YOKOGAWA CENTUM CS 3000 Integrated Production Control System

Network system: CENTUM CS 3000 adopts a dual layer network architecture.

V net: This is a real-time control system bus that connects sites such as HIS, FCS, Bus Converter (BCV), and Communication Gateway (CGW), with a speed of 10 Mbps. V net supports dual redundancy, using coaxial cable (YCB111, up to 500 meters) or dedicated cable (YCB141, up to 185 meters). By using bus repeaters and optical repeaters, V net can be extended up to 20 kilometers.

Ethernet: used to connect HIS, Engineering Stations (ENG), and upper level monitoring systems. It is responsible for synchronizing HIS databases, sending trend data files to monitoring computers, and conducting other non real time communications to reduce the load on V net.

3. High reliability and redundant design

For FCS with direct connection process, high availability is a basic requirement. CENTUM CS 3000 achieves redundancy at multiple levels:

CPU redundancy: In dual redundant FCS, processor cards work in pairs (one active and one standby). Each processor card has two CPUs inside, which perform the same control operations and compare the results. If the results are consistent, it is judged as normal; If there is inconsistency, it is judged as "CPU abnormality", and control is immediately switched to the backup processor card without interrupting control. The main memory adopts ECC (Error Correction Code) memory, which can automatically correct instantaneous bit reversal errors.

Bus redundancy: Both the ESB/ER bus in the FIO system and the RIO bus in the RIO system can be configured as dual redundancy. Two buses are used alternately. When one bus experiences an abnormality, the system will automatically switch to the other bus for communication and regularly test whether the abnormal bus has returned to normal.

Node redundancy: In I/O nodes, both the node interface module and the power module can achieve dual redundancy. The internal bus from the node interface module to each I/O module can also be configured as dual redundancy.

Power redundancy: Multiple models of FCS offer dual redundant power module options.

This multi-level and all-round redundant design ensures that even if a single component fails, process control will not be interrupted, greatly improving the availability of the system.

4. Powerful control and engineering functions

Control functions: FCS performs continuous control (PID, etc.), sequential control (logic diagram, sequence table, SFC), and complex calculations. The control function is built on "function blocks" that can be interconnected, similar to traditional instrument flowcharts. The Control Drawing option allows multiple functional blocks to be combined into one control function, facilitating engineering and maintenance. Sequential control supports program control and conditional control. SFC blocks and SEBOL (Sequence and Batch Oriented Language) are used to handle large-scale and complex sequence control.

Engineering environment: The engineering functions of CENTUM CS 3000 run on a general-purpose PC and can be shared with the operation monitoring function on the same PC, making it easy to switch between engineering and operation. Its core is the "System View", which displays all components (FCS, HIS, etc.) in the engineering database in a tree structure. Double clicking can launch the corresponding builder program.

Concurrent Engineering: Utilizing the Windows file sharing feature, multiple engineers are allowed to edit a project database simultaneously, greatly improving project efficiency.

Virtual testing: The Engineering Station (ENG) provides a "virtual testing" function that simulates the operation of the control station without actual FCS hardware. Engineers can perform verification immediately after completing a program segment without waiting for hardware to be in place.

Reusable engineering data: Engineering data can be easily reused between different stations or projects, which helps with standardized control and knowledge accumulation.

Online maintenance: The system supports online modification of control functions without affecting other unmodified parts, minimizing the impact on factory operations.

5. Deep integration of ProSafe RS safety instrumented system

The manual introduces the ProSafe-RS Safety Instrumented System (SIS) in a dedicated chapter, reflecting the CENTUM CS 3000's emphasis on factory safety.

Compliant with international standards: ProSafe RS is a safety instrumented system that meets the IEC 61508 standard, with a safety integrity level of SIL3, and has been certified by T Ü V Rheinland in Germany. As a prevention and mitigation layer in the "protective layer" model, it performs emergency parking, fire and gas protection, and other actions in the event of an accident to protect personnel, equipment, and the environment.

Seamless integration with CS 3000: ProSafe RS adopts the same architecture as CS 3000 and is directly connected through V net, achieving unified operating environment. Operators can use the same interface (window) as monitoring FCS to monitor the Safety Control Station (SCS), and FCS can also read SCS data just like reading data from another FCS.