe Barriers

The N-IO baseplate supports Intrinsically Safe I/O barriers.

FIO (Field network I/O)FIO (Field network I/O)

FIO (Field network I/O) is a series of low-cost I/O modules which have been developed to improve packaging density. The large available range of modules enables you to configure your system to match the requirements for process signals, and to provide for different levels of isolation.

Isolation types

Non-isolation, isolation (all channels are collectively isolated), and isolation (each channel is individually isolated)

Field connection

Pressure clamp (Weidmuller), dedicated terminal boards, and MIL cables

Environmental resistance

Class G3 corrosive gas and a wide range of operating temperatures

Hazardous area classification

Type N and non-incendive protection provided as standard. I/O modules with a built-in intrinsic safety barrier available.

Integrated Operations

CENTUM VP achieves the Operational Excellence that is the focus of Yokogawa's Production Excellence, Safety Excellence and Asset Excellence initiatives. It offers integrated viewing and data handling functions.

For example, alarms from the ProSafe-RS Safety Instrumented System and Plant Resource Manager, Yokogawa's Asset Management product, can be seen and handled seamlessly in the Human Interface Station (HIS). All plant process data and device data are handled by CENTUM VP.

Easy to operate with clear visibility

Yokogawa offers an intuitive and easy-to-understand HMI environment for plant operation and monitoring, which is the result of vast experience with CENTUM systems in operation. Flexibility in displaying operation windows and monitors helps in adapting to various aspects of operation needs.

CENTUM VP provides easy-to understand graphics based on the ergonomics and knowledge engineering. For instance, data displays are provided with high visibility that enables intuitive awareness of the situation. The use of colors considers the best contrast and environments of the central control room and the configuration of the displays integrates the knowhow of experienced operators. With all these functions, CENTUM VP enables operators to make quick and accurate decisions during operations and contributes to improve operation efficiency.

Integrated Operations
System message banner

Continuously displays the latest alarm messages, keeping operators up to date on process conditions.

Browser bar

Contains navigation tools for the convenience of operators, frequently-used icons can be grouped in a My Favorites folder.

Window history

Lists the previous operational displays. Operators can quickly call up previously-used graphics windows.

AOG SolutionIntegrated Operations

The AOG (Advanced Operator Graphics) solution emphasizes ergonomic design and seeks, through improved color selection, layout, and visual function, to improve operators situational awareness. A team of Yokogawa engineers visited many plants to conduct a detailed analysis, review the tasks carried out by operators, and learn about the plant's operations. In accordance with general principles on industrial design and human engineering, Yokogawa then redesigned the GUIs for the HMI displays to reduce operator errors, make their work easier to perform, and reduce physical stress.

 

By using the Trend Recording

trend data displayBy using the Trend Recording function, process data such as temperature, pressure and flow rate coming into the Control Station are gathered by the HIS, and the time-series changes in the process data are displayed in a graph (trend graph).

The HIS trend recording function acquires a variety of trend data types, suitable for a continuous process plant and a batch process plant. The continuous-type data acquisition is suitable for recording and monitoring data for a long period of time. The batch-type data acquisition starts and stops acquiring data according to the commands received from operators. Comparison between the actual data and a reference pattern is also available for the batch-type.

Operation Keyboard

Operation Keyboard A unique USB keyboard is available for CENTUM VP option. The 64 function keys and the numeric keypad can be used by operators to call up graphics by pressing a single key.

Switching between frame tabs can be done by pressing the container window key. The keyboard has two built-in speakers and the key pitch complies with IEC 9241-11.

A touch sensor highlights the selected operating instrument on the screen to prevent unintentional input errors.

A single-loop operation keyboard and an 8-loop simultaneous operation are available.

Engineering

 Yokogawa paves way for a new engineering paradigm for the next-generation. It is not uncommon for a project to experience backsliding and significant rework, all of which affects the TCO (Total Cost of Ownership). Yokogawa's engineering prevents these inefficiencies and ensures our customers reap all these benefits throughout a plant’s lifecycle.

Yokogawa provides smart engineering thanks to three innovative products.

  • Automation Design Suite, Yokogawa's engineering environment
  • N-IO (The Network I/O), Yokogawa's software configurable smart I/O
  • FieldMate Validator, Yokogawa's commissioning tool for N-IO

 

Flexible I/O Binding with N-IO and FieldMate Validator

After the DCS is sent to a site, design changes often happen due to physical restrictions of implementation or inadvertent miscalculations and these changes can significantly affect the project schedule. And shortening the term of a project is an ever-present challenge. Flexible I/O binding, Yokogawa’s improved late I/O binding solution, helps overcome these customer challenges.

Reducing the Risks to Scheduled Project Delivery

The flexible I/O binding facilitates simple and hassle-free I/O binding. This is made possible by software marshaling and the N-IO’s universal channels. The type of I/O and the interconnection between the I/O module and the controller can be modified remotely which significantly absorbs the impact of last-minute I/O changes. Furthermore, the flexible I/O binding achieves early delivery of I/O cabinets to the site, and problems can be found and fixed on-site at a very early stage.

Early Start-up

The flexible I/O binding shortens duration of a project. After I/O design is fixed, application engineering and hardware engineering can progress independently and parallel. This is made possible by System Independent Loop Commissioning. System Independent Loop Commissioning project capability utilizes Yokogawa's FieldMate Validator, an innovative tool allowing the field testing and validation of N-IO without requiring a deployed system.

The Automation Design Suite, Yokogawa's new engineering environment, retains the entire engineering history of your plant from design phase, through commissioning and live operation; which ensures up-to-date plant knowledge with every expansion, or hardware and software change throughout your lifecycle.


Module Based Engineering

The Automation Design Suite adopts a Modular approach to automation design and execution, where process loops, alarm design philosophy, graphics and more are deployed as design patterns: downloaded, shared and re-used as standards across the enterprise, saving time and resources.

Yokogawa leverages its long history and vast expertise in process automation, with standardized, industry proven engineering modules available that span a broad range of processes and functions for production, safety and asset excellence.

 Management of Change and Resources

The Automation Design Suite is more than the ‘As built’ specification of your plant… It provides dynamic management of design, investment and project effectiveness by auditing and versioning engineering changes, and facilitating effective engineering through ModPacks (Modification Packages).

This serves to maintain project schedules by reducing the delays and the engineering impact of late design changes or scope changes. The Automation Design Suite also auto-documents and checks inconsistencies in project activity and software resources, removing the pain from project management, and significantly reducing project risk.

Methodology

Agile Project Execution (APEX)

Field Digital

Yokogawa realized the potential of field networks in a production control system early on and designed its systems with field networks in mind. CENTUM VP supports FOUNDATION™ fieldbus, HART, PROFIBUS-DP, DeviceNet, Modbus, Modbus/TCP, Ethernet/IP and ISA100.11a wireless. The CENTUM VP integratedly controls and monitors these field devices from various vendors with various communication protocols.

Yokogawa's Fieldbus Related Products

Applying Fieldbus in Plant Control System

The engineering for fieldbus function blocks can be performed in the same way as for other function blocks in FCS. The operation and monitoring environment is also the same for the fieldbus function blocks and other FCS function blocks. No additional requirements for engineering, operation and monitoring of the fieldbus applications in Yokogawa DCS. The most favorable merit for applying fieldbus is highly efficient maintenance of field devices. Yokogawa offers an asset management software package, Plant Resource Manager (PRM), for device management and diagnosis. With PRM, the advantage of fieldbus can be optimized so as to make the maintenance of the whole system more efficient.

Plant Resource Manager (PRM)

The maintenance information of devices are collected by PRM via fieldbuses and stored in the PRM database. The corresponding maintenance schedules, maintenance procedures and spare parts information are also stored accordingly in the same database. The maintenance of the field devices can be performed through fieldbus. Thus the maintenance engineers are considerably relieved from going to the fields of the devices in the remote areas and hazardous areas.

Audit Trail

Audit trail management is important in both control and maintenance systems. All maintenance works on devices, which are maintained by PRM, are recorded and stored, and can be easily retrieved too.

Predictive Maintenance

By integrated management of device management information, the replacement cycle of devices and trend of device troubles can be predicted. This technique minimizes the impact of device problems on plant operation, and maintenance work and parts procurement can also be planned and scheduled.

Solutions to Non-Fieldbus Devices

PRM can create a database for legacy devices in addition to Fieldbus devices. Maintenance information is recorded and managed in a database for integrated, overall planned maintenance of all devices in the plant.

DD and CF Download

The FOUNDATION™ fieldbus device files in this section are categorized according to whether the devices have undergone Host Interoperability Support Testing (HIST). HIST is an invaluable tool in determining whether a specific fieldbus device is interoperable with a host system.

About HIST at Yokogawa

  • FOUNDATION™ fieldbus laboratory is established in Yokogawa Singapore.
  • Yokogawa is running the HIST program according to the FOUNDATION™ fieldbus specifications.
  • Yokogawa is continuing development of HIST in cooperation with other device manufacturers.
  • The list of field devices that have passed the HIST can be checked on the Interoperability page.

Interoperability Menu

List of HIST Completed Devices (Link to Yokogawa Global Website)
List of FIST Completed Devices (Link to Yokogawa Global Website)

Recommended FOUNDATION™ fieldbus Accessories (Link to Yokogawa Global Website)

 

Unified Gateway Station (UGS)

The unified gateway station (UGS) acts as an interface, allowing CENTUM VP to communicate with STARDOM network-based control systems or other third-party subsystems such as Modbus RTUs, Modbus/TCP units, EtherNet/IP units, OPC DA units, and intelligent electronic devices (IEDs). It utilizes the EC 61850 protocol, which has been widely adopted by the power industry.

Unified Gateway Station (UGS) (0.4 MB)  PDF
IEC 61850 IED Communication Package (for UGS) (0.4 MB) PDF

System Architecture

Robustness Against Cyber Attack

CENTUM VP field control unit has obtained the ISASecure® Embedded Device Security Assurance (EDSA) certification from the ISA Security Compliance Institute (ISCI). The certification was obtained through a process that involved an examination by the CSSC (Control System Security Center) Certification Laboratory. It ensures that CENTUM is equipped with the cyber security features to be used in the industries such as oil, petrochemical, power and many others.

Wurldtech Security Technologies, Inc. has duly tested and certified Yokogawa’s AFV10D controller, AFV30D controller, AVR10D V net router, and AW810D WAC router with Achilles Level I test, which ensures the end-point security of the controllers.

Security Lifecycle Approach and Service

Yokogawa built its security lifecycle approach upon industry cyber-security standards. And Yokogawa provides an effective security service in response to the customer's requests and operational conditions.

Yokogawa's Global Network

Yokogawa's global network of 25 manufacturing facilities and 88 companies spans 55 countries. Since its founding in 1915, the US$4 billion company has been engaged in cutting-edge research and innovation, securing more than 7,200 patents and registrations.

Yokogawa’s global network of engineering resources is ready to respond whenever and wherever to our customers’ requirements. We take pride in our VigilantPlant mission of realizing the ideal plant for our customers.

Our customers can depend on our service offices and maintenance engineers for support whenever it is needed, at all phases of the plant lifecycle. In line with our VigilantPlant vision for the ideal plant, Yokogawa provides a comprehensive suite of services that ensure safe, reliable, environmentally friendly, and profitable plant operations.

System Software Updates

Periodically, system software must be brought up to date by adding new functions, enhancing existing functions, and fixing bugs. For a variety of reasons, many of our customers would prefer to wait for a scheduled plant shutdown to update their system software to the latest version. Even if a customer has not yet installed an earlier version of the software, Yokogawa guarantees that the system will keep working normally and without interruption when the latest software version is installed. Yokogawa also guarantees that the software will be fully compatible.

System Modification & Expansion

Our customers often need to modify or expand a control system after it is installed, and major concerns with this include avoiding disruptions to plant operations, minimizing the shutdown period, and minimizing the risks of a hot system cutover.

Yokogawa offers a virtual environment for FCS and HIS where both the control and operator functions of the CENTUM database can be tested without FCS hardware. It ensures the new programs will work when they are installed, reduces risks of system failures, and minimizes the shutdown period.

Upgrading (moving from one Yokogawa system to another Yokogawa system)

For each of its CENTUM systems, Yokogawa has paid particular attention to helping its customers manage lifecycle costs by optimizing the upgrade process. Upgrading is simple and quick.

All of Yokogawa's legacy CENTUM systems can be controlled and monitored from a newer CENTUM system. Via a control network, CENTUM VP can control and monitor operations at a plant that relies on a CENTUM V, CENTUM-XL, CENTUM CS, or CENTUM CS 3000 system. The latest CENTUM VP can also communicate with both the N-IO and the more traditional FIO and Yokogawa will continue to sell and provide long-term support to both types of I/O. Thus, by allowing its customers to utilize their existing assets wherever possible, Yokogawa offers them a cost-effective way to upgrade their production control systems.

 

CENTUM 40 year history

CENTUM 40 year history

Migration (moving from a non-Yokogawa system to a Yokogawa system)

CENTUM has been Yokogawa’s DCS brand since 1975, when the first generation CENTUM system was released to the market. Many of our competitors in the DCS market have either been acquired by other companies or have disappeared from the market together with their control systems. Only a handful of the companies that were first active in this market are still around today.

Not satisfied with another vendor’s control systems? Consider migrating to it to CENTUM VP. We have successfully migrated over 350 non-Yokogawa systems so far and the number is steadily growing. To name a few: Bailey INFI90, Foxboro I/A, Emerson RS3/PROVOX/DeltaV, Eurotherm, Hartman & Brown ContronicP, Hitachi, Honeywell TDC2000/TDC3000/PKS, Siemens SIMATIC, Taylor MODCELL, Toshiba, Allen-Bradley PLC.

Overview:
  • Yokogawa supplied an integrated boiler and turbine control, monitoring and protection system for each of the four generating units in a coal-fired power plant in Australia.
  • Yokogawa also delivered two high fidelity operator training simulators for this plant.
Industries:
Overview:
  • Hibiki LNG Terminal is supplying natural gas to a broad area of northern Kyushu.
  • CENTUM VP and FA-M3V provide a centralized monitoring environment and contribute to safe and stable operation.
Industries:
Overview:
  • Integrated CENTUM VP and ProSafe-RS Systems Ensure Nonstop Operation of ADU/DKU Processes.
  • "This is a real VigilantPlant! We will continue to improve our production efficiency."
Overview:

Okinawa Prefecture is promoting clean energy with the aim of becoming a low-carbon society in the 21st century. Ocean thermal energy conversion (OTEC) technology is particularly well suited for this purpose, and is expected to both reduce the environmental impact that power generation has in the prefecture and lessen the prefecture's dependence on imported fossil fuels.

Overview:
  • CENTUM VP Batch replaces the legacy system and improves production efficiency in the acrylic plant.
  • CENTUM VP Batch capability can handle the recipe management to Batch report handling and unit management.
Industries:
Overview:
  • Highlyadvanced biopharmaceutical plant uses CENTUM, VP Batch, Exaquantum and PRM.
  • Total system integration for large-scale biotech production facility.
Industries:
Overview:
  • As the main automation contractor (MAC) for this plant construction project, Yokogawa Brazil engineered, installed, and commissioned an integrated control and instrumentation solution
  • Yokogawa Brazil completed the commissioning of these systems ahead of schedule and the production of green polymer was started just one week later
Industries:
Overview:
  • Operational Excellence by Asset Maximization, Utilizing Yokogawa's DCS, SIS, Analyzers, and Field Instruments.
  • The CENTUM VP PCS and ProSafe-RS SIS were integrated using the same engineering environment.
  • Nearly 60 gas chromatographs and a large number of other types of analyzers in several analyzer houses.
Industries:
Overview:
  • World's largest LNG terminal relies on CENTUM to maximize safety and reliability.
  • It is very important for KOGAS to be able to adjust flexibly to shifts in demand in the gas that it supplies to power plants, industrial companies, and residences.
Overview:
  • OTS for familialization of liquefaction processes and operator training.
  • Yokogawa's integrated solutions contribute to safe and steady production at gas liquefaction plant in Norway.
Overview:

First generation CENTUM had contributed to the production of high-quality steel product at the NSSMC's Yawata Works for 33 years.
Yokogawa had pursued innovation of process control technology with the customer during the decades.

Industries:
Overview:
  • Complex starting up and shutting down operations of a biomass power plant were automated with CENTUM VP.
  • Operator errors and interventions were eliminated in all critical processes.
     
Overview:

Rousselot Ghent won Belgium Factory of the Future Award. Yokogawa has supported Rousselot with automation systems since 1993.

Data of 20,000 tags gathered by Exaquantum helped to find the ideal production parameters.

Industries:
Overview:

Network and system security is now a necessity in process automation industry. YOKOGAWA provides a service lifecycle solution for cyber security to ensure that the security measures and deployments are continuously enhanced, monitored and inspected.

This white paper explains the details of the security design, implementation, operation and validation solutions from the technical perspective.

Overview:

Process automation in oil refineries is undergoing major changes, driven by customers frustrated by what they consider to be slow and incremental advances from the main automation original equipment manufacturers (OEMs) in the industry. ExxonMobil has become a de facto industry representative and is driving vendors like Yokogawa and others to reevaluate how large-scale automation projects are implemented.

Product Overviews

    Product Overview
    Overview:

    Todays modern industrial control systems have a significant impact on your plants operational efficiency and bottom line. Are your process control engineers operating in a secure environment? In an increasingly mobile workforce getting critical information top the right people is now possible with Yokogawa VPSRemote.

     

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