CENTUM
Bulletin 33G1A51-01E
Migrating to a Production Control System for 21st-Century Networks
Migration to a state-of-the-art production control system while maintaining legacy facilities lets you integrate your business domain (corporate decisions) and control domain (production) through networking.
As consumer needs become more diverse and competition among companies intensifies, the market environment is undergoing enormous changes. For example, e-commerce, supply chain management, and increased information technology spending are changing the way business is done. Executives are now faced with the question of how changes in the market can be rapidly reflected in the production environment. Integration of business decisions with production is now an important issue for the production environment. It is critical that companies implement flexible production control systems capable of accelerated production that allow production volumes and the products made to be easily changed according to market needs. With CENTUM, "Evolution Through Migration" means using the resources of your legacy CENTUM system while migrating to a production control system compatible with 21st-century networks. This system enables stable production under normal conditions, as well as accelerated production when needed.
Integration of business domain and control domain
High-level information systems such as enterprise resource planning (ERP) and manufacturing execution system (MES) are connected with the DCS through an information "highway" (PIMS; Exaquantum) based on OLE for Process Control (OPC). This connection enables migration to a production control system capable of rapidly responding to market conditions.
Better efficiency for unusual operations
Seamless connection with advanced operations assistance (AOA) enables better efficiency for operations such as plant startup, shutdown, and grade changes. Functions integrated with the operations monitoring screen reduce the workload for operators while allowing the know-how of veteran operators to be standardized and integrated for significant efficiency gains.
Getting the most out of production facilities
Connection with advanced process control (APC) functions enables process control optimization and further improvements in production efficiency.
Networked Production Control System
Networked production control system integrated in real time with market information and corporate information
Flexibility for accelerated production
M , ES P R E
Legacy production control system
Optimizing plant operations with a high-precision, high-reliability control system.
Market requirements
Growing diversity of needs Accelerating pace of market changes Intensifying competition among companies Better production efficiency Globalization of production
Stable production
AO
Stable production
PC
A
Phased Migration to a Networked Production Control System
Phased migration can be used to migrate a currently used system one component at a time. This approach helps reduce or smooth levels of investment due to the use of legacy resources, while minimizing opportunity costs thanks to reduced updating time requirements.
Step
enterprise resource planning
ERP
manufacturing execution system
MES
advanced process control
APC
Exaquantum TriFellows Exabif PRM
Exasmoc Exarqe Exacoast
1: Upgrade to the latest HMI
Seamless integration with information systems is achieved through networking an existing DCS. Connection with higher-level information systems such as ERP and MES provides a networked production control system.
Generalpurpose PC
Step
2 : Upgrade FCS CPU
This step provides the latest control functions while using existing I/O cards and field wiring. In addition, CPU power and application capacity are increased, and control functions linked with MES functions are enabled.
Supervisory computer
Internet/Intranet
Step
3 : Upgrade FCS I/O
This step upgrades to the latest I/O, which is function-interchangeable, interfaceinterchangeable, and nest structure-interchangeable, while using existing field wiring.
CS 3000 R3
Ethernet
advanced operation assistance
AOA
COPSV
HIS
HIS
Exapilot Exaplog Exapro plus
Step : Upgrade to the latest HIS
ABC
Networking an existing system
This step allows you to migrate to a networked production control system while using an existing system's facilities and resources. You can migrate to the latest model-the CS 3000 R3, which provides a balanced mixture of open-standard features and robustness-while maintaining the functionality, high reliability, and ease of use of the CENTUM Series.
CPU CPU
CFCD2
CPU
CPU
Benefits
Enhancement of the most important network functions at a minimal investment. Ability to seamlessly integrate ERP, MES, AOA, and APC.
I/O SC
I/O SC
I/O SC
I/O SC
HIS: Human interface station FCS: Field control station ABC:Bus converter SC: Signal conditioners
Step
2: Upgrade FCS CPU
Enabling networked control functions
This step enables networked control functions. In addition to increasing CPU power and application capacity, this step allows you to introduce the latest networked control functions.
Benefits
Significant increase in capacity for continuous control and sequence control applications. Integration of multiple control stations in a single new station. Existing I/O cards and cabinets can still be used, so costs are low and lead time is reduced.
Internet/Intranet
CS 3000 R3
Ethernet
COPSV
HIS
HIS
ABC
CFCD2
CPU
CPU
CPU
CPU
New station following CPU replacement
I/O SC
I/O SC
I/O SC
I/O SC
No need to change field wiring
Step
3: Upgrade FCS I/O
Enabling all new CS 3000 R3 functions
This step seamlessly upgrades the existing I/O using a new Fieldnetwork I/O (FIO) which is function-interchangeable, interface-interchangeable, and nest structure-interchangeable. Support for future versions of Fieldbus can also be provided. Benefits
A remote node can be installed near field equipment. Better noise resistance (noise immunity EN50082-2; CE mark qualified). Better environmental durability (wider range of operating temperatures; resistant to corrosive gases in G3 environments). Full support for FOUNDATION Fieldbus.
Internet/Intranet
CS 3000 R3
Ethernet
HIS
HIS
CPU
CPU
CPU
CPU
FIO SC
FIO SC
Upgrade to latest I/O
FIO SC
FIO SC
FIO SC
I/Os can be added in conjunction with production line modifications.
No need to change field wiring
Field Network
*1: CENTUM, Exabif, Exapilot, Exaplog, Exapro plus, and Exaquantum are registered trademarks of Yokogawa Electric Corporation. *2: Registered trademark applications have been submitted for Exacoast, Exarqe, and Exasmoc. *3: Ethernet is a registered trademark of XEROX Corporation. *4: FOUNDATION Fieldbus and the Fieldbus Association logo mark are registered trademarks of the Fieldbus Association. *5: TriFellows is a registered trademark of Yokogawa System Engineering Corporation. Other company names and product names in this document are trademarks or registered trademarks of their respective companies.
YOKOGAWA ELECTRIC CORPORATION World Headquarters 9-32, Nakacho 2-chome, Musashino-shi, Tokyo 180-8750, JAPAN Tel.: 81-422-52-5634 Fax: 81-422-52-9802 Internet Homepage: http://www.yokogawa.com/dcs/ Subject to change without notice.
All Rights Reserved, Copyright 1998, Yokogawa Electric Corporation. Printed on recycled paper. [Ed : 03 /b] Printed in Japan. 106(YG)
