DCS TRAINING YOKOGAWA

DCS TRAINING _ (Distributed Control System) Form: FO276102/1/08.04/WORD Form: FO276100/0/02.99/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc YOKOGAWA CS 3000 Issue 24.08.2006 Ausgabe Issue WUB DCS - TRAINING 08.06 - /- Datum Date WUB Visum Visa / 36 Content: INTRODUCTION HARDWARE 2.1 OVERVIEW 2.2 SYSTEM STATUS 2.3 FIELD CONTROL STATION STATUS SYSTEM VIEW 3.1 OVERVIEW 3.1.1 COMMON Security Engineering Units Switch Position Label 10 Operation Marks 10 3.1.2 BATCH 10 3.2 THE FIELD CONTROL STATION (FCS) 11 3.2.1 CONFIGURATION 11 3.2.2 SEQ_LIBRARY 11 3.2.3 IOM 12 3.2.4 SWITCH 13 3.2.5 MESSAGE 14 3.2.6 FUNCTION BLOCK 15 3.2.7 DISPLAY 16 3.3 THE HUMAN INTERFACE STATION (HIS) 17 3.3.1 CONFIGURATION 17 SCHEDULER 17 TREND DEFINITION 18 3.3.2 WINDOW 20 FUNCTION BLOCK KNOW-HOW 23 4.1 COMMON FUNCTION 23 Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc 4.1.1 COMMON VALUES 24 4.1.3 FUNCTION BLOCK MODES 25 4.2 FUNCTION BLOCK DETAILS 25 4.2.1 Analog Indication/Setting Blocks: (PVI / MLD / MLD-PVI) 25 4.2.2 Controllers: (PID) 26 4.2.3 Range Adjustment: (MLD-SW) 27 WUB DCS - TRAINING 08.06 - /- / 36 4.2.4 Split Range: (SPLIT) 27 4.2.5 Signal Selectors: (AS-H/M/L and SS-H/M/L, SS-DUAL) 28 4.2.6 Ramp Generator (VELLIM) 28 4.2.7 Batch Set Block for Dosing (BSETU-2/3) 29 4.2.8 Calculation: Addition (ADD) 30 4.2.9 Calculation: Multiplication (MUL) 30 4.2.10 Calculation: General Purpose Calculation (CALCU) 31 4.2.11 Switch Instrument Block (SIO) 32 4.2.12 Relations (RL) 33 4.2.13 Timer Block (TM) 33 4.2.14 Logic Control (LC64) 34 4.2.15 Sequences (_SFCSW) 35 Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc 4.2.16 Sequence Table (ST16) 36 WUB DCS - TRAINING 08.06 - /- / 36 INTRODUCTION This training is an introduction to the Hardware, System View and Function Blocks for System Engineers Most parts are taken from the Yokogawa CS3000 Manual, but simplified to the purpose of Uhde Inventa-Fischer (UIF) Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc Basic operating know-how of the Yokogawa CS3000 System is expected WUB DCS - TRAINING 08.06 - /- / 36 HARDWARE 2.1 OVERVIEW Ethernet HIS HIS HIS HIS V-Net Bus Node with FCS and I/O Modules Mulicable Marshalling Board Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc Barrier or Switch Amp Instrument WUB DCS - TRAINING 08.06 - /- / 36 2.2 SYSTEM STATUS The status of the system can be checked by clicking on system alarm Then click on the 4th button from the left side Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc The window "System Status Overview" shows, which stations are connected and also the status of the V-Net bus and WUB DCS - TRAINING 08.06 - /- / 36 2.3 FIELD CONTROL STATION STATUS Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc Here, the status of the FCS and to nodes can be checked There are two FCS; one is in control, the other is stand-by (Redundancy) The load of the FCS can be checked at CPU Idle Time: The displayed value is the amount of seconds out of 60 seconds, where the CPU is idle By clicking on an node, the different I/O-Modules can be checked After installing a new I/O-Module, the Module needs to be downloaded by pressing "IOM Load" WUB DCS - TRAINING 08.06 - /- / 36 SYSTEM VIEW The System View is the programming tool of the Yokogawa CS3000 It can be started directly from the Yokogawa CS3000 menu bar 3.1 OVERVIEW Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc The project tree on the left contains the folders COMMON, BATCH, the Field Control Stations (FCS0101 - in this project only one) and the Human Interface Stations (HIS0162 - HIS0164) The HIS0164 is the Engineering Station WUB DCS - TRAINING 08.06 - /- / 36 3.1.1 COMMON In the Common folder, the basic settings of the project are done Security There are three user levels: OFFUSER: ONUSER ENGUSER has only limited rights has the necessary rights, used as a shift leader has full rights, allowed to open System View In the file UserSec, other users can be defined, but they always belong to one of the groups above Every Function Block, I/O and switch gets a security level This defines, who is allowed to change it UIF uses the following levels: OFFUSER can change it OFFUSER cannot change it Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc Engineering Units All the units used in the whole project must be defined in the file EngUnit WUB DCS - TRAINING 08.06 - /- / 36 Switch Position Label All the button names used in faceplates are defined in the file InstLabel Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc Operation Marks This is a security tool With Operation Marks, it is possible to make a Function Block unchangeable This is used for interlocks, sequences and when a block is in local The faceplate of the Function Block gets a frame in the defined color of the operation mark 3.1.2 BATCH This folder is only in a batch plant of interest In a continuous plant it has no function WUB DCS - TRAINING 08.06 - /- 10 / 36 Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc Every function block has its specific tuning panel They cannot be changed as well See an example for a PID-Controller: WUB DCS - TRAINING 08.06 - /- 22 / 36 FUNCTION BLOCK KNOW-HOW As seen in chapter 3.2.6 Function Blocks, the whole programming is done in Function Blocks The figures in this chapter are taken from the Yokogawa Manual, but simplified to the purpose of UIF 4.1 COMMON FUNCTION Most Function Blocks have similar inputs and outputs See an example of a PIDController: Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc Some Function Blocks have input/output processing, some have not An I/O tag can only be connected to a terminal connection (IN, OUT) It is not possible to connect both, the "IN" and the "PV" Between the Function Blocks, normally a terminal output (OUT) is connected to a internal input (PV) and an internal output (MV) is connected to a terminal input (IN) But: The terminal input "SET" needs a terminal output (OUT) as well! So, simply try to connect, if it does not work, try the other one… WUB DCS - TRAINING 08.06 - /- 23 / 36 4.1.1 COMMON VALUES These values are often used in Function Blocks The special values of each Function Block will be discussed later Terminal Connections: IN SET OUT Input terminal Setting input terminal Output terminal Internal Values: PV SV MV CSV RV CPV DV Process variable Setpoint value Manipulated output value Cascade setpoint value Calculated input value Calculated output value Control deviation value Alarm Settings: HH LL PH PL VL DL High-high alarm limit Low-low alarm limit High alarm limit Low alarm limit Velocity alarm limit Deviation alarm limit Limit Settings: Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc SVH SVL MH ML Setpoint value high limit Setpoint value low limit Manipulated output value high limit Manipulated output value low limit WUB DCS - TRAINING 08.06 - /- 24 / 36 4.1.3 FUNCTION BLOCK MODES Common modes of Function Blocks are: MAN AUT CAS Manual Mode Automatic Mode Cascade Mode The output of the block is changeable The setpoint value is changeable, output is not The block gets the setpoint from another block Special modes: MAN IMAN CAL 4.2 Block is unable to work because a following block is not in the right mode Calibration mode: Only for testing purpose The input is ignored, PV is changeable FUNCTION BLOCK DETAILS 4.2.1 Analog Indication/Setting Blocks: (PVI / MLD / MLD-PVI) Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc PVI only left part with input processing MLD only right part with output processing WUB DCS - TRAINING 08.06 - /- 25 / 36 4.2.2 Controllers: (PID) There are several possible control calculations Please refer to the Yokogawa Manual for further details Controller Variables: P Proportional Band (%): A "P" of 100 means no gain Less than 100: faster I Integral time (sec): A value between 10 (fast) and 200 (slow) is often used D Derivative time (sec): Used only very seldom DB GW Dead Band: MV is stable inside DB Gap Width: Nonlinear gain Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc Interlock Function: In case of an interlock, the output of the controller must change to a specific value, mostly = close There are three possibilities In the logic, the PSW of a PID-Block can be changed from to 1,2 or PSW= 1: The controller output MV changes to the lower limit ML PSW=2: The controller output MV changes to the upper limit MH PSW=3: The controller output MV changes to the value which is set in the Tuning Panel of the controller at PMV: Preset Manipulated Value In all three cases, the mode of the controller changes to MAN WUB DCS - TRAINING 08.06 - /- 26 / 36 4.2.3 Range Adjustment: (MLD-SW) The MLD-SW is a very useful block It can either be in MAN mode, where the MV is changeable or in AUT mode, where the value from the SET input is taken and its range is adjusted This block is often used for the conversion from RPM to % 4.2.4 Split Range: (SPLIT) Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc Used, if a controller has to valves Block must be in CAS mode to work WUB DCS - TRAINING 08.06 - /- 27 / 36 4.2.5 Signal Selectors: (AS-H/M/L and SS-H/M/L, SS-DUAL) With the switch SW, the wanted input is selected When SW = then the automatic signal selection is active: The AS-H block selects to highest, the AS-M block the middle and the AS-L block the lowest input The SS-H/M/L blocks are basically the same, but there is no output processing The SS-DUAL has only two inputs In automatic mode (SW = 3), the better input is selected Used in redundant configuration 4.2.6 Ramp Generator (VELLIM) Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc Values set in the Tuning Panel: DMVP DMVM TU Upward velocity limit value Downward velocity limit value Velocity limit time unit: Select 0=sec or 1=min WUB DCS - TRAINING 08.06 - /- 28 / 36 4.2.7 Batch Set Block for Dosing (BSETU-2/3) BSETU-2 is for flow measurement, BSETU-3 for weight measurement Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc One Batch Cycle has this zones: Attention: ILST must be 0! Otherwise, if ML is as well, the dosing will not start Command Switch SW (in the sequence or Tuning Panel): Normal Abort Start Emergency stop Restart WUB DCS - TRAINING 08.06 - /- 29 / 36 4.2.8 Calculation: Addition (ADD) The calculation is: CPV = GAIN * (RV + ((GN1 * RV1) + BS1) + BIAS In a simple addition, make sure GN1 and GAIN are and BS1 and BIAS are 0! 4.2.9 Calculation: Multiplication (MUL) Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc The calculation is: CPV = GAIN * (RV * ((GN1 * RV1) + BS1) + BIAS In a simple multiplication, make sure GN1 and GAIN are and BS1 and BIAS are 0! WUB DCS - TRAINING 08.06 - /- 30 / 36 4.2.10 Calculation: General Purpose Calculation (CALCU) The CALCU block has inputs and outputs Further, there are variables (P01P08) A CALCU block allows text based calculations It is used for formulas and for motor logics Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc Tags can also be referenced without a connection to a input terminal with an alias: Example for an analog value: alias X1 FIC-1103.PV Digital values can be referenced directly in the code by using curly brackets: if ({YS-1230-1.PV.ON} and {YS-1230-2.PV.OFF}) then P01 = P03 end WUB DCS - TRAINING 08.06 - /- 31 / 36 4.2.11 Switch Instrument Block (SIO) There are different types of SIO blocks: SIO-11 input, output SIO-21 input, output SO-2 no input, output The SIO block is used for motors and valves The feedback from the field (YS, NVL) is connected to the IN terminal, the setting signal (MCS, NVS) is connected to the OUT terminal When a valve has to feedback signal (NVH and NVL) then a SIO-21 is used Only the NVH is connected to the IN terminal But the NVL must be the following input in the IOM Builder For two outputs it's the same with a SIO-12 block PV = PV = PV = Valve closed / Motor stopped Valve open / Motor running Valve with feedback signals: Valve is somewhere in between MV = MV = Output close / stop Output open / run Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc Special Functions: MTM Answerback check masking time (sec): If, after a command change, the feedback does not change as well in the MTM time, the Function Block generates an alarm (ANS+, Answerback alarm) TSW Tracking switch: If a motor is in local, the SIO block is in tracking mode That means, the output follows the input The TSW is changed in a LC64 Block i.e.: AM-1160.TSW.L (See LC64 block for details) WUB DCS - TRAINING 08.06 - /- 32 / 36 4.2.12 Relations (RL) Sometimes, a limit detection of an analog signal is needed without alarm Then, a RL block is used The Function Block Detail Builder: The block is referenced in a LC64 block like this: LI-1232-RL.X03.GT LI-1232-RL X03 GT RL block name X and Line number see table below 4.2.13 Timer Block (TM) Timers are often used together with sequences In a _SFCSW block, the TM block is referenced like this: TIMER.PH = TIMER.OP = TMSTAT wait until (TIMER.BSTS == "CTUP") TIMER.OP = TMSTOP Set the time to Start the timer Wait until timer has expired Stop the timer Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc In the Function Block Detail Builder the timer property may be changed from minute to seconds Then TIMER.PH = would be seconds WUB DCS - TRAINING 08.06 - /- 33 / 36 4.2.14 Logic Control (LC64) In a LC64 block, only digital signals can be processed The reference of an input is: TAGNAME.VARIABLE.VALUE HSZI-1602 PV OFF Tagname Variable Value OFF is equal to 0, ON is equal to If an OFF status of a variable is referenced, the logic status of the line is ON when the logic status of the tag variable is OFF In the Tuning Panel of the LC64 block a green line has to logic status OFF, a red line means ON Referencing an output: TAGNAME.VARIABLE.VALUE PM-1602 TSW L Tagname Variable Value (latched) An output may be latched (L) or set (0,1, sometimes 2,3) A latched output has the same logic status as the line A set output (VALUE = 1,2,3; depending on the Function Block) is only set when the logic status of the line is ON Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc There are many logic elements like - AND / OR / NOT - FLIP-FLOPS - ON/OFF DELAYS - ONE SHOT ON/OFF -… Attention: Do not use Reset-Dominant Flip-Flops and Flip-Flops with two outputs After downloading a drawing, the (both) output will be OFF until the first status change of an input of the Flip-Flop WUB DCS - TRAINING 08.06 - /- 34 / 36 4.2.15 Sequences (_SFCSW) Sequences are used for Additive Preparations and the Vacuum Control One sequence has several steps The programming code is inside the steps It is a Yokogawa specific code, but very easy to learn The first step always is the Initialization step The steps are connected together through step conditions Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc There are sub-sequences like ACTVALVE and ACTMOTOR They are stored in the folder FCS0101/SEQ_LIBRARY/SEBOL_USER_FUNCTIONS WUB DCS - TRAINING 08.06 - /- 35 / 36 4.2.16 Sequence Table (ST16) Seldom used, but then very useful… Form: FO276102/1/08.04/WORD D:\Data\wub\Knowhow\Schulung\D C S T R A I N I N G.doc In the upper part, there are the conditions (Cxx); in the lower part the actions (Axx) WUB DCS - TRAINING 08.06 - /- 36 / 36 ... 36 WUB DCS - TRAINING 08.06 - /- / 36 INTRODUCTION This training is an introduction to the Hardware, System View and Function Blocks for System Engineers Most parts are taken from the Yokogawa. .. pressing "IOM Load" WUB DCS - TRAINING 08.06 - /- / 36 SYSTEM VIEW The System View is the programming tool of the Yokogawa CS3000 It can be started directly from the Yokogawa CS3000 menu bar... D:DatawubKnowhowSchulungD C S T R A I N I N G.doc Basic operating know-how of the Yokogawa CS3000 System is expected WUB DCS - TRAINING 08.06 - /- / 36 HARDWARE 2.1 OVERVIEW Ethernet HIS HIS HIS HIS V-Net