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 (VIEWTREN.WPG)

– 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 (VIEWTREN.WPG)

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
(VIEWTREN.WPG)

• 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