Control Systems
• Distributed Control System
• Emergency Shutdown System
Sub- Systems
• Vibration Monitoring System
• Anti Surge Control System
• Truck Loading Automation System
• Tank Gauging Automation System
• Sulphur Solidification
Sub- Systems
• Effluent treatment
• Air Dryers
• MOV
• Fire Alarm System
• Cycle max Regeneration Control System
Distributed Control System
YOKOGAWA
Control Rooms
• CR-1 Main Control Room
• CR-2 Oil Movement Control Room
• CR-3 Blending Control Room
• CR-4 Truck Loading Control Room
Abbreviations
• FCS=Field Control Station
• ICS=Information Command Station
• ACG=Communication Gateway unit
• ABC=Bus Converter
• RIO=Remote I/O Bus
• NIU=Node Interface Unit
• IOU=I/O Unit
Networking
E net
Printer ICS ICS ICS EWS
V net
Networking
• V net: high performance process data
transfer
• E net: file server network
– Sharing of external devices
– Sharing of trend / graphic and MIF databases
Equipment List
FCS 22 Nos.
ICS 35 Nos.
I/Os. 10,000 Points
Control Loops 1,500 Nos. approx.
Redundancy Dual
Basic System Configuration
ICS
V net
FCS
RIO
NIU
Discrete
I/O
IOU
Analog
I/O
Subsystems
FIELD CONTROL STATION
(FCS)
• RISC Processing
– Mathematical Power at FCS Level V net
– Advanced Process Control (FCS Level) FCS
• Remote I/O Bus
– Reduction Cable Costs Remote IO bus
– Integration in Marshaling Panels
• Pair & Spare Redundancy Discrete
I/O
– Extremely High Reliability Analog
I/O
– Data Integrity, ECC Memory Subsystems
• Intersystem Serial Communication Communication
– Subsystem Communication
– PLC’s, ESD, Valve Bus Systems
Pair and Spare Redundancy
INPUT
Control Side INPUT Standby Side
• Guaranteed Integrity
of Calculated Data BUFFER
BUFFER BUFFER
BUFFER
• Bump less Transfer
CPU SYNC
CPU SYNC CPU
CPU CPU SYNC
CPU SYNC CPU
CPU
• Independent Memory COMP
COMP COMP
COMP
+ ECC BUFFER
BUFFER BUFFER
BUFFER
OUTPUT
OUTPUT
Control Signals
• Single Loop Integrity
• Free arrangement of In- and
Outputs
• Reduction of spare parts
Modules configurable from
engineering platform
000.123
In- Output Module
Internal Data
ICS
V-Net
Engr Unit Data
FCS
PID MV Q01 CALCU J01 VN PID MV
IN IN
Engr Unit Data
Input Buffer
Engr Unit Data
Output Buffer
Engr Unit Data
RIO Bus
NIU
Engineering Unit
IOU Conversion
Control Block - PID
FIC201-D
WATER
FLOW T6
CAS
HI
OPN
100.0
80.0
60.0
40.0
20.0
¯
0.0
CLS
SET
AUT/MAN
CAS
SV
I Input Control Algorithm CAS/AUT Output O
N
Processing PV En Algorithm MV Processing U
T
Mn Algorithm
MAN
PV, PV MV, MV
SUB
TI
INFORMATION & COMMAND
STATION (ICS)
• Open Industry Standards
– UNIX (With Real Time Extension)
*ALARM 01 88.06.29 3
BATCH REACTOR
• Single Window Concept
Time (min.)
¯ X PEN PLOT
- VIEW TREND
PRINT NOTES ZOOM OPTIONS CANCEL HELP
NEW
– Process Windows
100
75
50
25
850 950 1050 1150 1250 1350 1450
CLS FIT1001 FIT1002 FIT2001 FIT2002 FIT3001 FIT3002 FIT3003 FIT3004
TUNING ([Link])
– Half sized Windows
Management Information Functions
– Data gathering & Data processing
– Reporting, Logging, Long Term Trending
Information & Command
Station
Management Maintenance
Information
*ALARM 01 88.06.29 3
BATCH REACTOR
Time (min.)
¯ X
PEN PLOT
- VIEW TREND
PRINT NOTES ZOOM OPTIONS CANCEL HELP
NEW
100
75
50
25
850 950 1050 1150 1250 1350 1450
CLS FIT1001 FIT1002 FIT2001 FIT2002 FIT3001 FIT3002 FIT3003 FIT3004
TUNING ([Link])
System Process
Diagnostics Information
• Single window concept
• UNIX system V R4
• 100,000 TAG’s
External Devices
HP LaserJet Alarm Printer
Color
Hard Copy Unit
Alarm Indication
External Function Keys
External Recorder Output
Acknowledge and Buzzer off
Window Operation
*ALARM 01 88.06.29 10:53
.GR0023 23/200
BATCH REACTOR LEVEL
.PWO181
FIS2001A TIC2001A Product: ABC
FIC201-D Resin
TEMP. N SIDE
Int. Temp Lot No: #1234-C
139.0 DEGF
¯ 98.2 C
TIC2002A Production Vol.:
TEMP. 8000L
S SIDE
CAS FIS2002A Jacket Temp. 136.4 DEGF
HI 55.1 C TEMP. E SIDE
M Steps Time (min.)
143.5 DEGF
OPN
100.0 X Waiting TEMP. 00 W SIDE
Feeding 137.505DEGF
FIS2003A
80.0 PEN PLOT
60.0
- VIEW TREND
PRINT NOTES ZOOM OPTIONS CANCEL HELP
FIC201-D
Reactor Pressure (Internal)
¯
NEW
CAS
40.0
Materials Wg/CM2 100
HI
OPN
100.0
Tag # Feed L Total L 75
80.0
20.0
FIS2001A 1234 576420 50
60.0
FIS2002A 1234 576420 40.0
FIS2003A
0.0 1234 576420
25
850 950 1050 1150 1250 1350 1450 20.0
CLS
0.0
WATER FIT1001 FIT1002 FIT2001 FIT2002 FIT3001 FIT3002 FIT3003
CLS FIT3004
WATER
TUNING FLOW T6
FLOW T6
([Link])
• Multi-Window operation
– Call up of window without erasing current displays
– Effective use of monitor by half-size window
• All Panels can be displayed in “half-size” windows
Operation Panel Structure
#
Alarm Overview Graphic
Summary Display
To any panel Control Trend To any panel
Group Group
?
Operator Tuning Trend
Guide Panel Point
Status
Panel
To any panel Default hierarchy is shown!
• Configurable Hierarchy
• “One -Touch” Panel
Selection
Standard Faceplates
FIC201 FIC201-D FI201D BU201-D MC201-D
WATER WATER
FLOW T6 FLOW T6
CAS
HI STEP
OPN
100.0
80.0
PAUSE
60.0
40.0
20.0
CONT
¯
0.0
CLS
• Faceplate for each Function
Block
Operator Grouping
Example of Mode A Example of Mode B
ICS30 A1 ICS31 ICS32 A2 A1 ICS30 ICS31 A1 A2 ICS32
Printer Printer Printer Printer
FCS 1 FCS 2 FCS 3 FCS 4 FCS 5 FCS 1 FCS 2 FCS 3 FCS 4 FCS 5
• On-line change of Grouping
ModeThe start up of a unit will
not effect operators on other
units
Installation
Control Cabinets
ooo ooo
ooo ooo
ooo ooo
ooo ooo
Front Rear Front Rear
User Definable Block
MC201-D
Control Drawing FIC201-D
WATER
PID T1 IN FLOW T6
CAS
OUT IN CALCU F1 IN
HI
OPN
T1 IN 100.0
80.0
F2 IN CALCU PID
60.0
P IN T2 IN V OUT 40.0
20.0
V OUT
¯
0.0
CLS
• Simple Operator Interface for Complex Control and
Logic
ENGINEERING
WORKSTATION (EWS)
• Single Data Base Concept
–Concurrent Engineering
• Computer Aided Engineering (CAE)
–Control Drawings, Graphical Connection
–Extensive “Instruments” Library
–“Pick & Click”, Fill in the Forms
• Electronic Engineering Data-exchange
–Engineering Tools
THANK YOU
