CENTUM VP has a simple and 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.
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.
This release delivers enhancements that drastically reduce the amount of work needed to upgrade a control system’s CPU module, including a newly developed utility kit and standards certification for individual CPU modules. It also enhances a function that is able to upgrade a CENTUM VP system without interrupting the process control. Providing a smooth upgrade process will help customers achieve long-term stability in their plant operations and enable the efficient utilization of resources.
Availability and efficiency are always primary concerns in plant operations. To stay competitive, companies with plants that have been in operation for 10 to 20 years or even longer frequently need to install new equipment that makes use of the latest technologies. Ever since it introduced the first version of CENTUM VP (R6.01) in 2014, Yokogawa has continued to make enhancements to this platform that will ensure its customers are able to enjoy long-term stability in their system operations. This latest version of CENTUM VP meets our customers’ needs for faster equipment upgrades and high availability.
Development of this new CENTUM VP version is also in keeping with Yokogawa’s three sustainability goals for the year 2050, one of which calls for the achievement of a circular (recycling-based) economy. Toward this end, we are working to help our customers make more efficient use of their resources.
1. CPU module upgrade without need to replace cabinet
When upgrading a CENTUM VP controller’s CPU module, it has also often been necessary to replace the cabinet that houses these components. Replacing and rewiring these cabinets, which are around two meters tall and weigh more than 200 kilograms, is a very time-consuming process.
Yokogawa has developed a utility kit that eliminates the need to replace the cabinet when upgrading the CPU module. This kit includes environmental sensors and cooling fans. By eliminating the need in many cases for the complete replacement of the cabinet, this reduces workload, prevents waste, and lowers the barriers to the introduction of new technology. In so doing, Yokogawa is helping its customers achieve long-term stability in their plant operations.
2. Enhanced online upgrade function for batch processing operations
From time to time, it is necessary to upgrade the system software of a control system’s CPU modules with new functionality to improve both operability and the engineering environment. In the past, such upgrades required the production process to be shut down for several days. CENTUM VP R6.05, which was released in 2017, included an online upgrade function that eliminated the need to halt a plant to perform such upgrades, and gradual improvements have been made to enable a wider range of applications. With version R6.08, this online upgrade function has been enhanced with the addition of support for SEBOL, the principal programming language for batch processing sequence control.
3. CPU module replacement without invalidating certification to local standards
Until now, certification for compliance with local explosion-proof and safety standards has needed to be done for the field control unit as a whole. This means that certification for the entire unit, which in addition to the CPU module includes a power module and terminal block, would be invalidated when just the CPU module was upgraded.
With R6.08, certification to these standards has been obtained for the CPU module and for each of the other components, so replacement of just the CPU module will no longer invalidate certification for the entire field control unit. Enabling the replacement of individual components reduces costs over the long term, and also lessens the need for the addition or removal of wiring. This increases operational efficiency and also reduces the attendant risks of any wiring errors. And as with the above-mentioned enhancement that eliminates the need for discarding entire cabinets, this feature reduces waste by eliminating the need to replace the entire field control unit just to upgrade the CPU module.
Yokogawa has enhanced CENTUM VP R6.07.10 through the introduction of a unified alarms and conditions server (UACS) that ensures safe and secure operations, even with large-scale systems.
Based on standard rules, the UACS organizes and consolidates the alarms issued by plant devices so that only the more important alarms are brought to the attention of operators, allowing these personnel to concentrate on monitoring processes and improving overall plant efficiency.
In recent years, manufacturers have sought to consolidate and integrate their plant control rooms and control systems to enable more efficient operations with the minimum number of human operators.
This requires individual operators to monitor a wider range of activities and respond to an increased number of alarms while prioritizing their actions depending on the indicated type of process abnormality.
However, if many alarms are displayed in quick succession, an important alarm may be ignored, leading to a delayed response and a potentially serious accident. Yokogawa has developed the UACS to integrate and manage alarms across large scale systems and thereby ensure that all important alarms are brought to the attention of operators.
1. Unified alarm management for large-scale systems
The UACS operates based on a client-server architecture*, centrally managing alarms that are displayed at operators’ human interface stations (HISs). The UACS is suitable for use even with large-scale plant control systems that include safety instrumented systems, programmable logic controllers (PLCs), electrical systems, and other components. The server and the control functions have been designed to operate in a redundant configuration, so if an abnormality occurs in the operating server, operation is smoothly and automatically switched over to the standby server.
*Client-server architecture: A computing model whereby specialized tasks are executed by a server and user-specific tasks are handled by clients connected to the server via a network
2. Alarm management that drives compliance with IEC 62682 (Ed1, 2014)/ISA18.2-2016 standards
The UACS includes functions that meet the shelving, suppressed-by-design, and out-of-service requirements defined in the IEC 62682 (Ed1, 2014)/ISA18.2-2016 alarm system management standards. The UACS supports an advanced function that suppresses alarm indication based on predefined alarm logic, so that only the more important alarms are brought to the attention of operators. To improve efficiency, this function can be set to, for example, display only key alarms when alarm flooding occurs, or suppress all alarms during equipment maintenance.
Alarm status can be displayed in a format that complies with the requirements of the alarm status transition diagram defined in the aforementioned standards. In conformance with these standards, the UACS also supports alarm management with other Yokogawa solutions and services in the OpreX Control and OpreX Transformation categories.
OpreX is the comprehensive brand for Yokogawa’s industrial automation (IA) and control business. The OpreX name stands for excellence in the technologies and solutions that Yokogawa cultivates through the co-creation of value with its customers, and encompasses the entire range of Yokogawa’s IA products, services, and solutions. This brand comprises the following five categories: OpreX Transformation, OpreX Control, OpreX Measurement, OpreX Execution, and OpreX Lifecycle. One of the product groups that make up the OpreX Control category is the OpreX Control and Safety System family, which includes the CENTUM VP DCS. With its various OpreX Control solutions, Yokogawa is able to quickly effect changes for its customers that lead to a transformation in such areas as management and operations, and provides highly reliable control technology that ensures high efficiency, high quality, and safe and stable plant operations.
With the OpreX brand, Yokogawa will deliver integrated solutions that address specific needs and support its customers in their efforts to transform and grow their businesses.
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.
Non-isolation, isolation (all channels are collectively isolated), and isolation (each channel is individually isolated)
Pressure clamp (Weidmuller), dedicated terminal boards, and MIL cables
Class G3 corrosive gas and a wide range of operating temperatures
Type N and non-incendive protection provided as standard. I/O modules with a built-in intrinsic safety barrier available.
Yokogawa's virtualization separates system software operations from physical hardware dependencies, allows software reusability to optimally commission system hardware.
Virtualization platform enables a single server to perform the work of multiple virtual computers, thus reducing the number of computers required to configure a control system. With this platform, both the hardware and software required to build a virtual environment are provided.
By means of this virtualized server environment, it is possible to separately update and make modifications to hardware and software as required.
This translates to customer's business centric benefits like smooth migration to new physical hardware with reduced downtime, shorter migration process and system tests time.
From maintenance point of view, segregation of hardware and software maintainability are also the significant advantages.
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.
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.
Continuously displays the latest alarm messages, keeping operators up to date on process conditions.
Contains navigation tools for the convenience of operators, frequently-used icons can be grouped in a My Favorites folder.
Lists the previous operational displays. Operators can quickly call up previously-used graphics windows.
Unified Alarms and Conditions Server (UACS) is Yokogawa's new management alarm system that ensures the safe and secure operation helping compliance with ISA18.2-2016. Based on standard rules, the UACS organizes and consolidates alarms that are issued by plant devices, helping operators to focus on those alarms that are judged to be crucially important. This lets operators to concentrate on monitoring processes and improving overall plant efficiency.
The AOG 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 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.
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.
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.
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.
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.
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.
The Automation Design Suite adopts a Modular approach to automation design and execution, where process loops (regulatory/complex Loops and sequence control), alarm design philosophy, graphics and more are deployed as design patterns. Also multiple application modules can be handled as one module (Group Module). These functions enable easily downloaded, efficiently 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.
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.
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, PROFINET, DeviceNet™, Modbus®, Modbus/TCP, Ethernet®/IP and ISA100 Wireless™ (ISA100.11a wireless standard). The CENTUM VP integratedly controls and monitors these field devices from various vendors with various communication protocols.
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.
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.
Go to the related web page (Asset Management Software page)
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 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.
40 year history of CENTUM
Williams Opal successfully reduced start-up time of stabilizer column and turbo expanders with Exapilot.
Exapilot also standardized operators' start-up processes as Standard Operating Procedures.
Yokogawa provided integrated control and safety system to Banagas's CGP-3 gas processing plant.
N-IO based system contributes to reducing maintenance and other operating expenses (OPEX).
GC8000 was selected to detect components responsible for stainless steel corrosion of pipeline.
GC8000 with custom container analyzes crude oil components every 4 mins at an offshore platform.
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.
Yokogawa China successfully replaced control system with CENTUM VP at 4th phase of caustic soda production plant in China.
Thanks to their project execution capability, the replacement was completed within a shorter period than the planned shutdown time.
Yokogawa contributes to the education of process industry talents by providing its own products.
TAFE Queensland students learn process industry by controlling the color of toast with CENTUM VP DCS.
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.
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.
GC8000, CENTUM VP
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.
Process manufacturers continue to demand more from their plants and automation systems. This demand is driven by business pressures for greater manufacturing flexibility and by customer pressure for faster, smaller deliveries and higher service levels. Manufacturers also realize that they need to improve the quality of their manufacturing operations for any number of reasons, most especially safety, as recent major accidents have shown. Abnormal operations, especially, present risks that these manufacturers need to reduce.
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.
Don't gamble with your plant's legacy DCS system. Contact us to help you plan and implement a safe, cost effective DCS migration that creates new value for your business.
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.
Yokogawa South Africa was appointed to design, supply and commission the Integrated Control and Safety System (ICSS) as well as the overall Terminal Management System at Sunrise Energy’s liquid petroleum gas (LPG) Import Terminal, the largest on- and offshore open-access LPG import terminal facility in Africa. Yokogawa’s Terminal Management System, Terminal Logistic Suite VP (TLSVP), was designed and developed to meet the exacting operational demands and logistic needs in terminals. Yokogawa’s experienced engineering resources ensured the project was successfully delivered, enabling Sunrise Energy to provide accurate mass balances and efficient terminal operations to its customers.
- Enhancements to this core product in the OpreX Control and Safety System family ensure an optimum operating environment and system continuity -
- Enhancement to OpreX Control and Safety System family core product adds unified alarms and conditions server for safe and efficient operation of large-scale systems -
- Enhancements to this core product in the OpreX Control and Safety System family that improve connectivity and productivity -
- To be installed at coal-fired power plant in Bosnia and Herzegovina -
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