Yokogawa's Latest Generation DCS
The CENTUM VP Distributed Control System (DCS) is Yokogawa's most advanced, integrated process control system, providing enhanced productivity and optimization across a wide range of industries. For over forty years, the Yokogawa CENTUM DCS family has evolved to meet and exceed the needs of businesses and will continue to do so as they reinvent themselves through digital transformations and incorporate new technologies such as IoT far into the future.
CENTUM VP DCS Top 10 Features and Benefits
1. Highest Field Proven System Availability
When sustainable operation without shutdown time is a requirement for your plant, CENTUM VP is the most reliable distributed control system available. CENTUM VP has a proven availability better than “seven nines” (99.99999%), delivering an allowed downtime less than one minute over ten years.
2. “No Shutdown” Application Modifications and CENTUM VP Software Updates
With the latest release of CENTUM VP, operators can still make application changes or perform version updates when foregoing shutdowns.
The recently released CENTUM VP R6.06 includes the following new functionality:
- Control system virtualization
- “On the fly” version updates – no shutdown necessary
- “On the fly” application modifications – no shutdown necessary
- Compatibility with the latest operating systems
3. Network I/O (N-IO) with Flexible Binding
Our N-IO greatly streamlines project execution by completely decoupling application engineering from field wiring and hardware installation. Universal I/O modules at the edge eliminate marshalling and reduce wiring by up to 80%. Cabinet delivery, skid integration, and wiring termination can be done anytime during the project. Last-minute changes result in nearly zero project delays. With project decoupling, no factory acceptance test (FAT) is required.
Watch the videos to learn more.
4. Automated Commissioning
Yokogawa’s CENTUM VP technology and OpreX Execution methodology have come together to automate the processes of verification, binding, configuration, testing, and documentation for multiple field devices. Compared to traditional methodology, project teams can realize reductions of up to 80% in drawings, 90% in wiring design work, and 95%+ in commissioning time.
5. High Performance HMI
High-performance HMI optimizes situational awareness and enables Advanced Decision Support. Fully compliant with Abnormal Situation Management (ASM) recommendations, our HMI uses the ISA-101 standard symbol library to enable higher productivity and a safer operating environment in process applications.
6. Extensive Advanced Solutions Portfolio
Yokogawa offers a broad advanced solutions portfolio that allows users to optimize all aspects of their processes and sustain profitability throughout the entire system lifecycle.
Our advanced solutions all deliver proven results, measurable ROI and definitive risk reduction.
7. Comprehensive Enterprise-wide Interoperability
CENTUM VP supports standard interfaces, which provide applications compatibility and interoperability throughout the entire enterprise. For users, anytime, anywhere, CENTUM VP provides complete availability of information and readily works with advanced solutions, analytics, artificial intelligence (AI), asset optimization, machine learning, and predictive maintenance systems.
8. Native Compatibility Across PLC, SCADA and SIS Architectures
CENTUM VP has incorporated native interoperability with Yokogawa’s Programmable Logic Control (PLC), Safety Instrumented System (SIS) and Supervisory Control and Data Acquisition (SCADA) Systems.
Standard displays and database compatibility reduce project execution costs while enabling an enterprise automation system with remote operations. Native interfaces with common, third-party OEM PLC products such as Rockwell ControlLogix automate database mapping and reduce integration costs by up to 70%.
9. Third party-certified defense-in-depth cyber security
Yokogawa has been prominent in the cybersecurity standards community for many years and offers a full portfolio of services. Yokogawa is the Cyber Security Managed Service Provider of choice for many customers. We are constantly testing CENTUM VP in our cybersecurity lab and have received such third-party certifications as Achilles, ISASecure EDSA (IEC 62443-4) and WIB (IEC 62443-2-4).
10. Automation Design (AD) Suite
Integrated Application Engineering Environment
AD Suite is a first-of-its-kind integrated engineering environment that transcends traditional DCS engineering functionality.
AD Suite facilitates project execution, system integration and site execution. It brings certainty and confidence to all control system project phases as well as through start-up, operation, maintenance, expansion/upgrade, and extension stages of the plant lifecycle.
In essence, AD Suite generates a total engineering environment, with an entirely new database structure that feeds standardized and consistent engineering information, maintains engineering data integrity, eliminates inconsistencies between the design information and the actual system, manages change, and supports the automation lifecycle.
In addition, it facilitates the reuse of valuable engineering knowhow and eliminates duplication of work for subsequent projects.
AD Suite Key Functions
A rich library of standard application modules substantially reduces customized development, streamlines engineering and eliminates duplication of effort.
Hardware-independent application modules prevent discrepancies between design and implementation information by automatically updating the design as changes are made.
Bulk engineering functions such as the ability to edit hundreds of ranges in a single edit enable considerable project efficiencies. Version comparison rapidly highlights differences between existing and to-be-imported databases.
AD Suite maintains a revision history of all modifications and keeps design implementation information up-to-date throughout the entire plant lifecycle. A dependency analysis allows engineers to check all impacts before modifications are made.
Since all project aspects are self-documenting, there is no need for engineers to spend time generating documents and drawings.
By separating logical applications from physical hardware such as I/O wiring, AD Suite eliminates dependencies and provides considerable flexibility in project scheduling.
CENTUM VP R6.06 - Improving productivity and eliminating downtime with quick system upgrades and a one-of-a-kind virtualization platform
Control System Virtualization Platform
With the addition of a control system virtualization platform, a single server now performs the work of multiple virtual PCs, reducing the number of PCs required to configure a control system.
The virtualized server environment allows the operator to update and make modifications to hardware and software separately as required.
Both the hardware and software required to build a virtual environment are provided.
Yokogawa DCS Software Updates While FCS is Operating
With the latest CENTUM DCS, operators can perform work when they want - there’s no need to wait several years until the next shutdown maintenance period.
Modifications to the CENTUM VP software enable a smoother switchover between the dual-redundant control-side and standby-side CPU modules, improving uptime and giving operators the freedom to choose when to install upgrades.
In addition, Yokogawa’s enhanced support organization ensures customers receive all necessary technical support with their system maintenance activities.
Ability to quickly perform minor modifications to applications software
Updates to the AD Suite* give users the ability to quickly and easily implement modifications to application control logic and alarm attributes. Such modifications to system software can be immediately executed with the single action of clicking on an icon on the editor screen and allow users to implement changes individually or in groups.
*Yokogawa's Automation Design Suite (AD Suite) is a powerful yet flexible engineering environment that helps engineers produce quality work and improves efficiency over the entire project lifecycle.
Compatible with the Latest Server Operating System
CENTUM VP R6.06 is compatible with Windows Server 2016, which delivers the latest security functions.
To learn more about the release of CENTUM VP software version R6.06, read the press release here.
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.
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
Hazardous area classification
Type N and non-incendive protection provided as standard. I/O modules with a built-in intrinsic safety barrier available.
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.
System message banner
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.
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
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’s innovative engineering tools provide greater flexibility and up-to-date plant knowledge, resulting in improved ease of use and management within the CENTUM VP distributed control system.
Our three smart engineering products - N-IO (The Network I/O), FieldMate Validator, and Automation Design Suite - simplify project management, shorten project duration, and reduce project risk, helping overcome our customers’ toughest challenges.
Flexible I/O Binding with N-IO
Flexible I/O binding is Yokogawa’s improved late I/O binding solution, providing the following benefits:
- Simple and hassle-free I/O binding
- Ability to be modified remotely
- Early delivery of I/O cabinets to the site
- Shortened duration of projects
System Independent Loop Commissioning utilizing the FieldMate Validator is an innovative tool, which allows for field testing validation of N-IO without requiring a deployed system. After the I/O design is fixed, application engineering and hardware engineering can progress independently and parallel.
Automation Design Suite
Yokogawa's new engineering environment, the Automation Design Suite:
- Retains your entire plant engineering history from design phase to commissioning and live operation, providing up-to-date knowledge with every expansion or change throughout the lifecycle.
- Provides dynamic management of design, investment and project effectiveness by auditing and versioning engineering changes and facilitating effective engineering through ModPacks (Modification Packages). This helps maintain project schedules by reducing the delays and the engineering impact of late design changes or scope changes.
- Auto-documents and checks inconsistencies in project activity and software resources, significantly reducing project risk.
Management of Change and Resources
Download the brochure to learn more.
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 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.
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.
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.
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
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.
Nitrogen Fertilizer Manufacturer Cyber Security Implementation Success Story
CENTUM VP was selected for the BOP in a concentrated solar power plant of the Xina Solar One Project.
Yokogawa provided a complete control system solution that integrates the subsystems in the plant as a system of systems.
- DDMO for the optimization of the air-blowing rate of the aeration tanks
- Interlink between DCS and DDMO to maximize the energy saving effect
Yokogawa Romania successfully modernized the control system at ELCEN's combined cycle heat and power plant.
A major challenge in deploying the system when all work moved to the virtual space was the Covid-19 pandemic.
- 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.
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).
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.
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.
- Highlyadvanced biopharmaceutical plant uses CENTUM, VP Batch, Exaquantum and PRM.
- Total system integration for large-scale biotech production facility.
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.
- 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
- 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.
- 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.
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.
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.
- Yokogawa successfully carried out the upgrade of off-site system in a 48 hour shutdown period with Seibu Oil.
- Control room design for HSE and smooth communication contributes to the operational efficiency and safety.
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.
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.
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.
- CENTUM VP Integrated Production Control System (3.2 MB)
- CENTUM RIO System Upgrade (2.9 MB)
- Cyber Security for Industrial Control Systems (3.0 MB)
- CENTUM VP for Batch Control (3.8 MB)
- Sustainable Plant / Yokogawa's solutions for lifecycle sustainability of modern process automation systems (6.8 MB)
- Refining Solutions (12.5 MB)
- Alarm Management - To Enable Higher Stability and Safer Plant Operations (5.3 MB)
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 that improve connectivity and productivity -
- To be installed at coal-fired power plant in Bosnia and Herzegovina -
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