Yokogawa Electric Corporation (headquarters: 2-9-32 Nakacho, Musashino-shi, Tokyo 180-8750, Japan; president: Eiji Mikawa; capital: 32.306 billion yen) has developed an integrated production control system for large-scale process called CENTUM CS 3000, which was released, both domestically and globally, on May 28. The CENTUM CS 3000 is developed as the core system for realizing Yokogawa's new business concept, "Enterprise Technology Solutions." It has not only inherited the same high reliability and superior control functions and engineering environment featured in current distributed control systems, but also has the most advanced operating environment and open architecture offered in general-purpose computers.
Ever-changing Production Control System Market
The rapid advancement in network and information technology is now making it possible to integrate the various, independent information systems scattered throughout a company. As a result, the specifications requested by users of plant operation systems have also changed. Plant operators are no longer solely concerned with the purchase of a production control system and its associated engineering services. They are now asking about comprehensive systems that enable them to operate their plants and facilities optimally from an enterprise management viewpoint.
To meet current user needs, Yokogawa aims to supply not only the latest in field instruments and control systems, but also complete solutions to user needs. This involves the development of state-of-the-art process control technology, such as advanced controls, operation support systems, and simulations, and also requires integration of a broad range of systems spanning manufacturing execution and enterprise resource planning (ERP).
This "Enterprise Technology Solutions" concept (abbreviated ETS) represents Yokogawa's approach to the systems business. In September last year, Yokogawa released another key component for this approach, the CENTUM CS 1000 production control system for small- and medium-scale process. This time, Yokogawa targets large-scale applications, presenting an integrated production control system with leading-edge technology, the CENTUM CS 3000.
Features of CENTUM CS 3000 Integrated Production Control System
Reliability and versatile control functions are considered paramount when it comes to distributed control systems. The CENTUM CS 3000 inherits the high reliability and superior control functions of the world-wide acclaimed CENTUM CS system. In addition, the CENTUM CS 3000 achieves the latest in information and network technologies by using a Windows NT-based personal computer as the platform for operation, monitoring, and system configuration. The system scale, and redundant, architecture of the CENTUM CS are inherited and open architecture and engineering functions such as the virtual test function featured in the CENTUM CS 1000 are added. These advancements enable the CENTUM CS 3000 to meet the requirements of large-scale systems, and offer enhanced functions including integration of a manufacturing execution system; concurrent engineering over a network; a container function; and compatibility with existing systems (for easy addition to or replacement of existing systems).
System Configuration
The CENTUM CS 3000 integrated production control system consists of a human interface station (HIS), which is used for operation, monitoring, and engineering; and a field control station (FCS) that is connected to field sensors and control elements and performs control. A general PC/AT-compatible computer can be used for an HIS. The HIS runs under the Windows NT operating system, under which both the operation and monitoring software and engineering software developed by Yokogawa is designed to run. To cater for differing needs, a UNIX-based HIS is also offered - UNIX being the operating system of the current CENTUM CS.
These stations are connected on the Vnet system bus whose high reliability is field-proven in CENTUM CS systems. Although Windows NT-based distributed control systems are nothing new, the major difference between other venders' systems and Yokogawa's is that the Yokogawa-original operation and monitoring software is optimum for distributed control systems.
Main Features
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Open System Architecture for Engineering and Operating Environments
Windows NT is used as the operating system, and Microsoft DDE, a standard function for open data exchange, and OLE for process control (OPC), which is promoted by the OPC Council, are both supported. This means that the user can simultaneously operate a control window and another application window such as Excel, exchange data, and use the container function to paste commercially-available graphics (e.g., valve and meter symbols) onto an operation and monitoring window. The user can make use of the most advanced, open network environment to carry out system configuration, engineering, and operations.
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Integratation of a Manufacturing Execution System (MES)
An application server can be connected in parallel to HISs as the platform for plant operation and management-level systems, such as an MES and plant information management system (PIMS). This allows the plant operation and management-level systems to be integrated into the CENTUM CS 3000 system configuration. For systems at the ERP level, an interface for the SAP R/3 ERP package is prepared to allow hot linking with the ERP and enable system integration.
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Complete Functions for Efficient Engineering
The system has a virtual test function, which allows the user to configure virtual field control stations (FCSs) on an HIS and perform testing and debugging of application software without actual FCS hardware. Since the user need not wait until an actual FCS is prepared, the engineering lead time is greatly shortened. Furthermore, by installing this function on a notebook computer, the user can perform engineering and testing anywhere. This virtual test function is original to Yokogawa; first realized for the CENTUM CS 1000.
Concurrent engineering by multiple persons over the network is also made possible. In the past, when multiple persons carried out engineering on multiple platforms of the same project, it was time-consuming and troublesome to reflect all of the engineering results into one master database.
The CENTUM CS 3000 allows engineering databases to be shared by multiple persons for concurrent engineering.
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These features vastly improve the efficiency of engineering, which constitutes a large part of the configuration work for a distributed system.
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Full-scale Batch Package Conforming to ISA S88
The CS Batch 3000 package integrates operation, management, and engineering functions for batch processes, and complies with the ISA S88 standard. All of Yokogawa's past efforts to develop batch process packages for various distributed control systems, have now been perfected and released as the CS 3000 Batch. This package provides clear and easy operations and an efficient engineering environment for complex batch process controls that produce small quantities of many different products.
- Compatibility with Existing System
The CENTUM CS 3000 can co-exist with an existing distributed system such as CENTUM CS, CENTUM-XL, and CENTUM-V, or be used to replace them. A CENTUM CS system can be replaced with a CENTUM CS 3000 system by simply upgrading the software, and a CENTUM-XL or CENTUM-V system can be replaced by replacing the CPUs and software of field control stations.
The user can use the CENTUM CS 3000 system with the existing instrumentation as is, without requiring any construction work for replacement. Operation and monitoring can also be integrated and the existing systems replaced gradually with the most up-to-date systems.
Major Target Markets
Plant operation control in various industrial sectors including: petrol refinery, petrochemical, fine chemical, food, pharmaceutical, iron and steel, gas, paper and pulp, waterworks and sewage treatment. The range of processes is also broad, from regulatory processes to batch processes.
Yokogawa's "Systems Business" Business Strategy
Yokogawa has been actively trying to increase its technical capability for various systems related to instrumentation and control in order to deliver the optimum solutions proposed by the ETS concept. Under such a strategy, Yokogawa:
- established an alliance contract with Aspentech Corporation, which have technologies for multi-variable predictive control, process databases, and production management support functions;
- obtained the approval of an implementation partner of R/3 ERP system from SAP S.A. and developed an interface package for R/3;
- merged GTI-IA, a company renowned for their advanced process safeguarding systems;
- established a joint venture with Mitsui Toatsu Chemical Corporation, which has advanced modeling technology;
- merged Marex Corporation, which has process database technology; and
- 100% take-over of Tonen System Plaza Corporation, an affiliated company of Tonen Corporation.
The brand new CENTUM CS 3000 integrated production control system is the next key product for the realization of ETS strategy after the CENTUM CS 1000 production control system. The CENTUM CS 3000 covers large-scale processes, and forms a product focus in Yokogawa's systems business. It is manufactured at Yokogawa headquarters in Japan and the Singapore-based subsidiary, Yokogawa Electric Asia Pte. Ltd. Yokogawa actively promotes and distributes the CENTUM CS 3000 through an international network of sales offices and sales representatives in an effort to maintain its position as the top supplier in Japan as well as expand its share in the overseas market.
Trademarks:
- Windows NT and Excel are registered trademarks of Microsoft Corporation, USA
- R/3 is a registered trademark of SAP Aktiengesellshaft, Germany
If you have any questions or would like to request product documentation, please contact:
Product Marketing Department
Control Systems Center
Systems Division
Yokogawa Electric Corporation
2-9-32 Nakacho, Musashino-shi, Tokyo 180-8750, Japan
Phone: +81-422-52-5634 Fax: +81-422-52-4499
