CENTUM CS 3000 Integrated Production Control System

CENTUM CS 3000 Integrated Production Control System 

System basic information

Key content of the project

Product Name: CENTUM CS 3000 Integrated Production Control System

Developer Yokogawa Electric Corporation

Applicable to over 10 industries including petroleum refining, petrochemicals, chemicals, pharmaceuticals, food and beverage

Core positioning for large-scale process control applications, achieving monitoring, control, and optimization of production processes

Related safety system ProSafe RS (Safety Instrumented System, compliant with IEC 61508 SIL3 standard)

Core advantages of the system

Open and compatible enterprise level environment

Support linkage with ERP, MES and other systems, and achieve data sharing through OPC interface

Compatible with Windows 2000/XP system, can run general office software (such as Excel)

Flexible and scalable hardware configuration

Support 100000 monitoring tags (expandable to 1000000)

Connect up to 256 sites (16 domains, with a maximum of 64 sites per domain)

Control station type: FIO/RIO standard type, compact type, suitable for different factory sizes

High reliability design

Dual redundancy configuration: FCS processor, power supply, bus, I/O module and other key components are redundant

Fault switching: active/standby mode with no interruption, I/O module crashes within 4 seconds in case of CPU failure

Whole life cycle cost optimization

Compatible with existing Yokogawa systems (CENTUM CS, CENTUM-XL, etc.), supporting hardware reuse

Remote I/O deployment reduces wiring costs, PRM tool optimizes equipment maintenance efficiency

System hardware composition

(1) Core equipment

Human Machine Interface Station (HIS): divided into console type (closed/open display style) and desktop type, supporting multi display function

On site Control Station (FCS):

FCS for FIO (KFCS, KFCS2, etc.): paired with Fieldnetwork I/O modules

FCS for RIO (LFCS, LFCS2, etc.): paired with Remote I/O modules

Compact FCS (PFC  - H/- S/- E, etc.): close range deployment, adapted to subsystem communication

Other key equipment:

Engineering PC (ENG): System Generation and Maintenance Management

Bus Converter (BCV): Connecting different domains or old systems

Communication Gateway (CGW): Interconnection between V net and Ethernet bus

(2) Network Architecture

V net: 10Mbps real-time control bus, supporting dual redundancy, with a maximum transmission distance of up to 20km (including repeaters)

Ethernet: connects HIS, ENG, and monitoring systems for data file transfer and HIS data synchronization

Fieldbus: Supports Foundation Fieldbus, replacing traditional 4-20mA analog interfaces

Core functional modules

(1) Operation and monitoring functions

Display modes: full screen mode, multi window mode (up to 5 operation monitoring windows can be displayed simultaneously)

Core functions: Window hierarchy management, navigation windows, dynamic window groups, alarm processing (priority level 5), trend analysis (supporting 8 data overlay displays)

Support functions: multi monitor, ITV camera access, voice message notification, web monitoring

(2) Control function

Adjustment control: Standard functional blocks such as PID and proportional control, supporting continuous/batch process control

Sequential control: sequence table, logic diagram, SFC, SEBOL language programming

Advanced Control: APCS (Advanced Process Control Station), supporting long cycle complex calculations (scan cycle 4/8/16 seconds)

Batch management: CS Batch 3000 package, compliant with ISA S88.01 standard, supports multi product formula management

(3) Engineering Function

Core features: concurrent engineering (multi person collaboration), virtual testing (hardware free), engineering data reuse

Tool support: system view (tree database), module builders, self document generation function

Maintenance functions: online maintenance (uninterrupted control), remote maintenance (via public network)

(4) Safety feature (ProSafe RS)

Safety protection: emergency parking, fire and gas protection, interlocking control

Compliance certification: T Ü V Rheinland certification, compliant with IEC 61508 SIL3 standard

Integration feature: Shared operating environment with CENTUM CS 3000, supporting unified monitoring

Key software packages and extended features

Software Package Name Core Features

Exapilot standardized operating procedures (SOP) to improve efficiency in non steady state operations

Exaopc OPC interface service, realizing data exchange between DCS and MES/ERP

PRM (Plant Resource Manager) equipment maintenance management, supporting preventive maintenance and remote parameter reading

FDA 21 CFR Part 11 compatibility package for data security and audit tracking, meeting electronic record/signature compliance requirements

SEM (Sequence of Events Manager) 1ms level event recording and analysis, supporting traceability of trip causes

LTTH (Long term Trend Historian) stores 1-year trend data and event messages, supporting trend comparison analysis