YOKOGAWA OpreX Control and Safety System CENTUM VP Integrated Production Control System

YOKOGAWA CENTUM VP Distributed Control System

Basic and Product Positioning

Product Name: CENTUM VP Distributed Control System (DCS)

System: Yokogawa Oprex Control and Safety System

Manufacturer: Yokogawa Electric Corporation

Core positioning: Yokogawa's most advanced integrated production control platform, which has undergone more than 40 years of technological evolution, aims to create value with customers through "process collaborative innovation" and meet the needs of digital transformation and integration of new technologies (such as IoT) in multiple industries

Core value proposition: customer-centric, possessing five core characteristics of reliability, scalability, flexibility, strength, and ease of use, balancing safety performance and operational efficiency, achieving cost reduction and efficiency improvement throughout the entire lifecycle and long-term stable operation

Core advantages of the system and customer value

Advantage Category Key Features Customer Value

Standardization of engineering efficiency, modular engineering, flexible I/O binding, Automation Design Suite eliminate duplicate work, shorten project duration, reduce change impact, and lower installation costs

Intuitive HMI operation experience, integrated alarm management, dedicated operation keyboard, AOG solution to avoid information overload, improve decision-making speed, reduce operational errors, and lower operator stress

System reliability with dual redundancy design (FCS, power supply, I/O, etc.), online maintenance, seamless fault switching to ensure 24/7 continuous operation, reduce downtime, and improve production stability

Lifecycle assurance includes backward compatibility, online upgrades, third-party system migration, maximizing the value of existing assets through a global service network, reducing upgrade costs, and providing long-term technical support

Security protection includes ISASecure EDSA certification, Vnet/IP secure network, endpoint security services to resist network attacks, compliance with industry security standards, and ensuring production and data security

Detailed explanation of the core functional modules of the system

（1） Operation module: Focus on efficient and intuitive operation

Integrated Management: Integrating the three major goals of production excellence, safety excellence, and asset excellence, optimizing data management through cognitive vision integration, HIS (Human Machine Interface Station) can uniformly display alarm information from DCS, ProSafe RS, and PRM systems, achieving seamless cross system operation

Human Machine Interface (HMI):

Design philosophy: Putting people first, based on ergonomics, adapting color matching to environmental lighting, optimizing contrast, and ensuring high visibility of data

Flexible configuration: supports multi screen display and custom windows, can group commonly used functions through "My Favorites", and quickly call past interfaces through "Window History"

Advanced Services: AOG (Advanced Operating Graphics) solution, designed by certified consultants based on human factors and knowledge engineering to enhance anomaly detection efficiency and decision-making speed in PCS graphics

Specialized operation keyboard: provides two types of simultaneous operation for single circuit and eight circuit, optimized function key layout, supports one click calling of graphics or control circuits, and helps operators quickly respond to process changes

Virtualization technology: decoupling system software from physical hardware, supporting software reuse and smooth hardware migration, shortening migration and testing time, and reducing maintenance difficulty

（2） Control module: ensuring high availability and stable control

High availability design:

Dual redundancy architecture: The FCS processor module, power supply, I/O module, and I/O network are all designed with dual redundancy. The primary and backup processors run synchronously, seamlessly switching in case of failure to ensure uninterrupted control

Online maintenance: supports FCS application logic and parameter online modification, fault modules can be replaced online without downtime, and does not affect the production process

Core Control Unit (FCS): independently developed and manufactured by Yokogawa, with powerful processing capabilities and large capacity application storage, fully adapted to advanced on-site digital technology, ensuring control efficiency and stability

Control network (Vnet/IP):

Technical specifications: Compliant with IEEE802.3 Ethernet standard, with a transmission rate of 1Gbps, supporting both star and ring topologies

Core advantage: It combines openness and security, does not affect the transmission of process control data, ensures HIS updates data every second, and adapts to projects of different sizes and complexities

I/O module selection:

N-IO (Network I/O): The next generation of software can configure intelligent I/O, with a single module supporting AI/AO/DI/DO signals. Signal type software configuration is achieved through adapters, reducing installation delays and eliminating the need for traditional wiring grouping, saving space and cost. It can be deployed as a remote I/O module

FIO (Field Network I/O): Classified by process signal type, it can be connected to field equipment through pressure clamp terminal blocks, dedicated terminal boards, or MIL cables

Other options: RIO (Remote I/O) module, RIO system upgrade I/O module, supports maximizing the use of existing assets to quickly upgrade the system

（3） Engineering module: Accelerating project delivery and quality improvement

Core Engineering Environment: Automation Design Suite

Full lifecycle management: Record the engineering history from design, debugging to operation, ensuring data integrity during system expansion, software and hardware changes

Modular engineering: Encapsulate process loops, alarm design, graphics, etc. into standard modules that can be downloaded, shared, and reused across enterprises, saving resources

Change management: Implement version based engineering changes through ModPacks, automatically document and detect project inconsistencies, and reduce risks

Flexible I/O binding:

Core advantage: Supports software grouping and N-IO universal channels, allowing remote modification of I/O types and module controller connections, significantly reducing the impact of later design changes

Project value: Achieve early delivery of I/O cabinets, detect and solve problems early on site, combine with FieldMate Validator debugging tool, support system independent circuit debugging, and shorten project duration

Agile project execution: Compared to traditional project processes, modular design and flexible I/O binding are used to reduce rework and waste, improve project quality and delivery efficiency

（4） Sustainable Plant: Ensuring Long Term Value

Lifecycle Services: Yokogawa provides full lifecycle support such as online upgrades, patch updates, migration services, and security solutions. Through deep collaboration with customers, it ensures sustainable investment returns for control system assets

Compatibility and Migration:

Backward compatibility: All Yokogawa legacy CENTUM systems (such as CENTUM V, CENTUM-XL, CENTUM CS, etc.) can be controlled and monitored by CENTUM VP to maximize the value of existing assets

Third party migration: Over 350 non Yokogawa systems (such as Bailey INFI90, Honeywell TDC2000/3000, Siemens SIMATIC, etc.) have been successfully migrated, with a simple migration process

Network security protection:

Security certification: CENTUM VP on-site control unit obtained ISASecure certification ®  EDSA (Embedded Device Security Assurance) certification meets the security requirements of industries such as petroleum, petrochemical, and power

Security features: Built in anti spoofing, anti tampering, and anti DoS attack functions for Vnet/IP networks, supporting Windows PC/Server security configuration

Security services: Provide USB port locking, security information services, antivirus software, whitelist software, etc., to verify the compatibility of products with antivirus software, Microsoft security updates, etc

Long term stable operation: Through component updates, peripheral replacements, FCS upgrades, and other methods, the system seamlessly transitions, and maintenance activities can be synchronized with factory shutdowns to ensure long-term functional availability

System architecture and core components

（1） Hardware components

Component Name English Abbreviation Core Function

Human machine interface station HIS operator control and monitoring interface, supporting multi screen display and dedicated keyboard

Engineering station ENG system configuration, programming, debugging, and maintenance, equipped with a complete engineering kit

On site control station FCS system core control unit, dual redundancy design, independently developed and manufactured

Unified gateway station/general subsystem gateway UGS/GSGW implementation for interface and control with STARDOM or third-party subsystems

Bus converter BCV connects multiple control network domains and is compatible with the previous generation CENTUM system

（2） Network and Communication

Control network: Vnet/IP (1Gbps, redundant design, star/ring topology)

Digital fieldbus: supports FOUNDATION ™  fieldbus、HART、PROFINET、PROFIBUS-DP、DeviceNet、Modbus、Modbus/TCP、EtherNet/IP  wait

（3） Key software suite

Alarm Management System: Compliant with ISA 18.2 and EEMUA # 191 standards, supports Six Sigma DMAIC method, provides historical data analysis, automatic alarm reduction, event sequence management, and avoids alarm proliferation

Factory Resource Manager (PRM): Collaborate with intelligent on-site devices to remotely monitor asset status, predict equipment failures (such as valve jamming and pulse line blockage) through built-in diagnostic functions, and optimize preventive maintenance plans

Unified Alarm and Status Server (UACS): Complies with IEC 62682 (Ed1, 2014)/ISA18.2-2016 standards to standardize alarm management

Product History and Evolution

The Yokogawa CENTUM series has undergone more than 40 years of development and has always adhered to independent research and development to ensure the upgrade compatibility of various generations of systems. The key milestones are as follows:

Year Product Version Key Developments

1983 CENTUM V Series First Product

1988 CENTUM-XL Technology Iteration Upgrade

1993 CENTUM CS New Generation Control System

1998 CENTUM CS 3000 Enhanced Features and Compatibility

2001 CENTUM CS 3000 R3 Version Update and Optimization

2008 CENTUM VP R5 VP Series First, Equipped with Vnet/IP

2011 CENTUM VP officially launched CENTUM VP

2015 CENTUM VP R6 version upgrade with enhanced functionality

Key issues

Question 1: What are the core reliability design and I/O module selection advantages of the CENTUM VP system, and which core pain points can be solved in industrial scenarios?

Answer: The core reliability design is reflected in the dual redundancy architecture (FCS processor, power supply, I/O module, network full redundancy) and online maintenance function. In case of failure, seamless switching between primary and backup is supported, and online module replacement and logic parameter modification are supported. This can solve the pain points of "high downtime loss" and "maintenance affecting production" in industrial scenarios; Advantages of I/O module selection: ① N-IO modules support software configuration of multiple types of signals (AI/AO/DI/DO), without the need for traditional grouping, saving space and cost, and adapting to design changes; ② The FIO module is classified by signal type and compatible with multiple connection methods; ③ The RIO module supports the reuse and upgrade of existing assets, which can solve pain points such as long installation cycles, difficult adaptation to changes, and asset waste, and meet the flexible deployment needs of different scenarios.

Question 2: What are the core optimization measures of CENTUM VP in terms of engineering efficiency and operational experience, and what direct value can it bring to customers?

Answer: Engineering efficiency optimization measures: ① Adopting modular engineering design (Automation Design Suite), standard modules can be reused to reduce repetitive work; ② Flexible I/O binding supports remote configuration modification, I/O cabinets are delivered in advance, and early debugging is achieved by combining FieldMate Validator; ③ The change management function automatically documents and detects inconsistencies, reducing project risks. Optimization measures for operating experience: ① Ergonomic HMI, multi screen support, high visibility display, integrated alarm management; ② AOG solution optimization operation graphic design; ③ Specialized operation keyboard (single circuit/eight circuit) for one key operation. Direct value: Shorten project duration by more than 30% and reduce installation and change costs on the engineering side; The operating end reduces operator errors, improves abnormal response speed, and achieves "cost reduction and efficiency improvement" and "safe and efficient operation".

Question 3: What are the compatibility and network security capabilities of CENTUM VP, and why can it meet the long-term stable operation needs of multiple industries?

Answer: In terms of compatibility: ① It is backward compatible with all Yokogawa legacy CENTUM systems (such as CENTUM V, CS 3000, etc.), which can directly control and monitor old systems, maximizing the value of existing assets; ② Support 350+third-party system migrations (such as Honeywell TDC, Siemens SIMATIC, etc.), with a simple migration process. In terms of network security protection: ① Obtained ISASecure EDSA certification, meeting the security requirements of industries such as petroleum and petrochemical; ② Vnet/IP network has built-in anti spoofing, anti tampering, and anti DoS attack functions; ③ Provide endpoint protection such as USB locking, antivirus software, and security information services. The core reason for ensuring long-term stable operation is: ① Compatibility guarantee "smooth upgrade" to avoid high costs of overall system replacement; ② Dual redundancy design and online maintenance reduce downtime; ③ Full lifecycle services (upgrades, maintenance, migration) and continuous support provided by the global service network; ④ Strict security measures are implemented to resist industrial network attacks and ensure the long-term reliable operation of the system.