DCS TRAINING YOKOGAWA

Every Function Block, I/O and switch gets a security level.. for a Controller PID: In the Function Block Builder, all the ranges for input and output, alarm settings etc.. SET Setting in

1 INTRODUCTION 4

2 HARDWARE 5

2.1 OVERVIEW 5

2.2 SYSTEM STATUS 6

2.3 FIELD CONTROL STATION STATUS 7

3 SYSTEM VIEW 8

3.1 OVERVIEW 8

3.1.1 COMMON 9

Security 9

Engineering Units 9

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

4 FUNCTION BLOCK KNOW-HOW 23

4.1 COMMON FUNCTION 23

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

S

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

4.2.10Calculation: General Purpose Calculation (CALCU) 31

4.2.11Switch Instrument Block (SIO) 32

4.2.12Relations (RL) 33

4.2.13Timer Block (TM) 33

4.2.14Logic Control (LC64) 34

4.2.15Sequences (_SFCSW) 35

4.2.16Sequence Table (ST16) 36

but simplified to the purpose of Uhde Inventa-Fischer (UIF)

Basic operating know-how of the Yokogawa CS3000 System is expected

Instrument

The status of the system can be checked by clicking on system alarm

Then click on the 4th button from the left side

The window "System Status Overview" shows, which stations are connected and also the status of the V-Net bus 1 and 2

2.3 FIELD CONTROL STATION STATUS

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"

There are three user levels:

OFFUSER: has only limited rights

ONUSER has the necessary rights, used as a shift leader

ENGUSER 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:

3 OFFUSER can change it

4 OFFUSER cannot change it

Engineering Units

All the units used in the whole project must be defined in the file EngUnit

Switch Position Label

All the button names used in faceplates are defined in the file InstLabel

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

3.2 THE FIELD CONTROL STATION (FCS)

Each Field Control Station (FCS) contains of the I/O-Definitions, the logics (Function Blocks) and the definitions of alarms and software switches

In the IOM all analog, digital and software (i.e PROFIBUS) in- and outputs are

defined the modules (1AA841-H to 8ADV151-P in the example above) must be in the exact order as mounted on the corresponding node in the FCS-rack

In the module, the I/O's are defined as in the example below:

Switches are digital variables They are used i.e for interlock logics The first 200

switches are reserved for the system For every switch, the corresponding faceplate must be defined (Switch Position Label and buttons) as well as the security level and the Upper Window

In the file AN0101 (Annunciator Builder), all the alarms must be defined as in the

example below The other messages are not important

In the Control Drawing, the signal flow between the Function Blocks must be defined

An example of a Control Drawing looks as follows:

In the upper part two motors (PM-1105A/B) with run signal (YS-1105A/B) and

command signal (MCS-1105A/B) In the lower part a cascade of two controllers with input (%%TT-1104/1105) and output (%%TV-1104)

for a Controller (PID):

In the Function Block Builder, all the ranges for input and output, alarm settings etc are defined

There are special Function Blocks for sequences and for logics See chapter

4 Function Block Know-how for further details

3.2.7 DISPLAY

These are not the main graphics! Here, it is possible to add some graphics to the

Control Drawings which are already defined in the Control Drawing Builder This

feature is not used by UIF

3.3 THE HUMAN INTERFACE STATION (HIS)

All the definitions are done in the HIS0164, which is the engineering station The other HIS (HIS0162 and HIS0163) contain only shortcuts to the engineering station

HIS0164

3.3.1 CONFIGURATION

In the configuration folder, several HIS specific definitions are done The file FuncKey

is used to define the function of the external Function Keyboard In the Scheduler, the time to print the reports is defined

SCHEDULER

Function Specification:

F Function -nName of File -p print -f generate file

In the CONFIGURATION folder several trend files can be defined (TR0001 etc.)

By opening the properties, sampling period and store time can be entered

Trend Format should be "Continous and Rotary Type" Sampling period should be 1 min except for critical and fast changing trends as motor current where a sampling

period of 10 sec is appropriate Be aware, that it is not possible to mix trends with

different sampling period in one trend window To store one trendblock for one year (365 days), a harddisk space of 2.2 GB is necessary It is recommended to store the long-term files from time to time to external mediums Every file is ~10MB and stores one trendblock for one week at a sample period of one minute

In this folder, all the graphical windows are stored

There is a strict hierarchical order So, every window has its upper window In the

same way, every function block and every digital variable (switch, annunciator or I/O) has its upper window

The Graphic Builder is easy to use as any drawing program

Attention: Do not mark multiple objects to set a binding Bindings may be lost! If

multiple objects have the same binding, make a group before changing the binding After changing the binding press "ENTER" By clicking only "OK", the binding may be lost as well

Displays for trends cannot be changed

4 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

SET Setting input terminal

OUT Output terminal

Internal Values:

PV Process variable

SV Setpoint value

MV Manipulated output value

CSV Cascade setpoint value

RV Calculated input value

CPV Calculated output value

DV Control deviation value

Alarm Settings:

HH High-high alarm limit

LL Low-low alarm limit

PH High alarm limit

PL Low alarm limit

VL Velocity alarm limit

DL Deviation alarm limit

Limit Settings:

SVH Setpoint value high limit

SVL Setpoint value low limit

MH Manipulated output value high limit

ML Manipulated output value low limit

4.1.3 FUNCTION BLOCK MODES

Common modes of Function Blocks are:

MAN Manual Mode The output of the block is changeable

AUT Automatic Mode The setpoint value is changeable, output is not

CAS Cascade Mode The block gets the setpoint from another block

4.2 FUNCTION BLOCK DETAILS

4.2.1 Analog Indication/Setting Blocks: (PVI / MLD / MLD-PVI)

PVI only left part with input processing

MLD only right part with output processing

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 Dead Band: MV is stable inside DB

GW Gap Width: Nonlinear gain

Interlock Function:

In case of an interlock, the output of the controller must change to a specific value,

mostly 0 = close There are three possibilities In the logic, the PSW of a PID-Block can

be changed from 0 to 1,2 or 3

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

is adjusted This block is often used for the conversion from RPM to %

4.2.4 Split Range: (SPLIT)

Used, if a controller has to valves Block must be in CAS mode to work

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 = 4 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)

Values set in the Tuning Panel:

DMVP Upward velocity limit value

DMVM Downward velocity limit value

TU Velocity limit time unit: Select 0=sec or 1=min

4.2.7 Batch Set Block for Dosing (BSETU-2/3)

BSETU-2 is for flow measurement, BSETU-3 for weight measurement

One Batch Cycle has this zones:

Attention: ILST must be 0! Otherwise, if ML is 0 as well, the dosing will not start

Command Switch SW (in the sequence or Tuning Panel):

2 Restart

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 1 and BS1 and BIAS are 0!

4.2.9 Calculation: Multiplication (MUL)

The calculation is: CPV = GAIN * (RV * ((GN1 * RV1) + BS1) + BIAS

In a simple multiplication, make sure GN1 and GAIN are 1 and BS1 and BIAS are 0!

4.2.10 Calculation: General Purpose Calculation (CALCU)

The CALCU block has 8 inputs and 4 outputs Further, there are 8 variables

(P01-P08)

A CALCU block allows text based calculations It is used for formulas and for motor logics

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

4.2.11 Switch Instrument Block (SIO)

There are different types of SIO blocks:

SIO-11 1 input, 1 output

SIO-21 2 input, 1 output

SO-2 no input, 2 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 = 0 Valve closed / Motor stopped

PV = 2 Valve open / Motor running

PV = 1 Valve with 2 feedback signals: Valve is somewhere in between

MV = 0 Output close / stop

MV = 2 Output open / run

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)

The Function Block Detail Builder:

The block is referenced in a LC64 block like this:

4.2.13 Timer Block (TM)

Timers are often used together with sequences In a _SFCSW block, the TM block is referenced like this:

wait until (TIMER.BSTS == "CTUP") Wait until timer has expired

In the Function Block Detail Builder the timer property may be changed from minute to seconds Then TIMER.PH = 5 would be 5 seconds

In a LC64 block, only digital signals can be processed

The reference of an input is:

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

There are many logic elements like

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

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

There are sub-sequences like ACTVALVE and ACTMOTOR They are stored in the folder FCS0101/SEQ_LIBRARY/SEBOL_USER_FUNCTIONS

Seldom used, but then very useful…

In the upper part, there are the conditions (Cxx); in the lower part the actions (Axx)