centum vp 1

Material Submittal

For

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DSC System

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Giza System

Y okogawa - Japan

Des System - Al Shabab Power Plant Rev.O

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Technical Proposal

Des System - AI Shabab Power Plant Rev.O

GIZR SYSTEMS

we InlJeQrate

OVERVIEW

Technical Proposal to:

East Delta Electricity Production Company

the document is for damitta project

GIZR SYSTEMS Industrial Applications B.U. 8 AI-Fawakeh St., Mohandessin, Giza 12311, Egypt Tel: +202 37604597 Fax: +202 37603247 http://www.gizasystems.com

herein is the property of Giza Systems, and may not be copied, used or in part except with the prior written permission of Giza Systems or,

under a contract with another party as expressly authorised under

Page 1 of 36

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Project: AlSHABAB • 1000 MW SIMPLE Customer: East Delta Electricity DOC No.: CYCLE GAS TURBINE UNITS Production Company IA-HT -C-AI-16-987 -10

Date: Client .REF: Tender No. Sheet: 23.12.2010 2of36 Document Description: Rev. No.: DCS TECHNICAL PROPOSAL OVERVIEW 0

TABLE OF CONTENTS

1 DCS SYSTEM DESCRIPTION (CENTUM VP) 4

1.1 Centum VP Benefits 5

1.1.1 System Architecture 5

1.1.2 Operation 5

1.1.3 Control 6

1.1.4 Engineering 7

1.1.5 Maintenance 9

) 1.2 Centum VP Major Components 9

1.2.1 Operator Interface, Human Interface Station - HIS 9

1.2.2 Engineering Work Station - ENG 13

1.2.3 Field Control Station - FCS 15

1.2.4 I/O Hardware - Field Network I/O (FlO) 17

1.2.5 Real Time Process Control Network - Vnet!IP 20

GIZR SYSTE/V\S -"~'._H· __ ··--···-vve integrate

Project: ALSHABAB - 1000 MW SIMPLE Customer: East Delta Electricity DOC No.: CYCLE GAS TURBINE UNITS Production Company IA-HT-C-AI-16-987-10

Date: Client .REF: Tender No. Sheet: 23.12.2010 30f36 Document Description: Rev. No.: DCS TECHNICAL PROPOSAL OVERVIEW 0

1.3 Centum VP Major Features 24

1.3.1 Expandability and Sizing 24

1.3.2 Total Integration 25

.. ~) 1.3.3 Plant Resource Manager (PRM) 27

1.3.4 HART Communication 29

2 PROPOSED SYSTEM FOR ALSHABAB POWER STATION 31

2.1 Project Specific Details 31

3 ASSUMPTIONS AND DESIGN CINSIDERATIONS 32

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GIZR SYSTEMS -"·-·-·--··-···-v..;e int2<;Jra t.e

Project: ALSHABAB· 1000 MW SIMPLE Customer: East Delta Electricity DOC No.: CYCLE GAS TURBINE UNITS Production Company IA-HT -C-AI-16-98? -10

Date: Client .REF: Tender No. Sheet: 23.12.2010 4of36

Document Description: Rev. No.: DCS TECHNICAL PROPOSAL OVERVIEW 0

1. Introduction

We thank you affording us this opportunity to submit this offer to your esteemed company.

Giza Systems a premier systems integrator for Y okogawa and solution provider, supplies the Middle East market with the latest Industrial Automation Solution.

We very well understand the importance of this tender, so we carefully selected the optimum solutions and products from our reputable partners

It is worthy to state that Y okogawa DeS system is now Installed successfully in FIVE power plants in Egypt which is Cairo West Power Plant unit 7&8 2x350MW, Nubaria III power plant 3x250MW, Atf Power Plant 3x250MW, Sidi Krir unit 5 power plant 3x250MW and Kafr Eldawar power plant unit 4, 110MW.

We are fully committed for project success in case of wining.

Sincerely yours,

Amr Sherif Power Sector Manager

Industrial Applications Business Unit Tel: +2023761-3751,3760-3247 Fax. : +2023760-3247 Mobile : +20102337671 E-Mail: [email protected]

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GIZR SYSTEMS --···----····· .. ·-we integrat.e

Project: ALSHABAB - 1000 MW SIMPLE Customer: East Delta Electricity DOC No.: CYCLE GAS TURBINE UNITS Production Company IA-HT -C-AI-16-987-10


1. DCS SYSTEM DESCRIPTION (CENTUM VP)

Yokogawa's Distributed Control System - CENTUM - was released in 1975 as the

first real Distributed Control System (DCS) in the world. Since then, it has been

continuously enhanced and upgraded, incorporating state-of-the-art technology

maintaining continuities and backward compatibility of the system. CENTUM VP as

a DCS is the key component in Yokogawa's concept "Enterprise Technology

Solutions". With this brief introduction of CENTUM VP, we hope to give you a

good understanding of the basic architecture without going into too detailed

information. The detailed technical information is provided in the enclosed technical

literature of our proposal. The CENTUM VP is a truly open system. It provides,

besides straightforward process control, excellent capabilities for:

D Integration of sub-systems such as PLC's, analysers, etc.

D Integrated Instrument Management with Plant Resource Manager (PRM)

D Integration over the control network (Vnet/IP) for ESD system (ProSafe-RS

case)

Altogether comprising in a total integrated production and facilities control system, and

operated via a single window. Due to the modularity and system architecture these

functions can all be implemented in a segregated way. By using these segregation

features the process control system can be implemented in such a way that the plant

segregation is fully reflected in the production control system architecture.

GIZR SYSTEMS

Project: ALSHABAB - 1000 MW SIMPLE Customer: East Delta Electricity DOC No.: CYCLE GAS TURBINE UNITS Production Company IA-HT -C-AI-16-987 -10

Date: Client .REF: Tender No. Sheet: 23.12.2010 6of36


1.1. CENTUM VP BENEFITS

1.1.1.System Architecture

The CENTUM VP System Architecture is straightforward. Highly flexible networks

can be designed using of commercially available network equipment like switching

HUB (Layer2 & Layer3). Although open and control communication data can be

transferred on the physically same V netlIP cables, these communications are logically

Jyy-" segregated so that they do not have an effect on each other. It will enable

integration of non- CENTUM components to the network. The System Architecture

allows up to 1,000,000 Tags and 512 Stations. Different Domains can be defined to

segregate functional disciplines within the user's organization. " ,\,,$ v)'

1.1.2 Operation

The Human Interface Station (HIS) is a powerful and easy-to-use Operator Station

with Operator Functions, Graphic Functions, Database Functions, and if required

Engineering Functions. It even provides User-defined Faceplates for an optimal Man

Machine Interface. The Windowing Operation allows the operator to place

frequently used displays (e.g. in a personal group) on the screen. Different Sources of

Information from the DCS (Graphic Panel, Trend Panel, etc.) as well as Information

from Supervisory Computers can be presented to the Operator on one Screen in a

uniform manner. The Report Package provides production reports by using spreadsheet

functions. Data Compression Techniques (e.g. Min., Max., Average etc.) are avalable.

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GIZR SYSTEMS ···-·-···-----··we inte9fate

Project: ALSHABAB -1000 MW SIMPLE Customer: East Delta Electricity DOC No.: CYCLE GAS TURBINE UNITS Production Company IA-HT -C-AI-16-987 -10

Date: Client .REF: Tender No. Sheet: 23.12.2010 7of36 Document Description: Rev. No.: DCS TECHNICAL PROPOSAL OVERVIEW 0

CABINETS

Figurel-1-2: Computer application integration in CENTUM VP operator interface (HIS)

1.1.3 Control

The Field Control Station (FCS) is a state of the art generation model that integrates

process and batch control, and computer functions. The Integrated Control Functions

include:

o Regulatory and Advanced Control Functions (Control Loops)

o Sequence Control Functions (Sequence Table, Logic Charts, Sequential

Function Chart)

o Subsystem Integration Functions

!] Field Instrument Management Functions

These control functions are executed at high speed by the high performance Reduced

Instruction Set CPU (RISC processor). These functions can be combined to optimize

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GIZR SYSTEMS ············_-_··_·_··-Vv'E!. inte~Jrar.e

Project: ALSHABAB -1000 MW SIMPLE Customer: East Delta Electricity DOC No.: CYCLE GAS TURBINE UNITS Production Company IA-HT-C-AI-16-987-10


continuous processes, batch processes and even discrete processes.

Redundancy

The Field Control Station is available in a "pair and spare" dual-redundant

configuration. For the first time in a DCS the Field Control Stations central processor

unit uses "pair and spare". Problems, which were not detected with fonner "duplex"

redundancy, are now easily detected.

Field Network I10JFIO)

The FlO range consists of direct nodes connected by Extended Serial Backboard (ESB)

bus and Remote nodes connected by Enhanced Remote (ER) bus. Both the busesvmay} '~.

~ dual redundant. ESB bus is used within the cabinets and, by using Optical Fiber

Cable; the ER bus can be used for longer distances. The physical media of ER bus is

compatible with 10Base2 coaxial Ethernet cable or 100BaseTX Unshielded Twist

Pair (UTP) Ethernet cable.

1.1.4 Engineering

CENTUM VP offers engineering solutions, which match the user's introduction

schedule and engineering procedures. Simplification of engineering work Since

CENTUM VP functions are configured using computer- aided engineering (CAE),

engineering work can be simplified. Function configuration techniques confonn to

Sequential Function Chart (SFC) standards. Reduction of engineering work time

CENTUM VP is capable of perfonning concurrent engineering. Thereby, two or more

engineers can share the engineering work. Also, the work time can be reduced by re

using previously developed application software that has been registered as parts of

models. Moreover, debugging can be improved by using off-line testing and simulation

in the test stage without having target hardware such as FCS available. Improvement

of engineering work enviromnent in CENTUM VP, the user can perfonn engineering

1

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Project: ALSHABAB -1000 MW SIMPLE Customer: East Delta Electricity DOC No.: CYCLE GAS TURBINE UNITS Production Company IA-HT-C-AI-16-987-10


work not only from the Engineering Workstations but also from personal computers in a

network, enabling concurrent engineering. This network can even be extended to

various locations all over the world by latest network technology. Integration of

user's engineering tools CENTUM VP is capable of connecting different engineering

tools from several users to minimize the human error for engineering as well as to

shorten the engineering work.

Figure 1-1-4: Typical CENTUM VP control application engineering window

1.1.5 Maintenance

The Maintenance Functions of CENTUM VP include monitoring, extensive self

diagnostics as well as on-line Maintenance Functions. The Maintenance Functions

automatically monitor the status of the system continuously. The status of each

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Date: Client .REF: Tender No. Sheet: 23.12.2010 10 of 36 Document Description: Rev. No.: DCS TECHNICAL PROPOSAL OVERVIEW 0

card in the stations is monitored and reported to the Operator in case of failure.

The Remote Maintenance Functions (Optional Service) link the user's Engineering

Workstation to the Maintenance Computer at a Yokogawa Regional Service. The

Maintenance Computer can diagnose the user's system and skilled Maintenance

Engineers can carry out a comprehensive diagnosis of the system status more quickly

and at lower cost compared to a site visit. Furthermore, by using Remote Maintenance

Service (RMS), the Maintenance Engineer can prepare himself if a site visit would be

required.

1.2 CENTUM VP MAJOR COMPONENTS

A brief description of CENTUM VP major components is stated within this section.

For more detailed technical information on the CENTUM VP components, please

refer to the technical literature enclosed to this proposal (In Part 3 in this proposal).

1.2.1 Operator Interface, Human Interface Station - HIS

The HIS is the operator interface of the system. It provides dedicated screens for

operation, monitoring, reporting, trending etc. It is directly connected to Vnet/IP,

ensuring real-time communication between the operator interface and plant behavior,

e.g. faceplates and alarms etc.

The HIS is also connected to Ethernet which interconnects all HIS allowing for client

server features on the operator interface level such as sharing of trend files, event data

bases etc.

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GIZR SYSTEMS ····_·_··_·······-······_···-···V'fe integratE'

Project: ALSHABAB ·1000 MW SIMPLE Customer: East Delta Electricity DOC No.: CYCLE GAS TURBINE UNITS Production Company IA-HT -C-AI-16-987-10

Date: Client .REF: Tender No. Sheet: 23.12.2010 11 of 36


man Interface Station

Figure 1-2-1a: Human Interface Station features

Depending on customer requirements several platforms can be used for HIS functions

viz. desktop or console type. The Yokogawa Console Type with dual/Quad stacked

LCD or CRT is state-of-the-art, ergonomically designed for ease of use and faster

) response to the operator. A general purpose PC is installed inside the console to

achieve maximum synergy with installed base, minimize spare parts and different

maintenance contracts. Standard mM compatible PC workstation can also be used as an

operator station.

Operation Capability

The HIS provides powerful operation environment by many capability and much

capacity. The HIS can be operated as stand-alone station without depending to a

central server etc. Each operator is able to do the daily operation independently by

using dedicated HIS. All HIS has a capability to communicate and exchange

necessary data flexibly, and realize mutual back-up configuration by any other HIS.

The following functional capability and capacity can be built up into each HIS station.

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o Number of Tags: 100,000 (Expandable up to 1,000,000)

o Graphic Window: 4,000 (400 data per window)

) o Trend Window: 800 (8 colored trends per window)

o Trend Point Window: 6,400

o Trend Data Save Period: No limitation

o Window Display Update Period: 1 second (as standard specification)

o Historical Massage Save Period: No limitation

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GIZR SYSTEMS

·-----·we integrate

Project: ALSHABAB - 1000 MW SIMPLE Customer: East Delta Electricitv DOC No.: CYCLE GAS TURBINE UNITS Production Company IA-HT -C-AI-16-987 -10


Terminal Service

The CENTUM VP HIS is able to provide a Tenninal Service (TS) by utilizing

Windows 2003 TS technology. The TS Server allows to access CENTUM VP

application simultaneously, maximum 8 clients. Operating and monitoring function can

be realized from remote PCs same as local HIS. The following drawing shows typical

system configuration of TS capability.

CENTUM CS3000 'I JI Server for Remote

~.~ Operation and Monitoring

VnetllP

Central control room

Figure 1-2-1c: System Configuration for Terminal Service

1.2.2 Engineering Work Station - ENG

fDH".i!I

An ENG is the engineering environment of the system and contains the master

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Date: Client .REF: Tender No. Sheet:

23.12.2010 14 of 36


database of the application. This system is based on a standard IBM compatible pc.

The engineering environment allows engineering in a fully graphical way. By using

"pick and click" and "drag and drop" standard Windows features, the entire

configuration can be built in a graphical manner, including logics, sequences, control

loops, graphics etc.

With the concurrent engineering possibility, multiple engineers can work on a

configuration simultaneously, thereby allowing for testing, configuration etc. at the same

time.

n& I

HlS r unctions

!

Vmrt

""c"'"""m"'''=.''~"~ •. _ •• "w.m''_='~'''''~.,,_.,,_,,. __ =~''".~,, __ ,,_. __ ''''="~ .. ''_<'''"~' .• _--_.",_ .. --1 FeB ConCl.llrll!nt~nginiE!erjng vi.a Y net (Control functions)

Figure 1-2-2a: Concurrent Engineering

Test Function

The ENG provides testing environment at the phase of in-house engineering, FAT, site

service, etc. Typically 2 types of test function are configured by ENG station, namely

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GIZR SYSTEMS

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Project: AlSHABAB· 1000 MW SIMPLE Customer: East Delta Electricity DOC No.: CYCLE GAS TURBINE UNITS Production Company IA-HT -C-AI-16-987 -10


Virtual Test Function and Target Test Function. The Virtual Test Function provides

testing environment without actual Fes controllers. A FeS simulator is used on pe to

simulate the functions and actions of Fes. The Virtual Test Function mainly

includes the capabilities of FeS operation, Wiring simulation, Break point, One-shot

execution, Tuning parameter saving, etc.

Opt:>ration &: monitoring i functions andeng1neerlllg . functions are mquiroo.

CENnlM CS 3000

FCS

Figure 1-2-2b: Virtual Test Function

The Target Test Function provides testing environment with actual FeS, but without

field wiring or I/O cards. Even if the field wiring is furnished, this testing function is

available by ignoring the actual field wiring. Process I/O signals are simulated by

software I/O in FeS, and pe is able to receive input signal and send output signal

from/to FCS. The Target Test Function mainly includes the capabilities of FCS

operation, Wiring simulation, I/O disconnection, Break point, One-shot execution,

Tuning parameter saving, etc.

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GIZR SYSTEMS

Project: ALSHABAB • 1000 MW SIMPLE Customer: East Delta Electricity DOC No.: CYCLE GAS TURBINE UNITS Production Company IA-HT -C-AI-16-987 -10



VnGt

!/C) switching imagE! FeB

IN OlJT

ItO simulator

Figure 1-2-2c: Target Test Function

1.2.3 Field Control Station - FCS

The FCS is the heart of the CENTUM VP Control System. It consists of dual

power supplies, dual communication cards and single or "pair and spare" redundant

RISC processor(s) depending on the required availability of the system.

The FCS performs all process control related actions. It contains the actual PID

and other controllers, switches, logics, sequences and advanced control algorithms. It

communicates via the ESB/ER bus with the NIUs and via VnetlIP (the real time

process control Local Area Network (LAN)) with the operator interface and the

engineering environment.

GIZR SYSTEMS ------------we integrate



Figure 1-2-3a: Field Control Station

)

Figure 1-2-3b: Pair & Spare Configuration

1.2.4 110 Hardware - Field Network 110 (FlO)

110 Modules (FlO)

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The Input modules convert process signals to the digital data format used in the FCS.

Output modules convert the digital data format used in the FCS to analogue or contact

signals. I/O modules are available for all types of signals available in process industry.

FlO modules offer lots of flexibility in selection of connection with field signals viz.

pressure clamp terminals, MIL connectors and KS cable (Yokogawa's own system

cable) interface adapter. Dual redundancy is possible for all I/O modules and signal

types. HART compatible I/O modules are available, and realize a direct input of

HART signal to I/O module, without an intermediate HART multiplexers etc.

Field Network 1/0 (FlO) Configuration

FlO Eial:ure'

Direct Node: fv'lax 10 NodeslFCS

Remote Node:

Max 14 NodeslFCS Field COmmUnication

2 ports per RS card 4 segments I FF-H1

Figure 1-2-4a: Field Network 110 Configuration

The major I/O modules for FlO are listed as the following.

Table 1-2-4: 110 Module Line-up for FlO

GIZR SYSTEMS ·····_··· __ ... _·""· ... v-1e integrate

Project: ALSHABAB -1000 MW SIMPLE Customer: East Delta Electricitv DOC No.: CYCLE GAS TURBINE UNITS Production Company IA-HT -C-AI-16-9S7 -10



-Model Description SiO'llal HART Remnt'ks AAI141 16.::11 Analog Illput 4 to 20 mA Available

AAV141 16eh Analog In!)ut 1 to 5 V

AAV142 16c11 A.nalo2: Input -10 to 10 V A.AV542 16e11 Analog Output ·10 to lOY

Sell Aualo2: hlput 4 to 20 mA. .'\"."\1841 Sell Analo!.: Outmtt ,,1 'If\ ., Available

Seh Analog hlPUt 1 to 5 V AAB841 Seh Analog OlifJmt 4t020mA AAIl43 16c11 Analog hlput 4to 20mA. Available System I<;oIatioll

.. J AAI543 16ch Analo2: Ollt}:lut 4 to 20 lu..'\ Available ~tem Isolation

AAVl44 16e11 Analog Input 1 toSV System Isolation -10 to 10 V lI.!2ut Signal Selectable

1~.AV544 16ch Analog0utput -10 to lOV ~'5tem Isolation

T)~e J, K; E, B, R. S, T, N Sysfem Isolation

AAT141 16ch Tie Input ill' " hlPut Signal Selectable AA..R181 12ch RTUInput PUOO (3-wil'e) System Iso11tion AAI135 8ch i\nalog IIlput 4t020mA Available Challnel Isolation

4ch Analog Input 4 to 20 mA AAI835 4ch Analog 0il1]Jltt .A c..'lfi Available Channel Isolation

T)-{ie ,J, K, E, B, R, S, T, N Channel Isolation AA.Tl45 16ch TIC Input 111' ' Input Sizual Selectable

AAR.145 16ch RTD Input PtlOO (3-wire) Channel Isolation Potentiometer Input S~al Selectable

Contact 011fOff (2-wire) AAP135 Seh ·Pulse fnput Voltage Pulse (2i3-wire) Channel Isolation

Cum'mt Pulse (2-wire) AJJV141 16eh Digital Input 100 to 120 VAC System r'Solation ADV142 16ch Di2ital Input 20010 240 VAC System Isolation

) AD\1151 32eh Digital Input 24VDC System Isolation AJJV161 64.::h Di<>itaI Input 24VDC Sy;;tem I<;oiatioll ADV551 32c11 Digital Output 24VDC System Isolation AJJV561 64.::h Digital Output 24VDC System Isolation

ADR541 16el1 Relay Output 24 to 110 VDe

.i£ll"l.. · .... 11''-'1 .L'< . System Isolation ALRl11 2port Serial Com RS:ZJ1e< <>_.

ALR12 1 2port Serial Com RS-422!RS-485 ALEl11 lport Ethernet Com IEEE802.3, lOBASE-T ALFlll 4port FF Com Foundation Fieldbus ALPIll Iport Profibus Com Profius-DPVl

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GIZR SYSTEMS ·-···-·--·····-·-·-~,.i'\fe ~ntegrE~ te

Project: ALSHABAB ·1000 MW SIMPLE Customer: East Delta Electricity DOC No.: CYCLE GAS TURBINE UNITS Production Company IA-HT-C-AI-16-987-10

Date: Client .REF: Tender No. Sheet: 23.12.2010 20 of 36 Document Description: . Rev. No.: DCS TECHNICAL PROPOSAL OVERVIEW 0

I Tel1nina! tfuok I

MlL connector COVl;lf

IlOModule

PreSSUfe clamp iemlinal

FD~EPS

Figure 1-2-4b: Signal Connector for FlO 110 Module

Node Interface Unit - NIU

The NIU is signal processing unit which convert and transmit analogue or digital

process I/O signals received from the field devices to the Field Control Unit (FCU)

for FlO. The NIU for FlO has Extended Serial Backboard (ESB) bus node units

(local node units) installed at the FCS station and remote node units installed in remote

cabinets.

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Project: ALSHABAB • 1000 MW SIMPLE Customer: East Delta Electricity DOC No.: CYCLE GAS TURBINE UNITS Production Company IA-HT -C-AI-16-987-1 0


Enhanced Remote Bus - ER Bus

The ER bus connects the remote node units to the FCS via ER bus interface modules

installed in direct nodes. The ER bus can be further extended via fiber optic cable

utilizing standard off-the-shelf fibber optic converters, for remote node installation.

1.2.5 Real Time Process Control Network - VnetJIP

Yokogawa's VnetlIP is a control network with high reliability and quick response. It IS

a control bus conforming to IEEE 802.3 and UDPJIP, and has a transmission rate as

high as 1 Gbps. It uses commercially available cables, layer 2 switches, layer 3 switches

and the like.

VnetJIP connection topology utilizes a tree formation. Devices within domains are

connected using layer 2 switches. In a dual-redundant VnetlIP, buses 1 and 2

are independent subnets. Two independent communication routes exist in each bus.

In a VnetJIP network, a region in which devices are connected without using a router,

layer 3 switch or V net router is called a domain. VnetIIP constructs a network for each

domain.

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Project: ALSHABAB - 1000 MW SIMPLE CYCLE GAS TURBINE UNITS

Date: 23.12.2010 Document Description: DCS TECHNICAL PROPOSAL OVERVIEW

Customer: East Delta Electricity Production Company

Client .REF: Tender No.

HIS, ENG, SENG, SI,oS, APeS, GSGW. Exaop!::

DOC No.: IA-HT-C-AI-16-987-10

Sheet: 22of36 Rev. No.: 0

Layer :3 switch

Figure 1-2-5a: VnetlIP Network Configuration

VnetlIP System Components

Vnet/IP systems utilize commercially available networking devices. It enables to

make VnetlIP as open network, and utilize latest network technologies. VnetlIP enable

devices include PC equipments with VnetlIP interface card (VI701), Yokogawa's

control system, and general purpose equipments which use general Ethernet

protocol. The following Yokogawa's components can be connected to VnetlIP.

o Human Interface Station (HIS)

o Engineering Workstation (ENG)

o Field Control Station (FCS)

o Generic Subsystem Gateway (GSGW)

GIZR SYSTEMS ------------vv0. inte(;;Jrate



o System Integration OPC Station (SIOS)

o Exaopc (OPC Interface of CENTUM VP)

o Advanced Process Control Station (APCS) )

o Field Communication Server for Plant Resource Manager (PRM)

o Safety Engineering Workstation (SENG)

o Safety Control Station (SCS)

o SOE OPC Server

Open Communication

The Open Communication on Vnet/IP network is achieved by using bus 2 of VnetlIP

) network. Ethernet based devices can be connected to VnetlIP as Open Communication.

Control and open communication coexist in the same VnetlIP network. Bus 1 is used

for control communication and bus 2 is for open communication. If any failure occurs

on the bus 1, its control communication is automatically and instantly changed over to

Bus 2, and bus 2 communicates control and open communication until bus 1 recovery.

Yokogawa designed and take sufficient capacity for VnetlIP specification to prevent

any failure situation. The Open Communication is physically integrated to same

network as control communication, but logically segregated completely to make no

effect on control communication.

VnetlIP Secured Design

Generally speaking, as adopting an open technology the system will need to fight

GIZR SYSTEMS

Project: AL5HABAB ·1000 MW SIMPLE Customer: East Delta Electricity DOC No.: CYCLE GAS TURBINE UNITS Production Company IA-HT-C-AI-16-987-10


against the threat of cyber attack. To coexist with open network and secured network,

VnetlIP control network has well-considered strict secured functionalities. Yokogawa

developed the technologies of network security by the methods of distinctively

secured connection, entirely wrapped conduit, etc.

To make secured connection, Security Association will be established between every

Vnet/IP nodes such as HIS, ENG, FCS, etc., by making shared key. Each Security

J Association is unique for each connection between individual nodes. The Security

Association with shared key is mandatory to communicate with other nodes.

Additionally, the individual shared key will be updated periodically.

)

Figure 1-2-5b: Security Association between VnetlIP Nodes

In conventional CENTUM system, the Vnet protocol was used on a physical

Ethernet layer. This Vnet protocol is specific for Yokogawa system and never opened

its internal specification. In VnetlIP protocol, the conventional Vnet frame is wrapped

without any special modification, and transmitted by standard UDP lIP protocol. Even

if a packet on VnetlIP is listened illegally, it should be impossible to read the

original Vnet packet.

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Af······· ...

I Recei .... er

SA I T ran·s~iller

Figure 1-2-5c: Vnet Frame on VnetlIP Tagged

1.3 CENTUM VP MAJOR FEATURES

1.3.1 Expandability and Sizing

CENTUM VP provides a hierarchical system configuration to ensure flexible system

expansions. The basic concept of the hierarchical system configuration is illustrated

below. For every system domain a total of 64 FCS and HIS can be connected. Incase

more stations are needed to fulfil the end user's requirements, more domains Can be

) specified, up to maximum of 31 domains. The total system however remains fully

transparent throughout all these domains. For example, a HIS located in domain I can

provide the consolidated operation of all processes which are controlled by each

control system (domain 2, 3 ..... n) since all HIS have a large database to accommodate

the process data (1,000,000 tags). The process data/events monitored/controlled data by

each control system (domain 2, 3, ..... n) are transmitted to the HIS located in domain I

via a Layer 3 Switch so that an HIS can execute total plant operation located in

domain 1 as consolidated operator stations. For future expansions within the limits of

one particular domain, it is possible to add FCS in that domain.

GIZR SYSTEMS _····_·_·········_·····we lnr.E::Clrar.e



Max. Domaill!

Max .• S1jStem

... )

:f4

Figure 1-3-1: CENTUM VP System Scale

) 1.3.2 Total Integration

CENTUM VP can easily realise the total integrated control and management

solutions not only with subsystems such as high level computers, programmable logic

controllers (PLC), machine monitoring systems etc., but also with multi-vendor

software such as advanced control packages to provide single window operation.

Subsystem Integration

As an interface to subsystems, such as PLC, Vibration Monitoring System etc. a

communication card located in the FCS is provided. This card has RS232C or

RS485/RS422 interface port or Ethernet, and the cable from the subsystem is plugged

into the port directly. The communication cards contain the subsystem driver

GIZR SYSTEMS ···_····· .. ·_ .. ·_-· .. ··we Integrate

Project: ALSHABAB • 1000 MW SIMPLE Customer: East Delta Electricity Doe No.: CYCLE GAS TURBINE UNITS Production Company IA-HT -C-AI-16-987 -10

Date: Client .REF: Tender No. Sheet:

23.12.2010 27 of 36


function. The transmitted data from the subsystem is stored in subsystem data image file,

and the stored data is transmitted to the standard CENTUM instruments andlor

sequence control elements in the FCS. After the transmission, the data is

transferred into the database (CENTUM standard instruments/sequence control

elements) of the FCS. These are processed in exactly the same way as other CENTUM

YP data. The HIS can represent the subsystems data in the similar fashion as other

) CENTUM data (face plates, graphics, etc.), ensuring full integration of the subsystem

into CENTUM YP. In case redundant communication is required, two communication

cards are used to update the subsystem data simultaneously.

)

FCS

"Regulatory SlOIqnsl"IOS oontrol controltl ook block

rei ~ D~ !Datfi mfarenoo

,. f8ll?tting

I Communi·callon 1<'0 dam are.a I ALE11i

I Communicalion module 1.'0 imilgl9' I Sllbs~'518m

oommunlcatlon package

Ethamet

Sulx,ystem

I SUbllystElm dam I

Figure 1-3-2a: Data Flow of Subsystem Communication (In case of ALEnl)

Intelligent Integration

The CENTUM VP HIS is designed to support very large system (Max 1,000,000

Tags) to realize the total operation integration (consolidated Operator Station) for the

)

)

GIZR SYSTEMS ·.······.----.· .. Vvt.o ,nte~Jra te

Project: ALSHABAB· 1000 MW SIMPLE Customer: East Delta Electricity DOC No.: CYCLE GAS TURBINE UNITS Production Company IA-HT -C-AI-16-987 -10


whole plant with unit-based operation. The HIS is also designed to provide operation

flexibility (CRT access level priority, operation groups etc.). Especially, operation

grouping is the effective function to segregate the operation functions among the HIS -

on a process unit basis - as if they are dedicated Operator Stations for a certain process

unit although this HIS has the total database for the overall process.

". "e::;:::i "- ""' 11Ptegrated "I ." "mIT" " .

.. J: Ins!:l"uments

E: Efectricai fadires

CiComputers

Figure 1-3-2b: CENTUM VP System Integration

1.3.3 Plant Resource Manager (PRM)

Today, networked production sites are becoming the norm. These networks greatly

improve maintenance work. Plant Resource Manager (PRM), the software package

from Y okogawa, offers a new style of maintenance tailored using the benefits of

intelligent field instruments. PRM is applied for both HART and Fieldbus

application plant to enable remote and automated maintenance functions. PRM

acquires device information including the device ID, various parameters, and self

diagnostic information and other device related details, in addition to measured data.

This wealth of information is used for administration and supervision of assets such as

field devices, and also for remote automated inspections. PRM transforms the style of

)

GIZR SYSTEMS

· ... _-····we !megrd!.e



maintenance from manual work mainly done on site, into IT -based automated device

management. PRM can support its users to embed the competency gap between the

latest technologies and current maintenance practices.

1.3.4 HART Communication

The FCS is able to connect HART devices directly via HART compatible I/O

modules, without any intermediate multiplexers. The analog data and HART variable

from field devices are stored in the I/O image area in analog I/O module, and

exchanged between I/O module and FCS controller. The HART related variables

can be transmitted on VnetlIP control network, and managed by PRM asset management

system. The typical configuration with HART instrumentation is shown as the

following.

HART I/O module> (111 .. e,vi""') HART flO module (stand-bY)

<==k= PRM CK"nt Field C-ommunica-tio·ns Server

'11191

lIP

68401; G'S.B DUB Interfutce sla"", module,; In Loonl Node) EB401: E.R bus interface- ",asmr modul,g (in Loca1 Nod.;.) 1:950'1: EA bU6 int9riaoQ. eln~ .m-c-dulp {In Remot-Q No-:lQ"/.

(dual.redundant)

Figure 1-3-4: System Configuration with HART

GIZR SYSTEMS ----we integra!.E:'



1.3.5 Time Synchronization

VnetlIP control network of CENTUM VP has a capability to synchronize the time

between the stations connected via Vnet/IP. The time synchronization sets the clock

time in each VnetlIP station, at the same time the OS clock is also set by Vnet/IP master

time with inter-station time synchronization service.

) Time Synchronization within a Domain

Time synchronization in each VnetlIP station within a domain is performed so that the

clock time is set to its own domain master station's clock. The domain master

station is the station that manages the setting information within a domain. The

master station within a domain is automatically selected from the VnetlIP stations

within the domain. Users need not be aware of the domain master station. The domain

master station broadcasts its own VnetlIP clock time (performs clock time multicasting)

periodically to the VnetlIP stations within the domains.

Time Synchronization between Domains

If multiple domains are present, Vnet/IP defines the time groups by domain

) property in CENTUM VP engineering function on a domain-by-domain basis. Time

equalization will be carried out between domains belonging to the same time group. A

time group allows the selection of a Vnet/IP time master from the domain master station

within a domain belonging to the same time group. A VnetlIP time master is also

selected automatically. Users need not be aware of the VnetlIP time master. The time

group is specified by a number from 0 to 7. A domain specified with time group

number 0 is a special domain that the time is synchronized within the domain, and it is

not synchronized with other domains.

)

)

GIZR SYSTEMS _·····_············ .. ·····we integrate

Project: ALSHABAB -1000 MW SIMPLE Customer: East Delta Electricity Doe No.: CYCLE GAS TURBINE UNITS Production Company IA-HT -C-AI-16-987 -10


2. PROPOSED SYSTEM FOR ALSHABAB POWER PLANT

PROJECT

2.1 PROJECT SPECIFIC DETAILS:

Please refer to the following documents in our offer for project specific:

o Des I/O Summary and Sizing

o DeS Bill of Material- Hardware

o DeS Bill of Material- Software

o DCS System Architecture Drawing

2.2 SCOPE OF WORK

2.2.1 Engineering:

Review of Input/Output List, Vendors logic diagrams and Piping & Instrumentation Diagram (PID) for the Plant Systems mentioned in list of main Package

• Generator Step Up Transformer • Auxilliary Transfomrer • Distribution Transformer • Generator Circuit Breaker • Diluge System for Step Up transformer • Oily waste sump system • MY Switchgear 6.6 KV • LV Switchgear • Emergency Deisel Generator • Fire Pump System • Unloading Fuel Pumps • Solar Oil Tank • Sevice Air and Instrument Air

system shall Control/interface with the following areas: service water system-RO water system-Oemi water system waste water and sewage treatment systems ana shall Interface with: CEMS-Instrl.lment Air-Service Air-fan cooiers

DCS design will be based on Field Controllers with Input/Output Racks located in the MY Switchgears rooms in order to mimize the field cable lengths, distributed in the following areas

GIZR SYSTEMS _····_---_···--\/'-ie ;nte~H"i'..lf.e

Project: ALSHABAB - 1000 MW SIMPLE Customer: East Delta Electricity DOC No.: CYCLE GAS TURBINE UNITS Production Company IA-HT-C-AI-16-987-10



• Local control Station -1 to manage the Power Island - I and 2

• Local control Station -2 to manage the Power Island - 3 and 4



• Local control Station -5 to manage the BOP and Fuel Unloading area

The DCS will responsible to communicate through OPC TCP/IP with the Turbine Control System, Mark VI for the CTG 1,2,3,4,5,6,7,8.

Our proposal is based on modbus communication with the Substation Automation System (SAS), to be modified according to SAS provider requirement.

Modbus Communication with the Water Treatment Plant PLC.

Prepare wiring diagrams, panel front views and internal arrangement.

The DCS panels will be supplied with prefabricated terminal boards to minimize the tennination work at site.

Preparation of factory test reports for the DCS.

Preparation of O&M manual and AS Built for the supplied DCS.

2.2.2 Manufacturing and Supply:

Manufacture the DCS systems and Marshalling panels. Pack and transport the complete DCS panels to

Supply of Field cables from MV Swg and Local Boxes to the DCS remote Input/Output racks distributed in the field.

Supply the Interconnecting Cables, Data Communication Cables.

Supply of 5 UPS for each system cabinet and One UPS for the control room

--)

GIZR SYSTEMS ····_-_· __ ··_·-we jntegrdt.e




4.S KV A, 30 min UPS Manufacturer: Mer1lin Gerin, ARTRONIC OR Equivalent

Note: A provision of 22,000 m cables CUIPVC/PVC/OS (14Xl.S mm), 6,000m (14X2Xl.Smm) and SOOO m (7X2Xl.Smm).

Cables Payment to be as actual cable lengths used at site.

2.2.3 Site Servies

Giza systems will handle the site services required to complete the job - DCS Panels, Junction Boxes and Consoles Installation. - Loop Check per Signal - Function Test for each system - Cables from Junction Boxes to DCS Laying and termination.

2.2.4 On shore Training:

Our proposal includes On site training for the Plant Operators & Maintenance Engineers.

2.2.5 Work out of scopc:-

- The custom duties and sales taxes will be paid by customer. - Any civil work activities in the place of the panels. - Supply or install any cable trays or Cable management Systems - Any external electrical andlor mechanical installations to complete the job

Technical data sheets

, .


}

)

«Contents» «index»

General Specifications

GS 33L01A10-40E

II GENERAL

Integrated Production Control System CENTUM VP System Overview (VnetllP Edition)

C£NTUMYp

~iJr

VnetllP is a control network with high reliability and quick response and achieves steady response with little delay even under heavy load. Using general-purpose network equipment conforming to IEEEB02.3 and UDPIIP standards, it realizes open-based communications. VnetllP can connect to a V net system with a V net router. This GS provides the system specifications, system configuration equipment, and network specifications for CENTUM VP Systems with VnetllP.

II SYSTEM CONFIGURATION

---------------------------I I I I

Open Display Style Console

Enclosed Display Style Console HIS

HIS Human Interface

VnetllP domain ---------------------------

ProSafe-RS Safety

Instrumented System

SNTP .-----------. · · · · · ·

I I I I I

: L3SW I Layer 3 switch

I L3SW : Layer 3 switch I I

V net router re!'l9=m

I

Remote node : --------------------------------------------- _________ ___________ J

YOKOGAWA+

Figure Example of System Configuration

Yokogawa Electric Corporation 2-9-32, Nakacho, Musashino-shi, Tokyo, 180-8750 Japan Tel.: 81-422-52-5634 Fax.: 81-422-52-9802

F01E.ai

GS 33L01A10-40E ©Copyright Feb. 2008 (YK)

1st Edition Feb. 4, 2008 (YK)

)

«Contents» «Index»

IIiIl SYSTEM COMPONENTS

• Human Interface Station (HIS) An HIS serves as a human interface for operation, monitoring, and engineering. Software packages installed in a general-purpose personal computer (an IBM PC/AT compatible computer, hereinafter referred to as a general-purpose PC) or in a console HIS, consisting of a general-purpose PC and Open Display Style Console Assembly, implement operation and monitoring functions as well as engineering functions.

Users can install and run operation and monitoring functions and/or engineering functions in an HIS as necessary. For connections to the VnetllP, a VI701 Control Bus Interface Card is used.

As for HIS hardware requirements, refer to following General Specifications:

GS 33M50B40-40E "Enclosed Display Style Console Assembly"

GS 33M50B50-40E "Open Display Style Console Assembly"

GS 33M05D10-40E "Standard Operation and Monitoring Function"

GS 33L50C10-40E "VnetllP Interface Card"

• Field Control Station (FCS) The FCS performs process control and manages communications with subsystems such as PLCs. Two types of field control stations for Vnetll P and FlO are available:

AFV10S: Field Control Unit (for VnetllP, FlO, rackmounted)

AFV10D: Duplexed Field Control Unit (for VnetllP, FlO, rack-mounted)

By mounting ESB Bus Coupler Module on FCS, local node can be connected. By mounting ER Bus Interface Master Module on FCS or local node, in addition, remote node can be connected.

As for FCS hardware requirements, refer to following General Specifications:

GS 33L50E20-40E "Field Control Unit (for VnetllP and FlO)"

GS 33M50E25-40E "ESB Bus Coupler Module" GS 33M50F25-40E "ER Bus Interface Master

Module (for FlO)" GS 33M50F20-40E "Node Units (for FlO)" GS 33L50F10-40E "FlO System Overview (for

AFV10D)"

All Rights Reserved. Copyright © 2008, Yokogawa Electric Corporation

2

• Advanced Process Control Station (APCS) An APCS advanced process control station implements control functions with a general-purpose PC connected to a VnetllP, aimed at improving advanced control and plant efficiency. For this purpose, install LFS1200APCS control functions. Use VI701 Control Bus Interface Card for connection to VnetllP. For more details, see APCS Control Functions General Specifications (publication GS 33M15U10-40E).

• Generic Subsystem Gateway Package (GSGW)

With a general-purpose PC connected to a VnetllP, GSGW packages can collect and set data of various types of subsystems using an OPC DA server. They can easily collect and set subsystem data without creating dedicated communications programs.

Install LFS1250 Generic Subsystem Gateway Package. Use VI701 Control Bus Interface Card for connections to VnetllP. For more details, see publication GS 33M20F10-40E.

• Safety Instrumented Systems (ProSafe-RS) ProSafe-RS has been approved by German safety test labs TOV (Technische Oberwachungs Verein) as the SIS (Safety Instrumented System) that meets SIL (Safety Integrity Levels) 3 established by IEC 61508.

The SCS (Safety Control Station) for ProSafe-RS monitors the safety state of plants and performs predetermined safety operation according to each request for safety control. The SENG (Safety Engineering PC) performs engineering and maintenance of SCS. Moreover, ProSafe-RS can be . integrated with CENTUM VP and enables operation and monitoring of SCS from HIS.

For details, refer to GS 32S51B10-01E ·Safety Instrumented Systems ProSafe-RS System Overview (VnetllP Edition)".

• System Integration OPC Station (SIOS) System Integration OPC Station (SIOS) is a station used when other companies' PCS (Process Control System) is integrated to CENTUM VP system. It provides functions to import other companies' PCS data to CENTUM VP using OPC (OLE for Process Control) and to have CENTUM VP receive alarms and events occurred in other companies' PCS.

LBC2100 System Integration OPC Client Package is installed. For connection with VnetllP, VI701 (VnetllP Interface Card) is used.

As for details, refer to GS 33M20D10-40E "System Integration OPC Client Package".

GS 33L01A 1 0-40E Feb. 4, 2008-00

.>


• VnetllP VnetllP is IEEE802.3 compliant control bus configured with dual-redundant busses. Each dual-redundant bus is configured with a layer 2 switch (*1) with the maximum transmission speed of 1 Gbps and 1000BASE-T cables and devices in a domain are connected in star connection or tree connection.

VnetllP dual-redundant bus 1 is exclusively used for control communication and bus 2 is used not only for control communication but for open communication by a various kind of standard protocol based on Ethernet Bus 2 enables data access by Exaopc OPC interface and communications based on TCPIIP protocol.

General-purpose, commercially available products are used for network device such as repeaters, cables, layer 2 switches and layer 3 switches for VnetllP. In VnetllP, IPv4, ClassC private address is used as IP address for communication. (Some ClassB private address is also used.)

*1: Layer 2 switch is a switching HUB with a bridge function and it does not send data to terminals other than destination. Using layer 2 switch reduces bus traffic.

• Layer 3 Switch Layer 3 switch is a network device to connect VnetllP domains. It has path control by IP address and a routing function to relay communication frame in two domains when necessary. Use layer 3 switch which relays communication frame by hardware at high speed. Use all-purpose, commercially available layer 3 switch.


3

• Boundary Router Boundary router is a network device to connect VnetllP with external network such as in-house LAN. Bus 2 is used for connection with external network. Boundary router needs to have firewall function to protect CENTUM VP from the threat of external network. Use all-purpose, commercially available boundary router.

• V net Router A V net router is a device to connect a VnetllP domain and a V net domain for relaying control communications. This router realizes operation and monitoring of a control station in one domain from another domain by connecting the VnetllP and V net domains. The following product is available:

AVR10D: Duplexed V net Router (for redundant use of communications and power supply modules)

For the hardware specifications, see publication GS 33L50D30-40E.

• SNTP Server When synchronizing the time of the VnetllP station with UTC (Coordinated Universal Time), the SNTP server is connected .

• Peripherals Since an HIS supports Microsoft Windows Vista, Windows XP, or Windows Server 2003, windowscompatible peripherals, such as printers, can be used. Consult Yokogawa for more details on peripherals that can be used with an HIS .

GS 33L01A1O-40E Feb. 4, 2008-00

)


iii SYSTEM SPECIFICATIONS

• HIS Operation/Monitoring Capacity (Tags) Number of tags: Up to 100000 (when using LHS4000,

up to 1000000 per system) Number of tags that can be entered in one HIS: Up to

100000 (*1) *1: \M1en a system is configured as CENTUM VP

Entry Class; however, the maximum number of tags shall be 8000.

• Minimum System A minimum system consists of one HIS and one FCS.

• Maximum System In a CENTUM VP system, a system within an area that does not communicate via devices such as routers, layer 3 switches, or the like is called a domain. Up to 64 VnetllP-enabled devices per domain can be connected. Our VnetllP-enabled devices include equipment with VI701 (control bus interface cards) incorporated in a general-purpose PC, FCS for VnetllP and V net routers. The following lists our specific VnetllP-enabled devices: .

Human Interface Station (HIS) Field Control Station (FCS) Advanced Process Control Station (APCS) Generic Subsystem Gateway (GSGW) System Integration OPC Station (SIOS) Safety Instrumented Systems (ProSafe-RS) OPC Interface Package (Exaopc) OPC server

- - - - - -- --, I

Field Communications Server for Plant Resource Manager (PRM)

V net Router (AVR10D) On the bus-2 side, up to 124 general-use Ethernet devices (including intelligent network devices) other than listed above can be connected.

• Expanded System A layer 3 switch allows a hierarchical construction with other VnetllP domains. In addition, a V net router allows connection to a system using other V nets or

4

VL nets. Existing systems (via an HF-bus or RL-bus) cannot be directly connected to a VnetllP network. These systems can be connected via a BCV on a V net. A hierarchical connection using a layer 3 switch and a V net router allows a system expansion that exceeds the maximum system indicated in the previous section. In other words, hierarchical connections of other control systems allow hierarchical system expansion at the core of CENTUM VP.

Total number of interconnected domains: Up to 16 (VnetllP domains + V net domains)

Hierarchical connections by V net router: Three-level control bus hierarchy, i.e., three control bus levels, linked by two bus converters

Number of tag names: Max. of 100000 (up to 1000000 per system when using LHS4000)

Connecting devices: V net routers and bus converters Note that the levels ofVnetllP domains on an access router and the levels of V net routers are not counted when hierarchical connections are restricted.

VnetllP domain

Layer 3 switch Ff==;;FFf._TI V net router

V net domain

V net domain

BCV-V BCV-H

FCS V net domain HF-bus domain

EFCS I

FCS : BCV-V: Bus converter I I I

I I 0J net to V net} I : BCV-H: Bus converter

Bus converter (0 level) One control-bus level

,-------_ .... : I (HF-bus to V net) ----------------------------------------~

One bus-converter level and one control-bus level that are connected via a V net router

Two bus-converter levels and three control-bus levels (max.) connected via a V net router

Figure Expanded System Configuration

VnetllP domains and V net domains can be managed in the same project. In addition, these two domains can be integrated with a multiple project connection package. As for details of Multiple Project Connection Package, refer to GS 33M05K20-40E "Multiple Project Connection Package".

FD2e..1

All Rights Reserved. Copyright © 2008. Yokogawa Electric Corporation GS 33L01A 10-40E Feb. 4. 2006-00

)

)


• Installing of Server pes Each number shown below includes the number of CS 3000 station.

CENTUM VP realizes many functions using file sharing function of Windows. The number of PCs to share files simultaneously is restricted on the Windows Workstation OS. Therefore, when there are 9 or more stations (HIS, ENG, Exaopc) in one project, the server PC may be required.

Please count the total station number in one project using the equations shown below in order to judge whether server PC is required or not. If the number is eight or smaller, a server PC is not required. If the number is larger than 8, consult our sales rep for further examination.

In case of PCs storing master Engineering database file When not using Engineering Tool for Foundation Fieldbus (SSS5700)

Total station number = HIS + «ENG - 1) x 2) + Exaopc

When using Engineering Tool for Foundation Fieldbus (SSS5700)

Total station number = HIS + «ENG - 1) x 2) + Exaopc + 2

HIS: Number of PCs in which Standard Operation and Monitoring Function (LHS1100 or LHM1101) is installed

ENG: Number of PCs in which Standard Builder Function (LHS5100 or LHM5100) is installed.

Exaopc: Number of PCs with Exaopc Interface Package (NTPF100)

When using Multiple Project Connection Package (LHS4450), please see the specifications for Multiple Project Connection Package (GS 33M05K20-40E).

When using Expanded Test Function (LHS5425), server PC is always required for storing master Engineering database.


5

In case of PCs storing Audit trail data When using LHS5170 Access Administrator Package, one PC which is dedicated to the audit trail data must be prepared. When there are 9 or more stations (ENG, Recipe Management PC) in one project, the server PC may be required for storing Audit trail data.

Please count the total station number in one project using the equations shown below in order to judge whether server PC is required or not. If the number is eight or smaller, a server PC is not required. If the number is larger than 8, consult our sales rep for further examination.

Total station number = ENG + Recipe Management

ENG: Number of PCs in which Standard Builder Function (LHS5100 or LHM5100) is installed.

Recipe Management: Number of PCs in which CS Batch 3000 Recipe Management package (LHS5161) is installed

GS 33L01A10-40E Feb. 4, 2008-00

)

«Contents» «index»

General Specifications

Models AFV10S, AFV10D Field Control Unit Duplexed Field Control Unit

GS 33L50E20-40E (for VnetllP, for FlO, 19" Rack Mountable Type)

II! GENERAL This GS covers the hardware specifications of the Field Control Unit which is the processor of the Field Control Station (FCS).

II! HARDWARE SPECIFICATIONS For the installation specifications and the environmental conditions common to the systems, refer to "VnetllP System Overview (GS 33L01A10-40E)."

Processor VR5432 (133 MHz)

Main Memory Capacity 32 Mbyte

Memory Protection During Power FailUre Battery Battery Back-up for Main Memory: Max. 72 hours Battery Recharge Time: Min. 48 hours

FCU Status Contact Output 2 terminals (NC, C) Contact Points open during FCU failure Contact Rating: 30 V DC, max. 0.3 A

Communication Interface VnetllP Interface: Dual-redundant ESB bus interface:Dual-redundant or Single(ln case

ofAFV10D, always Dual-Redundant.) VnetilP Communication Speed

1000 Mbps Full Duplex

Connection Specifications Cable: CAT5e (Enhanced Category 5 cable), UTP Transmission:

1000Base-T and 100Base-TX compliance Connector: RJ45 connector Max. distance: 100 m (Distance betweenAFV100

and Layer 2 switch) Autonegotiation

No. of Node Units Connectable Max. 14/FCU The total number of the local and remote nodes that can be connected to FCU are 14 or less. (The local nodes: 9 or less) 3 or less normally; however, can be expanded to 14 if LFS 1530 Application capacity Expansion Package (for AFV100) is purchased.

No. of I/O Modules Max.8/Node

Local Node Connection When connecting a Local Node to FCU, install ESB Bus Coupler Module (EC401) to FCU. EC401 must be installed in slot 7 and slot 8. To make single configuration, EC401 must be installed in slot 7, and Slot 8 must be empty.

F01E.al

[19" Rack Mountable Type FCU]

Remote Node Connection When connecting a Remote Node to FCU, install ER Bus Interface Master Module (EB401) to FCU. To make single configuration, EB401 must be installed in an odd-number slot, and make a space on the right side of the installed EB401. See "ER Bus Interface Master Module (for FlO), (GS 33M50F25-40E) for further information.

Power Supply (specify with Suffix Codes) Voltage: 100-120 V AC, Frequency: 50/60 Hz Voltage: 220-240 V AC, Frequency: 50/60 Hz Voltage: 24 V DC

Power Consumption 100-120 V AC: 200 VA 220-240 V AC: 230 VA 24 VDC: 5.5A

Weight Approx. 7 kg (AFV10S) Approx. 8 kg (AFV10D)

Mounting 19" Rack Mounting:

Connection

Rack mount (M5 x 8 screws) Insulation bush (accessory)

Power Supply: M4 screw terminal connection Grounding: M4 screw terminal connection Contact Output: M4 screw terminal connection Network: Connect CAT5e (Enhanced Category 5

cable) to Layer 2 switch.

YOKOGAWA+ Yokogawa Electric Corporation GS 33L50E20.40E ©Copyrighl Feb. 4, 2008{YK) 1 sf Edition Feb. 4, 2008{YK)

2-9-32, Nakacho, Musashino-shi, Tokyo, 180-8750 Japan Tel.: 81-422-52-5634 Fax.: 81-422-52-9802

)


• Local Node Connection When connecting a Local Node to Compact Field Control Unit (for FlO), install ESB Bus Coupler Module (EC401) to Compact Field Control Unit (for FlO).

2

EC401 must be installed in slot 7 and slot 8. To make single configuration, EC401 must be installed in slot 7, and Slot 8 must be empty.

• Power Supply (Specify with Suffix Codes)

Voltage: 100-120 V AC, Frequency: 50/60 Hz Voltage: 220-240 V AC, Frequency: 50/60 Hz Voltage: 24 V DC

• Electric Power Consumption 100-120VAC: 200 VA, 120W 220-240 V AC: 230 VA, 120 W 24 V DC: 5.5A

• Weight 10 kg (incl. 810Ms)

• Regulatory Compliance For the detailed information of following standards, see "Integrated Production Control System CENTUM VP System Overview (GS 33M01A10-40E)."

Safety Standards [CSA] (for 100-120 V AC and 24 V DC power supply) ICE Mark] (for 220-240 V AC and 24 V DC power supply)

EMC Conformity Standards ICE Mark] (for 220-240 V AC and 24 V DC power supply) IC-Tick Mark] (for 220-240 V AC and 24 V DC power supply)

Standards for Hazardous Location Equipment [CSA Non-Incendivej (Remote Node only, for 100-120 V AC and 24 V DC power supply) [FM Non-Incendivej (for 100-120 V AC, 220-240 VAC and 24 V DC power supply) [Type nJ (for 24 V DC power supply)

III CONFIGURATION

• Rack Mounting

Card configuration Power Supply Module: Two modules in case of a dual-redundant configuration.

Power supply to the 110 Modules, and supply power to the transmitters. The power supply terminals use M4 screws.

Bus Interface Module: Two modules in case of a dual-redundant configuration. E5B Bus Interface Slave Module (5B401) ER Bus Interface Slave Module (E8501)

III LIMITATIONS OF INSTALLATION AND NOTICES FOR iNSTALLATION For installing 110 modules in node unit, the quantity and allocation are limited. Also, when installing a node unit to the dedicated cabinet, there are limitations of installation under the ambient operating temperature conditions. When modules with built-in barriers are installed in any node unit, an insulating partition (Part No. T9083NA) must be installed.

For details, please refer to "Limitations and Precautions for Installation (GS 33M50F10-40E)."

All Rights Reserved. Copyright © 2008, Yokogawa Electric Corporation GS 33M50F20-40E Feb. 4, 2008-00

)

)


II EXTERNAL DIMENSIONS

• ANB10D, ANB10S Node Unit for ESB Bus (Figure of ANB10D)

~BI DO

JBB DO ~ ~

0 °I=F 0 o\--"-0 0 0 0

482.6

8.75 465.1

21.3 440

,r- ~HHH~~O 221.5

37.75

~ ~

205

150.6

I

I~

Hole for 19" rack mounting

(4 x M5 screw holes)

• ANR10D, ANR10S Node Unit for ER Bus (Figure of ANR10D)

4826 205 8.75 465.1 150.6 21.3 440

I

rfl> _fl: ) l-

Ie p r

i §t I

I[ ~ ~ ~~ ~ ~ r ~ I~ 146 i i • I-@ @ 1.5 I 22

RI = I I.'~ I

lIE mID IlLBo'

\ Hole for 19" rack mounting 37.75 (4 x M5 screw holes)

3

Unit: mm

18.4

F03E.a1

Unit: mm

18.4

F04E.a1

All Rights Reserved. Copyright © 2008. Yokogawa Electric Corporation GS 33M50F20-40E Feb. 4. 2008-00

)

)

«Contents» «~Index»~

1\1 MODELS AND SUFFIX CODES Node Unit for Single ESB Bus (19" Rack

Mountable)

Model

Suffix Codes

Option Codes

Description

ANB10S Node Unit for Single ESB Bus (19" Rack Mountable)

-3 Single power supply .4" ...................... ·Duai:redundani·power·suppiY· .. ················ 1 100 - 120 V AC power supply

:~:::I:~::::::::~:::~ :??Q:~~?~§.:Y..!::§.~p.~Y.i.~i:~~p.p.~::::~:::::::::~:::: 4 24 V DC power supply

o Basic type ...... _ ..................... ·Viiilh .. isASianda~d··G3 .. opiion··-················ ICU1 N Connector Unit for ESB Bus .;~~~.~ ............ ·Co;:;-~eclor·"ljnit·Wiih·Te;minaio;:·for·········

ESBBus

Z~f~:9.:¢'::::::::: :~~:~~~l~~i~!~:~!~:~;~~~~~~~:: !NDEL (Mandatory for connection with

AFF50D orAFV10o)

Node Unit for Dual-Redundant ESB Bus (19" Rack Mountable)

ModeJ

Suffix Codes

Option Codes

Description

ANB10D Node Unit for Dual-Redundant ESB Bus (19" Rack Mountable)

-4 Dual·redundant power supply

1 100 - 120 V AC power supply

::~:::~::::::::::::::~::: :?3.§.:::3.~9.Si.!::¢.:p.~~~~~~!?!?~i.::::::::::::::::::::: 4 24 V DC power supply

o Basic type ··········· .. 1············ ·Wtti·iSAStandard .. G3·0ptior;····················· ICU2N Connector Unit for ESB Bus ... -............................................................................................................... .. ICU2T Connector Unit with Terminator for

ESBBus

Z~f.~!?:~~::::~: ::~P.[~~~i?~:~:~~!i.?~~~:M~~~i.(::::::~:~:::::::::: !NOEL

Software License for Node Expansion (Mandatory for connection with AFF50D or AFV10D)


4

Node Unit for Single ER Bus

Model

Suffix Codes

Option Codes

Description

ANR10S Node Unit for Single ER Bus (19" Rack Mountable)

.~ ........................ ~~~\!~~.r.~~~E.~~f?!?~Y. ......................................... . -4 Dual-redundant power supply

1 100 -120 VAC power supply

:::::::r:::::::::::::::· :~!t~~9~~CZ:~~~t:~~Ei?~i.:::~:::::~::::~::: o Basic type ........................... ·Viiitii·isAG3··opii;;n·and··tem·peratuffi····· 3 (-20 to 70 DC) option

IATDOC Explosion Protection Manual ................... _ ........ 'softWars'L:lcenss'for'Nods'EXpans'i'on" IN DEL (Mandatory for connection with

AFF50D or AFV1 00)

Note: T·type Connector of ER Bus (YCB146) is supplied with this unit.

Node Unit for Dual-Redundant ER Bus

Model

Suffix Codes

Option Codes

Description

ANR 1 00 Node Unit for Dual-Redundant ER Bus (19" Rack Mountable)

-4 Dual-redundant power supply 1 100 - 120 V AC power supply

:::::I:~~::::::::::::: :~~Q:::~~§.:y!::§.:P.~~~~~~P.P.~¥.::::::::::~::::::~: 4 24 V DC power supply

o 8asictype ._ ......... ; ............. ·Viiitii·isA·G3 .. ;;ption·a~d·tem·pe;~iUis·····

(-20 to 70°C) option

IATDOC Explosion Protection Manual ............................ 'S;;ftWare'Licen'ss'for"Node'Expa~sioii" INDEL (Mandatory for connection with

AFF500 or AFV1 00)

Note: T-type Connector of ER Bus (YCB146) is supplied with this unit.

GS 33M50F20-40E Feb. 4. 2008-00


Dummy Cover

Description

Model ADCV01 Dummy Cover (for 110 Module) ADCV02 Dummy Cover (for Power Supply Module)

Insulating Partition

Description Part No. T9083NA Insulating Partition

Note: When mounting an FlO module with built-in barrier to a node unit, place this part to the 8th slot.

lIIII ACCESSORIES AND SPARE PARTS

Parts Names Parts Numbers Description Quantity Remarks

Insulating bush S9049PM - 4 Accessory

Accessory assembly S9768UK ANR10S 1

Accessory assembly S9768UK ANR10D 2

Clampfifter A1193MN ANR10S 2

Clamp filter A1193MN ANR10D 4

Content of S9768UK

Coaxial connector A1120JA - 1 Tjunction

Cover T9072MB - 1

Cover T9072MC - 1

III ORDERING INFORMATION Specify the model and suffix codes.

lIIIITRADEMARKS • CENTUM is a registered trademark ofYokogawa Electric Corporation . • Other product and company names appearing in this document are trademarks or registered trademarks of their

respective holders.

5

All Rights ReselVed. Copyright © 2008, Yokogawa Electric Corporation Subject to change without notice.

GS 33M50F20-40E Feb. 4, 2008-00

)


• VnetilP NETWORK SPECIFICATIONS The VnetllP is a real-time process control network used to connect system components. The VnetllP supports two types of communications: control-bus communications and open communications. The VnetllP is always dualredundant. Usually, control bus communications are carried out via bus 1. Open communications are carried out via bus 2. If a control communications error occurs at the bus-1 side, control bus communications will be carried out via bus 2. The VnetllP uses general-purpose communications devices for network connection.

~2 HISENG APCSGSGW Exaopc

6

F03E •• 1

Figure Network Configuration

• Connection within a Domain In a system used with the VnetllP, sections separated by communications devices, such as routers, layer 3 switches, etc., are called domains. One domain allows the connection of up to 64 of our VnetllP-based devices including the FCS, HIS, etc. In addition, a maximum of 124 devices, which includes switches, routers, etc., can be connected in configuring a network with Ethernet devices other than our VnetllP-based devices. Devices in a domain are connected in a star or tree-like fashion at the core of a layer 2 switch. A dual-redundant Vnetl IP bus is an independent subnet for each line; therefore, a layer 2 switch should be installed in each line. Up to seven levels of layer 2 switch connections can be connected in a domain.

• Inter-domain Connection General-use layer 3 switches allow connections between VnetllP domains. Up to 16 domains can be connected. Up to 15 level (i6-hierarchical) connections ofVnetllP domains can be connected. Two types of VnetllP domain connections are possible: bidirectional and hierarchical connections. In bidirectional connections, HIS's in both domains can perform operation and monitoring of the other domain.

Bidirectional Connection Both HIS's can perform operation and monitoring of the other domain. Stations in both domains can receive and send FCS and HIS messages.

Hierarchical Connection Hierarchical domain relations are established. The HIS of a high-order domain can operate and monitor a low-order domain. FCS and HIS messages generated in a low-order domain can be accepted by a station in a high-order domain. A V net conversion router allows connection to a system connected to a V net. Connection to an existing system (via an HF-bus or RL-bus) connected with a BCV via a V net is also possible.

All Rights Reserved. Copyright © 2008, Yokogawa Electric Corporation GS 33L01A 1 0-40E Feb. 4. 2008-00

--)

)


• Communications Specifications

Control bus communications Communication Method: Read/write communication,

message communication, and link transmission

Link Transmission Period: 100 msec

Open communications Open communications are executed via the bus-2 side. Connected with commercially available Ethernet communications devices. The bandwidth that can be used for open communications via the bus-2 side is up to 300 Mbps.

Transmission Path Specifications Network Topology: Star formation Transmission Path Redundancy: Available (control

bus communications only) Transmission Cable: Unshielded twisted pair (UTP) at

enhanced category 5 or greater.

Connection Cable Speed Maximum Standard Distance

Between station 100BASE-TX 100 Mbps (IEEEB02.3u) (*1)

and layer 2 1000BASE-T

100m switch

(lEEEB02.3ab) 1 Gbps

1000BASE-T 1 Gtips 100m Between layer 2 (IEEEB02.3ab) switches 1000BASE-LX 1 Gbps 5km (lEEEB02.3z)

1000BASE-T 1 Gbps 100m Between layer 2 (IEEEB02.3ab) switch and router 1000BASE-LX 1 Gbps 5km (IEEEB02.3z)

*1: For V net Router, SCS and Open communication network.

• Communications between Devices Maximum distance between arbitrary stations: 40 km Only a couple of media converter between devices can be connected.


• Network Device Specifications

Layer 2 switch Connection Port: 1000BASE-T, full duplex Connection between switches: 1000BASE-T,

1000BASE-LX with speed, 1 Gbps (1.5 Mpps@64 byte) or faster, full duplex

Auto-Negotiation: Essential

Layer 3 switch Connection Port: 1000BASE-T, full duplex Connection between switches: 1000BASE-T,

1000BASE-LX with speed, 1 Gbps (1.5 Mpps@64 byte) or faster, full duplex

Unicast dynamic routing protocol: RIPv2 (RIPv1 compatible mode essential)

Multicast Protocol: IGMP: Essential DVMRP or PIM-DM: Essential

Management function SNMP

• Address Used for VnetilP Class C private address is used for communications for control and open communications. For Yokogawa equipment supporting VnetllP, three IP addressed are automatically provided: one for bus 1 control communication; one for bus 2 control communication; one for bus 2 open communication. Communications for control

Bus-1 side 192.168.(Domain No.).1 to 129.254 Bus-2 side 192.168.(128 + Domain No.).1 to

129.254 Open Communications

7

Bus-2 Side 192.168.(128 + Domain No.).130 to 253

The following addresses are used for multicast communications. For stations within domains

Bus-1 side 239.192.24.0 Bus-2 side 239.192.24.1

For all domains Bus-1 side 239.192.24.4

. Bus-2 side 239.192.24.5

Class B address is used for the TCPIIP protocol communications on VneVIP. Make sure that there are no overlaps in IP addresses.

GS 33L01A10-40E Feb. 4, 2008-00

)


IIII/O COMMUNICATIONS BUS

• ESB Bus

Application An ESB bus is an I/O communications bus that connects the processing unit of an FCS to a local node.

Communication Specifications Connectable Devices: Node units (ANB10S and ANB10D) Number of Connectable Devices: The number of local node units that can be connected to an ESB bus varies

according to the database selected.

Database Maximum Number of Total Number of Local Nodes Local and Remote Nodes (*1)

Control Function for Standard Field Control Unit (*2) 3 3 Control Function for Standard Reid Control Unit plus Application Capacity 9 14 Expansion Package

*1: The total should not exceed this number. *2: If local node units are connected to an AFV1 OS or AFV1 OD FCU, ESB Bus Coupler Modules (EC401) should be installed in

~~7~& .

Transmission Path Specifications Network Topology: Bus formation Transmission Path Redundancy: Available Transmission Speed: 128 Mbps Transmission Cable: Dedicated cable (YCB301) Transmission Distance: 10m max .

• ER Bus

Application An ER bus is a remote I/O communications bus to connect an FCU or local node unit to a remote node.

Communication Specifications Connectable Devices: Remote node units (ANR10S, ANR10D) Number of ER buses: Max. 4 per FCU Number of Connectable Devices: The number of remote node units that can be connected to an ER bus varies

according to the model and database selected.

Database Maximum Number of Total Number of Remote Nodes Local and Remote Nodes (*1)

Control Function for Standard Field Control Unit 3 3 Control Function for Standard Field Control Unit plus Application Capacity

14 (*2) 14 Expansion Package

*1: The total should not exceed this number. *2: Up to eight remote nodes per ER bus can be connected.

8

All Rights Reserved. Copyright © 2008, Yokogawa Electric Corporation GS 33L01A10-40E Feb. 4, 2006-00

.)

)


Transmission Path Specifications Network Topology: Bus formation Transmission Path Redundancy: Available Transmission Speed: 10 Mbps Transmission Cable: Coaxial cable (YCB141, YCB311). Use YCB 147 ER-bus Adapter and YCB 149 ER Bus

Converter Unit for connecting YCB 141 and YCB311 cables. Transmission Distance:

YCB141: Max.185 m When mixing YCB141 and YCB311:

Length ofYCB141 + (185/500) x Length ofYCB311 ::; 185 Number of Bus Adapter Units: Max. 4 per segment (*1)

General-purpose Ethernet Repeater (*2): The total transmission distance is limited by the number of repeaters. L:=; 4 - 0.5 x n

L: total transmission distance (km) n: the number of the general-purpose Ethernet repeater (Max. 4 repeaters)

*1: When ER bus is connected with a repeater, one segment means the area between repeaters. *2: General-purpose Ethemet repeater can be installed in only non-hazardous areas.

EB401

AFF50D I.4'EB401 (Nadel)

. I " III~I~IBBII

ER bus --""'--

ANR10D (Node2) flEB50l

IIIII I] LL· .

I I Repeaterl L Repeate~ L Repeate~ l RepeaterJ

Figure Example of ER Bus connection

9

F04 •• '

All Rights Reserved. Copyright © 2008, Yokogawa Electric Corporation GS 33L01A1D-40E Feb. 4, 2006-00

)


III SOFTWARE

• Operation and Monitoring Software LHS1100 Standard Operation and Monitoring

Function LHS1120 Console HIS Support Package for

Enclosed Display Style LHS1130 Console HIS Support Package for Open

Display Style LHS 1150 Server for Remote Operation and

Monitoring Function LHS2411 Exaopc OPC Interface Package (for HIS) LHS2412 CENTUM Data Access Library LHS4000 Million Tag Handling Package LHS4100 Configured Information Reference

Package LHS4150 Recorder Output Package LHS4190 Line Printer Support Package LHS4200 Consolidated Historical Message Viewer

(Meeting FDA) LHS4410 Control Drawing Status Display Package LHS4420 Logic Chart Status Display Package LHS4450 Multi Project Connection Package LHS4600 Multiple-monitor Package LHS4700 Advanced Alarm Filter Package LHS6510 Long-term Data Archive Package LHS6530 Report Package LHS6600 CS Batch 3000 Process Management

Package LHS6710 FCS Data Setting/Acquisition Package

(PICOT) SSS4510 Long-term Trend Historian

For details on the above functions, see the respective GS's. The operating system for an HIS is Windows Vista Business Edition or Windows XP Professional. If it is necessary to run other third-party software on the HIS, contact our sales representative to confirm that it is supported.


• Engineering Software LHS5100 Standard Builder Function LHS5110 Access Control Package LHS5150 Graphic Builder LHS5160 CS Batch 3000 Builder LHS5161 CS Batch 3000 Recipe Management

Package

10

LHS5170 Access Administrator Package (FDA: 21 CFR Part 11 compliant)

LHS5420 Test Function LHS5425 Expanded Test Functions LHS5426 FCS Simulator Package LHS5427 HIS Simulator Package LHS5450 Multiple Project Connection Builder LHS5490 Self-documentation Package

For details on the above functions, see the respective GS's.

• Standard FCS Software LFS1500 Control Function for Standard Field

Control Unit (for FlO, VnetllP) LFS 1530 Application Capacity Expansion Package

(for AFV1 00) For details, see publication GS 33L 15C20-40E.

• Optional FCS Software LFS3132 Valve Pattern Monitor Package LFS8620 Off-site Block Package

For details on these functions, see the respective GS's.

GS 33L01A1~OE Feb. 4,2008-00

.~ .. )

)


• Subsystem Communication Software For each subsystem, optional communications software is available.

LFS2410 FA-M3 Communication Package (for ALR111, ALR121)

LFS2420 YS Communication Package (for ALR121) LFS2421 YS Communication Package with Direct

Connection (forALR121) LFS2430 MELSEC Communication Package (for

ALE111) LFS2431 FA-M3 Communication Package (for

ALE111) LFS2432 DARWINIDAQSTATION Communication

Package (for ALE111) LFS2433 PLC-5/SLC500 Communication Package

(for ALE111) LFS2453 Modbus Communication Package (for

ALE111) LFS2456 SLC500 Communication Package (for

ALR111, ALR121) LFS2457 PLC-5 Communication Package (for

ALR111, ALR121) LFS2542 PROFIBUS Communication Package (for

ALP111) LFS2610 Foundation Fieldbus Communication

Package (forALF111) LFS2710 HART Communication Package (for

AAlhhh-H) LFS9153 Modbus Communication Package (for

ALR111, ALR121) LFS9162 MELSEC-A Communication Package (for

ALR111,ALR121) For details, see the respective GS's.

• Sequence of Events Manager Software LPC6900 SOE Server Package LPC6910 SOE Server Configurator Package LPC6920 SOE Viewer Package LPC6930 SEM OPC Interface Package

For details, see publication GS 33L30D1 0-40E "SEM Sequence of Events Manager (for FlO and VnetlIP)".

• VTSPortal Software LPC7800 VTSPortal Basic Pack LPC7801 VTSPortal Multiple Client Builder License

As for details, refer to GS 33Q02N81-31E "VTSPortal Basic Pack, VTSPortal Multiple Client Builder License".

• Documents LHS5495 Electronic Document

As for details, GS 33M01W10-40E "Electronic Instruction Manual".

• Plant Resource Management SSS7700 Plant Resource Management Server SSS7710 Plant Resource Management Client SSS7720 Field Communications Server

As for details, refer to GS 33Y05Q10-31E "Plant Resource Manager".


• Operation Support Software (for HIS) NTPS100 Exaplog EventAnalysis Package NTPS200 Exapilot Operation Efficiency

Improvement Package

11

As for details of each function above, refer to GS 36J06A10-01E "NTPS100 Exaplog Event Analysis Package" and GS 36J06B20-01 E "NTPS200 Exapilot Operation Efficiency Improvement Package".

• Safety Instrumented System CHS5100 Safety System Generation and

Maintenance Package CFS1100 Safety Control Functions Package

As for details, refer to GS 32S51 81 0-01 E "ProSafe-RS Safety I nstrumented System Overview (for Vnetll P)".

I11III INSTALLATION AND ENVIRONMENTAL CONDITIONS

The installation and environmental conditions for Yokogawa's devices, except for general-purpose PCs, General-Purpose Network Device, console HIS's, node units for FlO and I/O modules, are shown below. For a general-purpose PC and General-Purpose Network Device, see their specifications. For an enclosed display style console HIS, an open display style console HIS, a node unit for FlO, or an I/O module, see the general speCifications for each device (publications GS 33M50B40-40E, GS 33M50B50-40E or GS 33M50F10-40E).

Ambient Temperature: 5 to 40 ·C (yAX101) 5 to 35·C (YAX801, YAX211) o to 50 ·C (FCS)

Ambient Humidity: 20 to 80 %RH 10 to 90 %RH (FCS) Non-condensation

Temperature Change Rate: ± 10·C per hour

Power Requirements: 100 to 120 V AC ± 10%, 50 or 60 Hz ± 3 Hz 220 to 240 V AC, 50 or 60 Hz ± 3 Hz 24 VDC ± 10%

Withstanding Voltage: 1500 V AC for 1 minute (for 100-120 and 220-240 V AC model) 500 V AC for 1 minute (for 24 V DC model)

Insulation Resistance:

Grounding:

20 MO at 500 V DC 10 MO at 500 V DC (yAX101, YAX801, YAX211)

Independent ground of up to 100 0 Noise:

Electric Field: Up to 3 VIm (26 MHz to 1 GHz) Magnetic Field: Up to 30 AIm (AC), up to 400 AIm

(DC) Static: Up to 4 kV (direct discharge), up to 8 kV

(aerial discharge) Continuous Vibration:

Displacement amplitude: Up to 0.25 mm (1 to 14 Hz) Acceleration: Up to 2 m/s2 (14 to 100 Hz)

GS 33L01A10-40E Feb. 4, 2008-00

)

«Contents» «Index» 12

II CENTUM VP Entry Class The CENTUM VP Entry Class is available for small-scale systems .

• Components and Software The CENTUM VP Entry Class uses specific Entry Class packages such as built-in HIS packages. There is no restriction on FCS models .

• Operation and Monitoring Software The following software packages are provided for the Entry Class. Except for the packages listed below, current CENTUM VP system operation and monitoring software packages can be used. But, the LHS4000 Million Tag Handling Package cannot be used in an HIS with the built-in LHM1101 Standard Operation and Monitoring Function.

Operation and Monitoring Software

Entry Class Model Product Remarks

LHM1101 Standard Operation and MonitOring Function Number of operation and monitoring tags: up to 8000

LHM1150 Server for Remote Operation and Monitoring Function -LHM4410 Control Drawing Status Display Package -LHM4420 Logic Chart Status Display Package -

CS Batch 3000 Process Management Package Maximum number of active recipes:

LHM6600 Type A: 4 TypeB: 10 Type C: 999

LHM6710 FCS Data Setting/Acquisition Package (PiCOn -Engineering Software

Entry Class Model Product Remarks LHM5100 Standard Builder Function -LHM5150 Test Function -LHM5490 Self-documentation Package -

All Rights Reserved. Copyright © 2008, Yokogawa Electric Corporation GS 33L01A10-40E Feb. 4, 2008-00

)

«Contents» «~Index»~

II REGULATORY COMPLIANCE The standards to which CENTUM VP hardware devices conform are listed below. See the applicable general specifications to ensure each device's compliance.

Safety Standards ("1) [CSA]

CSA C22.2 No. 61010-1-04 (for 100 to 120 V AC and 24 V DC power supply)

ICE Mark] Low Voltage Directive EN 61010-1 (for 220-240 V AC and 24 V DC power

supply) (*8)

EMC Conformity Standards (*1) ICE Mark] EMC Directive

EN 55011 Group 1 Class A (for 220-240 V AC and 24 V DC power supply) (*9)

EN 61000-6-2 (for 220-240 V AC and 24 V DC power supply) (*2)

EN 61000-3-2 (for 220-240 V AC power supply) (*3) EN 61000-3-3 (for 220-240 V AC power supply) (*4)

[C-Tick Mark] AS/NZS CISPR 11 (for 220-240 V AC and 24 V DC

power supply) Standards for Hazardous Location Equipment [CSA Non-Incendive] (*5)

Class I, Division 2, Groups A, S, C and D Temperature code T4

CSA Standard C22.2 No. 157-92 CSA Standard C22.2 No. 213-M1987 ISA Standard ISA-S12.12 1994 (for 100-120 VAC and 24 V DC power supply)

[FM Non-Incendive] (*6) Class I, Division 2, Groups A, S, C and D

Temperature code T4 FM Class Number 3600: 1998 FM Class Number 3611: 2004 FM Class Number 3810: 2005 (for 100-120 V AC, 220-240 V AC and 24 V DC

power supply) [Type n] (*7)

EN 60079-15: 2003 IEC 60079-0: 1998 IEC 60079-11: 1999 (for 24 VDC power supply)

[Intrinsic Safety] EN 50014 1997 +A1 +A2 EN 50020 1994 EN 50021 1999 *1: To conform to safety standards and EMC

conformity standards, install 19-inch rackmounted devices in a keyed metallic cabinet.

*2: A lightning arrestor or the like is required to meet this surge immunity standard.

*3: An external device such as a power unit with harmonic current neutralizer and an active harmonics conditioner must be connected to meet this harmonic current emission standard.

*4: The specified limits of voltage drops across wiring must be satisfied to meetthis standard.

All Rights Reserved. Copyright © 2008, Yokogawa Electric Corporation Subject to change without nolice. .

*5: To meet the standard for hazardous location equipment, 19-inch rack-mounted devices must be installed in a keyed metallic cabinet approved by CSA or non-incendive regulator in your area.

*6: To meet the standard for hazardous location equipment, 19-inch rack-mounted devices must be installed in a keyed metallic cabinet approved by FM or non-Incendive regulator in your area.

*7: To be compatible with Type n, the specification requirements of EN 61010 and EN 60079-15 must be met, and a keyed metallic cabinet, whose degree of protection is IP 54 or above, prescribed by IEC 60529 must be used for housing.

*8: The analog input side of this equipment is measurement category 1. For details, see CENTUM VP Installation Guidance (T133Q01J10-01E).

*9: A Class A hardware device is designed for use in the industrial environment. Please use this device in the industrial environment only.

Note: According to the New Approach Directive, the manufacturer and the representative office in EU are indicated below: Manufacturer: YOKOGAWA Electric Corporation (2-9-32 Nakacho, Musashino-shi, Tokyo 180-8750, Japan). Representative office In EU Community: Yokogawa Europe B.V. (Databankweg 20, 3821 ALAmesfoort, The Netherlands).

II TRADEMARKS

13

• CENTUM, VnetllP, DARWIN, DAQSTATION ProSafe and Exaopc are registered trademarks ofYokogawa Electric Corporation.

• Exaplog and Exapilot are trademarks ofYokogawa Electric Corporation.

• Windows is a registered trademark of Microsoft Corporation in the United States and/or other countries.

• Ethernet is a registered trademark of XEROX Corporation.

• Modbus is a registered trademark of Schneider Electric and/or such related companies.

• PLC, PLC-5 and SLC500 are trademarks or registered trademarks of Rockwell Automation, Inc.

• MELSEC and MELSEC~A are registered trademarks of Mitsubishi Electric Corporation.

.• SYSMAC is a registered trademark of Omron Corporation.

• "FOUNDATION" of "FOUNDATION fieldbus" is a registered trademark of Fieldbus Foundation.

• Other product and company names appearing in this document are trademarks or registered trademarks of their respective holders.

GS 33L01A 1 0-40E Feb. 4, 2008-00

yyy ••• • •••• ~

- ) >- this document is for Damitta project :

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)


~--)

)

YOKOGAWA VnetJlP PCllnterface Card

YOKOGAWA VneVIP PCllnterface Card

YOKOGAWA VnetJlP PCllnterface Card

YOKOGAWA Vnetnp PCllnterface Card

all screens to be 22" as per DeS architecture and contract spec. GOOl-OODDi item 5.17.4

1/8

YOKOGAWA+

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SYSTEMS C£NTUM~

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EAST DELTA ELECTRICITY PRODUCTION COMPANY (EDEPC) ALSHABAB - 1000 MW SIMPLE CYCLE GAS TURBINE UNITS

Ref.: IA-HT-C-AI-I6-987-IO Rev. 0

Field Control Unit (FCU)

Dual Redundant CPU with VneYIP 1000 Mbps, 19" rack-mounted

Dual Redundant Power Supply, 220 - 240 VAC

32 MB Main Memory

133 MHz Processor Speed

Node Unit for Dual Redundant ESB Bus, 19" rack-mounted type 3 Dual Redundant Power Supply, 220 - 240 VAC

Dual Redundant ER Bus Communication, 128 Mbps

2.1.3 Redundant ESB Bus Interface

2.1.4

2.1.5

2.1.6

2.2.1

2.2.2

EB401 ESB Bus Coupler Module

Modules

Ethernet Communication Module, Modbusnp

AI Module, 16-Channel, isolated, 4 .,. 20 mA

01 Module, 32-Channel, 24VDC

DO Module, 32-Channel, 24VDC

Termination & Cabling


Dual Redundant CPU with VneYIP 1000 Mbps. 19" rack-mounted


32 MB Main Memory


Node UnH for Dual Redundant ESB Bus, 19" rack-mounted type



3/B

2

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Ethernet Communication Module, ModbusllP

Including 25% spare

AI Module, 16-Channel, Isolated, 4 _. _ 20 mA





Dual Redundant CPU with VnetllP 1000 Mbps, 19" rack-mounted


32 MB Main Memory


2

10 15

2

Lot

Node Unit for Dual Redundant ESB Bus, 19" rack-mounted type 3



ESB Bus Interface

ESB Bus Coupler Module

Modules

Ethernet Communication Module, ModbusllP

Including 25% spare

AI Module, 16-Channel, Isolated, 4 ... 20 mA




cables, termination and Internal panel wiring are Included

418

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Ref.: IA-HT -C-AI-I 6-987-/0 Rev. 0


Dual Redundant CPU With VneUIP 1000 Mbps, 19" rack-mounted

Dual Redundant Power Supply. 220 - 241) VAC

32 M8 Main Memory


Node Unit for Dual Redundant ESB Bus, 19" rack-mounted type 3

Dual Redundant Power Supply. 220 - 240 VAC


Bus Interface


Ethernet Communication Module, Modbus/lP

AI Module, 16-Channel, isolated, 4 '" 20 mA




cables, termination and internal panel Wiring are included


Dual Redundant CPU With VneVIP 1000 Mbps, 19" rack-mounted


32 MB Main Memory


2

10 15 2

Lot

Node Unit for Dual Redundant ESB 8us. 19" rack-mounted type 3



5/8

)

GIZR YOKOGAWA+

SYSTEMS CENTUM"'ilI"p

~1"l£Wale


Modules

Ref.: IA-HT-C-AI-J6-987-JO Rev. 0


Ethernet Communication Module, Modbus/lP

AI Module, 16·Channel, isolated, 4 ••• 20 rnA

01 Module, 32-Channel, 24VOC

DO Module, 32-Channel, 24VOC

TermlnaUon & Cabling

Project 10 License

Software Media for HIS Including Electronic Instruction Manual

Statlon)

Standard Builder Function

Graphic Builder

Self Documentation Package

Test Function

Electronic Instruction Manual

Standard Operation and Monitoring Function

6/8

2

12 11 2

Lot

3

)

GIZR C-ENTUM1!/jt:a SYSTEMS

YOKOGAWA+

_ln~iIW

pos.\

3.3

3.4

3.5

3.6

NJl\ 4.1

4.2

4.3


Ref.: IA-HT-C-AI-J6-987-JO Rev. 0

Bill O(Material (BOM)

Description

Licenses for HIS (Operation and Operation Monitoring Stations)

LHS1100 Standard Operation and Monitoring Function (New Installation)

LHS2411 Exaopc OPC Interface Package (For HIS)

LHS6510 Long Term Data Archive Package

LHS6530 Report Package

LBC2100 System Integration OPC Client Package

LHS4600 Multiple Monitor Support Package

Licenses for Controllers

LFS1530 Application Capadty Expansion Package for AFV100

Licenses for Communications

LFS2453 MOOBUS Communication Package for ALE111

Licenses for Plant Resource Manager (PRM) (Optionl SSSSM02 Software Media for Plant Resource Manager

SSSSD02 Electronic Instruction Manual Media for Plant Resource Manager

SSS7700 Plant Resource Manager Server for 1000 devices

SSS7710 Plant Resource Manager Client

SSS7720 Fiefd Communications Server

DELL or HP PC· Based Station for Plant Resource Manager

DCS System Cabinet

Dimensions: 800x800x2000 mm (DxWxH), Electrostatic painted, IP54, Lighting,

Earthing Connection and system cables, Completely wired with all necessary,

breakers, fans, filters and terminals

DCS Marshalling Cabinet

Dimensions: 800x800x2000 mm (DxWxH), Electrostatic painted, IP54, Lighting,

Earthing Connection and system cables, Com pletely wired with all necessary, power supply

breakers, fans, filters and terminals

Power Distribution Cabinet

Electrostatic painted, IP54, Lighting, Earthing Connection and system cables,

Completely wired with all necessary, breakers, fans, fiRers and terminals

7/8

\ Qty.

3

2

2 2 1

1

1

1

1

1

1

1

1 1

5

5

1

YOKOGAWA+ GIZR SYSTEMS

C£NTUM~ ------we Inlk",a1J;!


Ref.: IA-HT-C-AI-16-987-JO Rev. 0

Communications and Interconnectivity Design

Display DralNings for up to 100 Graphic Pages

Dig~al Output Module, 32-Channel, 24VDC With Status Display 2 Ethernet Communication Module, ModbusllP 1 VneVIP PCllnterface Card

8/6

... )

)

all comments shall be reflected in the DeS system architecture submitted by KN "10067-9-V01-JQ07-00001"

connect the two switches for reduncancy

CTG GE MarkVle - 1

Subslailon Oisl. TX 20QOKVA LV Load Center~2 LV Package Substation Olesel Generators Fire Pump Stalion Unloading Fuel Pump SoJarOil Tanks Solar Fuel Treatment Plant Serviee/lnslrul'TM

shall Interface with: CEMS-instrument Air-Service Air-fan coolers

<}r,ES("~ COIllE.~

'--'

1 screen for the large screen PC as per the BOM"bill of material"

two independent power supplies (UPS+ uninterrupted J007-00COl item 2.4.2.1

<}JESCCCO~8 dual screen as per 80M

Co""" Room III GPSMuI'trCktct.

J

The plant's alert approach fa operalions, maintenance, and information is obvious. Operators are calm and in conlrol. Managers are well informed, but never overwhelmed with data. All facilities are under control, ready ta unleash their full polenlial for occasional peak load. Al the same time, palenlial problems are anticipated before Ihey happen. Aillhis in lhe life of D vigilant operation.

Th~l conlrol room is ql.liHt, with arrays ()f compuiet

semens dit;playing Iml1ds and Jllessag(~s on the walls and operating desks. Gone are ttlH chart recorders. plinters, metors and push bu~ons of yesterdr.,y. Oporat .. ing staff remain calm. monitOring operations, prepaling the plant ior routine tesling and maintenance.

Oll,er operating staff take time out from the control room

jor refresher training on the plant's lui! replica tmining siln~ator. Here. the atmosphere is not quite as calm as operating staff get put tl1fough their paces responding to

emergency conditions. and undergo training for less Willmon tasks such as plant start·up.

Being trained tOT a wide vHriety of emergencies: the operatcl's are ready to handle unexpected events with confidence, Unscl1edu!ed shutHdowns are minimized and rapid recoveries from unforeseen incidents are assured,

Plant Expansion With today's power plants remaining ", operation f'" sav-91al decades, there comes a time wilen instrumentation and ·.;ontrol systems must be renewed to mai,n\ain a competiUvfl (~dge.

At th(·) start of a repianemHnl project. Yok.ogawH':~ experienced engineering !earn c(uries nu! a piant and control system audit. The GUstainab!e and I!eKible archi!octure of Yokogawa's control system means that only the obsolete control units need to be changed over, allowing existing

equipment 10 be retained to the maximum extent, Strate" gles for increasing plant safety. avoiding project cost over

runs, and increasing plan! availabifrty are put into place.

\Ntlile the design and fabrication proceed, (,.'1Ul(~r proce$s applicatIon speclalist8 mviHw ttv.) plant control stra!egies nnd incorporate new centrel concepts. This is thoroughly tested by simulation, almost always with a full replica sin"l:ulator. Tesling proceeds separiitely from thl~ manumcltlre of contlol equipment, providing low risk engineering processes lor projects will, short outage times.

Once !he plant outage begins, existing control equipment is quickly removed. without disturbing existing cabinets and caDle •• The new factory-assembled and lested control equipment i.~ in.<;talled, and connections made !o p.)(iSling l(·)mlinafs and (:ablt}S, Comrnlss'!orilng and te&1ing of the r"eN oorr!roi (-)quiprner'rt cmnrr)(.)f)C(-I.s alrnO&1 frnrnediaJ(~Iy.

As the outHge concludes, opemtlng staff "run uP" the

plan! viilh ti1e confidence that comes from having under· gone extensive training on ~,e plant simulator.

With tile rew oonirol system, tilE! pewer plant Is set for many more years of safe, rellable and compelitive operation.

T© a casual ©bservar, this calm &. effident settil'l~ m<l'Y seem rl,';!ttaer b()ring. ilut thi5 is the W'lll'f C! pillnt should run -allowing 'Iou to See Cie<:!Ir!~ Know in Advance, and Ad with Agiliiy. It should run like a VigikmfP!ant.

51

vigilant'i'Jj:i!'C~~'~ft' i1F)"'~' .; > • ~ ¢'

Improving visibility of aU plant information vvith single unified architecture

The effectiveness and efficiency of power plant operations depend on Ihe availability of key performance information about the plant and the process. Yokogowa delivers a single-architecture monitoring and control syst&m thot integrales information from all facets 01 a pOW<lr plant and keeps th .. planl personnel well informed. The industry-leading availability, reliabilify, and long-term stability af the YOKogawa automation plaffo.m. ens" .... an operating environment where your people can have 20,20 vision of your entire operation.

Key Enablers:

Single architecture covering the entire plant - CENTUM VP total power plant control system for turbine, boiler anc! balance of plant (BOP) controls

- TOV SIL3 certified ProSafe-RS integrated salety controller tor the burner management system (BMS) and

protection system

- FOUNDATIONT .. fieldbus anc! HART interface for field instruments. analyzers, and valve positioners

- PROFIBUS interface for electrical equipment and molor valves

- lEe 60870-5 interface for substation equipment

High availability - Field-proven controller with seven 95 (99.99999%) availability in unique pair-and-spare redundant

architecture

- Pair 8. spare fail-safe architecture is also available for the ProSafe-RS safety controller

long term stability - =0.04% accuracy "f the DPharp EJX digital transmillar even in the most critical applications (drum level. ett~)

- ",0.1% of upper range limit (URl) for 10 years with EJAJEJX tr..msmitlars

ErrOl (%@rnax.span)

o.tO~.

i~~J fHFFP 1 2 3 4 "0 11 12 13

.. :L:j 14 '16 6

\'c'ler

16

()ptinlizing operation & maintenance for unprecedented plant managernent efficiency

Once into commercial operation, competitive po .... r planfs pursue operational excellence by continually improving effidency and 'preventing/minimizing abnormal situafions. Yokogawa enables optimization solution.lhal empower plant personnel under bolh normal and abnormal conclilions. Knowledge-based tools and consulling .eNices enable continual productivity improvement, advanced alarm management, and integrated plant asset management. No longer just reacting to problems, your people and your <ISseis are focused on meelingtomorro'N'. challenges.

Key Enablers:

- Intelligent alarm management aulomalically displ(~ys alarms requiring oporalor aUrmtion, intllrrni"~)

operators whether alarm pOints are improving while suppressing irrelevant alarm messages.

- Exapfog event analysis package analyzes the frequency of alarms and operator actions. visualizing

stalisti~,aI data and helping to find Ihe rool causes of alarm occurrence and areas for improvement.

- Event sequence analysis with built·in Sequence of Events Manager (SEM) allows 1 mseo time resolution

and 1 rnsec accurate lime synchronization system across all controllers.

- Integrated asset management with P RM Plant Resource Manager enables effective maintenance of plant

assets in a single unified database system across different protocols and multiple suppliers.

- Full-replica simulator performs highly accurate modeling of actual plant behavior under any scenario for

optimized operation and control.

- Performance calculation is fully integrated with tile Yokogawa DeS and uses predefined formulae to monitor

and optimize pelformance.

- Long-term data archiving and date transformation with F..xaquanium ensures enhanced, seamlElsa

Information flow within Mel between plant systems !Ina business applications.

ing agility of business vvith plant rvices throughout the plant life eyel

Our;ng the relatively long life cycle of a power plant, the .... comeS a time when Ihe instrumentation and

control systems must be r .. n .. wedle maintain a <o~peli!ive edge. Yokogawa supports power plants with

"'pert servi"". that maximize efficiency and minimize (osl over the entire life cycle, From initial design,

,on$lwel;on, and daily operation 10 revamp and reinstrumentation, Yokogawa stands by your power plant. This long-term partnership ensures hottl.meek-free performance and ongoing optimization Ihat bring speed and flexibility fo your business,

Key Enablers:

- Our philosophy of continuous evolution, demonstrated over a 30 year period with CENTUM, ensures a smooth migration path and keeps your investment for f&C refurbishment to a minimum.

I Efficient piant commissioning with plant simulator - OHfine commissioning on II high-fidelity simulator allows !horough validation of the DCS c!)I1l1guration

before the software is loaded at the actual plant. keeping to a minimum the final tuning that must be done

during plant commiSSioning,

- Certified professional trainers deliver competency-based training using a plant simulator to create training

scenarios that flexibly replicate normal, abnormal, and emergency operating conditions.

- 2417/365 remote monitoring combined with real-time diagnostic tools and services ensures system

maintenance can be condillon-based. not time-ba~ed, reducing maintenance spending.

- Automated operation procedures created with Exapilot enable the know-how of experienced operators to

be shared with less experienced staff.

- Documentation of standard procedures for operation, maintenance, training, cc>mmissioning, audit, and

reporting.

- Plant-wide audits examine human resources, fuel, asset management, environment, production, plant

operation, and information systems, identifying opportunities for improvement and cost reduction.

n j

',,-,

4'

In e wer ;ndus·-~w

Field in:s~ruments - Pressure. temperature. flow. and level measurement

- Valve positioners and converters

Analytical h1struments - liquid analysis (pH/ORP, conductivity. dissolved oxygen)

- Gas analysis (NOx, SO" CO. CO" 0,. hydrogen purity)

Safety Management Systems - TUV SIL3 certified integrated safety systems for burner management and

emergency shutdown

Unit Control Systems - Distributed control systems

- SCADA and network-based control systems

',,--,

Data Acquisition ;::md Contro~ - Paperless videographic recorders

- PC-based and stand-alone data acquisition equipmenl

• Single loop and highly scalable programmable logic controllers

Meters and Test Instrurnents • Analog/digital meters, clamp-on power meters, power monitors.

insulation testers. handy calibrate.rs

Plant Optimization SoftW<0H'(t - Performance analYSis. operntional elficiency improvement, and alarm managemem - Asset management

Power Ph,mt Services - Commissioning. operator training, operation, maintenance,

and simulation services

1,2

application ex

Fossil fuel fired power plants • CosVoiVgas fired - Combined cycle - Simple cycle .

- COiJooeraffon .' Industrial boilers

rience in the

CFB boiier plant

15 i

Turbomachinery

::t"f't ~., <!. S~/~"'·iih

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control

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Typical coal fired power plant

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All types of plant information including process data, alarms, events and sequence of events (SOE) are handled by plant information management, enabling the analysis of plant operational performance.

Plant resource management

- Boiler control - Burner management

1:1: " -1'::1. J:!:~I . ~

- Turbomachinery control - Balance of plant (BOP)

Cosl handling Waler treatment Ash handling Flue gas desulphurlzation (FGD), etc,

Plant resource management inlegrates and manages maintenance information from field instruments and monitors online conditions .

The ProSafe-RS SCS Is a TOV SIL3 certified safety system that incorporates Yokogawa's own pair-and-spare technology.

lit;

Services r a Ii fime of plant e

c".;; '7~~'~ .":" '·~i.{;;·· .,~,.,.,.

u~~;n#;$6~/;~~i~~~R;~ftn •• TS'.6aV<lrba~tar.·.I1~;ld .Ofthe1tIlTh~~rnal;~o,WeV~lal1t.

~~~iq; i~bell~og; Wl1at~'bea~tiful thlnil~~~sP~9Plesw.I~ .......... ' ... . ....unul '.1 seeltJemat wqrk;WtlQnw<l ~xpiJrierJciedth!> pl~rit trip,lIeam';dwh~ ~axe(! •• " Yokogaw'" d~f<1rorrl from (iiilaro.l.arbiliretl\eir siriCl;rily an~.&!VOliO"lowrll\l

4 x 420 tihr, cool fired, p,.n"·U."m.!l,ng

A mom stabfe and robust power supply The fe·instrumented boilers realized both higher stability and

increased throughput, assurin!J a stafJle energy supply.

Reduction of malfunctions and accidents Since the renovatIon, equipment malfunctions have dropped

dramatically, eliminating costly plant downtimes.

)

Yokogawa Vigilance at your service worldwide w representative projed's

Italy 400MW

IWPP

'" *1 t lli . ® Vlg. an I)lant f$ i!1

The clear path to operational excellence

YOKOGAWA ELECmlC CORPORATION World Headquarters 9-32, Nakacho 2-chome, Musashino-shi, Tokyo 180-8750, Japan htlp:llwww.yokogawa.coml

YOKOGAWA CORPORATION OF AMERICA 2 Dart Road, Newnan, Georgia 30265, USA htlp:/lwww.yokogawa.com/usl

YOKOGAWA EUROPE B.V. Databankweg 20, 3821 ALAmersfoort, The Netherlands htlp:/lwww.yokogawa.com/eul

YOKOGAWA ENGINEERING ASIA PTE. LTD. 5 Bedok South Road, Singapore 469270, Singapore htlp:/Iwww.yokogawa.com/sgl

YOKOGAWA CHINA CO., LTD. 3F Tower D Cartelo Crocodile Building No.56S West Tianshan Road Changning District, Shanghai, China htlp:llwww.yokogawa.com/cnl

YOKOGAWA MIDDLE EAST B,S.C.(c) P.O. Box 10070, Manama Building 577, Road 2516, Busaiteen 225, Muharraq, Bahrain http://www.yokogawacomlbh/

Trademarks

Australia 4xSOOMW cool firl!d revampmg

Peru 65(1MW combined cycle

o Fossil fired power plants

Iii Gas turbine power plants

u.s

o Renewable energy power plants

4ft Plant services and/or plant simulators

~ Yokogawa seJVkeoffices

VigilantPlant is YokogaW<l's automation concept for safe, reliable, and profitable plant operatians. YigilantPlant aims to enable on ongoing state of Operational Excellence where plant personnel are watchful and aflentive, well-informed, and ready to take adions that optimize plant and business performance.

1---------------------------------------f Represented by:

f ---------------------------------- ______ 1

URL:www.yokogawa.com/pwr

CENTUM, VneVIP, vigilance and vigilantplant are either trademarks or registered trademarks of Yokogawa Electric Corporation. All other company brand or product names in this bulletin are trademarks or registered trademarks of their respective holders.

'----' '.--

ver 300 projects awarded in 7 years Bulgaria Romania M I" K S 8 x 200 t/h 4 x 330 MW ongo la orea. . U. (since 2001) fI d If;" t" fl d If;" t" 8 x 420 t/hf coal fired 800 MW supercntlcal 480 MW ue gas esu I unza Ion ue gas esu I unza Ion revamQing & simulator traini

Ita Iy \ \: .... ____ ~_ .I"""'i""'''~'i''·iPicYV~UD.FS:!i'j:''!j:'''\;'':h'ii:h,i\~,},u...,w. 400MW

India 3 x 660 MW coal fired

Taiwarr 2x 550 MW coal fired

0/ Vietnam 2 x 300 MW, coal fired simulator & t .. "ininn

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i":'. '·':I;I.l\tfiGCpe.t;gypt:·;.;', . ...... 7S0MW,/CCPp /' MHI/C:S3000

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:'NIPPSapei~:pp;Nig~Ha' "4S0MW~ ~:GE9E; CS30pq

; ... NIPPth~vbOr;~p/Ni~¢ri~' .... ·.150Mvv,· c;r§t;9E,J:S3QQO

"iNIPPCaiaQ~~',g~;Nig~ria' 560MW,GT:GE9E,·Cs3000·'

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ji.· .. ·.·~··):!S~Oi~.It>~$~~;Ia~~~ys'·::,·.~~' 130MW,',CCRPtGt;Gy; UO:nfCS3QOO

:~\:.\·i~' ,:~. i:, :;. ,~.',:~'.(::I\, ':.: >.]~1~;;:;;I>A:j1;:,~::i!~;::;: ~):/<.~::·~.';::t::~:·;· >:i

Location: Bilbao, Spain Order Date: 2001 (BBE & BBG) Completion: 2003 (BBE & BBG) Industry: Power and LNG

A Yokogawa Commitment to Industry

vigilance:

) Background of the Proiect

In Spain, the demand for electricity and imported natural gas has been rapidly increasing, a trend that is anticipated to continue for years to come. To augment the country's energy supply, several new LNG regasfication plants as well as combined cycle gas turbine plants have been constructed in Spain.

About the Bahia de Bizkaia Plant - BBE and BBG

To achieve a stable supply of gas and electricity for the country, the Spanish government decided to build the Bahia de Bizkaia Plant. located in Bilbao, this plant consists of Bahia de Bizkaia Electricidad (BBE), an 800 MW gas fired combined cycle power station, and Bahia de Bizkaia Gas (BBG), a regasification facility with regasificators having a total capacity of 2.7 billion cubic meters.

The Bahia de Bizkaia Plant is one of the most significant power projects to be carried out in this region. The proiect has been led and financed by Ente Vasco de la Energia, Repsol-YPF, British Petroleum, and Iberdrole S.A., with the total investment coming to approximately 600 million euros.

) . The Challenges and Results

{1} High availability (BBE and BBG)

Both facilities aim to have high availability. The field-proven CENTUM CS 3000 distributed control system (DCS) ensures this by enabling the control and monitoring of the entire BBE power station. The BBG regasification facility is designed to operate 24 hours a day, 365 days a year without having to be shut down for maintenance. Yokogawa's highly reliable CENTUM CS 3000 DCS offers a high degree of redundancy that contributes to the entire plant's high availability.

(2) Unified operation of multivender control systems (BBE)

At the BBE power station, General Electric Company gas and steam turbines have been installed and are controlled by the company's own turbine control system. The electrical equipment of the power station is con-

A Yokogawa Commitment to Industry

vigilance:

trolled by another venderls system. With its Unified Operator Interface (UOI)I Yokogawa/s CENTUM CS 3000 enables the seamless operation of each of these control systems. With the UOI solutionl all of the actions required for the operation l management, and maintenance of turbinesl the heat recovery steam generator (HRSG)I and the balance of plant and electrical controls can be carried out from a single operator interface. The UOI also eliminates the requirement for operators to master the operation of multiple systems.

(3) Flexible operation and reduced start-up time (BBE)

The BBE power station is capable of working both at base load and at partial loads, which provides flexibility in the plant operation. In additionl to reduce the start-up time, 100-percent-f1ow by-passes were designed to start the gas turbine and the HRSG individually without starting up the steam turbine. The Yokogawa DCS for which the Spanish engineering company Siemsa Notre S.A. (SIEMSA) fully implemented the above operation logic has

. steadfastly supported the safe plant operation and smooth startup. )

)

Customer Satisfaction

The SIEMSA engineer commented, IIWe appreciate CENTUM CS 3000's operationality and system reliability. With the UOI solution l the DCS controls use the same HMI system as the turbine and electrical control system, and there is no need for a dedicated communication gateway and separate screens. This significantly reduces the engineering time and costs. I

'

System: CENTUM CS 3000/UOI (BBE) CENTUM CS 3000 (BBG)

System configuration: 4 x operator stations (BBE) 1 x engineering workstation

2 x UOI (Cimplicity) servers 4 x field control stations 2,600 inputs/outputs 1,800 Communication Signals

System configuration: 1 x Engineering Stations (BBG) 6 x Operator Stations

4 x Control Stations 1,500 Inputs/outputs 2,500 Communication Signals 1 x OPC Server

vigilance:

Location: New South Wales, Australia Order Date: 2003 Completion: August 2004-2005 Industry: Power

.) Executive Summary

1. Faster commissioning The control system replacement for the four units is continuing. The first two units have been successfully completed ahead of schedule, providing the customer with financial benefits.

2. Efficient operation ensuring high reliability The renovated units give very stable and efficient operation, allowing the customer to make everyday load changes at a faster rate than with the previous control system.

3. Improved system maintainability The integrated device management system enables real-time, remote maintenance of multivender field devices via the control system, helping the users to minimize routine maintenance work.

Background Eraring Power Station, located just north of Sydney, is one of the largest power stations in Australia, comprising four 660MW coal-fired units.

) The power station has operated reliably since 1981. To ensure continued reliability for the next few decades, Eraring Energy, the owner of the power plant, decided to replace the original hard-wired control equipment with a modern integrated control and monitoring system (ICMS). Significant project drivers were the requirements to maintain plant reliability and to gain operational improvements in order to ensure the competitiveness in the deregulated Australian power market. The re-instrumentation work started in early 2003 under the leadership of Yokogawa Australia, which teamed up with TechComm Simulation, a wholly owned Yokogawa subsidia ry.

The Challenges and the Solutions The customer required an integrated system to control the operation of the boilers, turbines, generators and other balance of plant equipment. Yokogawa proposed an integrated solution comprised of a distributed control system (DCS), plant information management system, field device management system, full-replica training simulator and field instruments together with strong local support.

Operational improvements ensuring plant reliability The Eraring plant has four large units with a total system input/output (I/O) count of more than 40,000 as well as 25,000 interfaces to other plant auxiliary systems. Yokogawa's CENTUM CS 3000 R3 DCS supported this large application in a single architecture while ensuring reliable plant operation with its"pair&spare" non-stop controller technology.

, To satisfy the need for further operational improvement, a Yokogawa ) Exaquantum plant information management system was used for

long-term data storage, data and alarm logging, and performance . calculation. The users can monitor the graphical data for both current and historical plant information in an Exaquantum window at their own PCs using the Eraring wide area network. This makes it easier for operators and plant managers to keep informed and to make decisions for future plant operation.

Sample window showing control performance

The customer also desired to improve plant operation in the aspects of human resources and operating environment. Yokogawa's high fidelity, full-replica simulator enabled custom-made operator training that fully replicated the characteristics of the Eraring Power Station. This allowed the operators to be familiar with all aspects of plant operation using the new control system before running the real plant.

)

The original analog-based control room was replaced with a new control room which is based on the latest ergonomic deSign, securing operator's higher performance.

Power plant simulator New control room (CAD deSign drawing)

vigilance:

System maintainability

Another important issue to be considered was system maintainability. From the late 1990's (before the control system replacement), the customer had progressively upgraded its analog field instruments selecting Yokogawa DPharp EJA transmitters as well as other vendor's devices. A further requirement was to upgrade the original paper-based field device management system to a Windows-based, user-friendly tool which integrates various data from multivender HART and analogue devices into a single database. The customer wanted system compatibility with the DCS and used the opportunity of the plant revamping to achieve tight integration of the field device management system into the DCS.

Yokogawa met these requirements for integrated device management across the HART protocol with a combination of its CENTUM CS 3000 DCS and its Plant Resource Manager (PRM) software. The new system inte-

) grates all field information into a single database on a PRM server and allows real-time, remote maintenance of many hundreds of devices, including around 500 EJA transmitters, via the DCS networks and HART I/O modules. The open architecture of PRM will also allow the diagnostics of smart Fisher valve positioners via the Yokogawa DeS just by loading diagnostic plug-in software onto the PRM server. This integrated maintenance solution helped Eraring's maintenance crew streamline plant maintenance work.

Ethl!.rnet--...... __ _

Vn&--------~~------T_----~~--~~~~:

)

II II 4";,!O,'lfA field de'lices Fisher vaf..e

'With HAAT pWooner$

PRM window (sample) Overall system configuration

vigilance:

Minimum plant outage

Another challenge was the tight commissioning schedule. The first outage was planned 15 months after the initial order. To minimize the time taken for the control system replacement, Yokogawa proposed a unique solution making full use of the capabilities of the Yokogawa DCS and simulator.

The CENTUM has a unique engineering test function that enables an application functional test on a generalpurpose PC without any real controller hardware. Yokogawa affiliate TechComm Simulation developed the high-fidelity Simulation system based on the detailed plant documentation supplied by the customer. Combining these capabilities, Yokogawa engineers were able to very extensively test the new control system on the simulator prior to DCS commissioning, thereby minimizing the final tuning work once the unit returned to

) service.

Eraring plant operators were well trained in the new control system utilizing the simulator. This avoided mistakes that could have occurred if they had not been familiar with the new system, ensuring a smooth plant commissioning process.

The Results

Faster commissioning

The four units at Eraring are being retrofitted progressively, with the first changeover in August 2004 and the second unit being completed at the beginning of 2005. The customer was very pleased that Yokogawa has completed return to service of the first unit ahead of schedule, with the second unit approximately two weeks early and similar results expected for the third and fourth units.

Efficient operation ensuring high reliability

) The renovated units give very stable, and at the same time more flexible operation than before. After the . revamping, the customer now makes everyday load changes at a rate faster than with the previous control

system. This can provide financial benefits in the competitive Australian electricity market.

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The result of control performance

Efficient maintenance

Integrated device management enables predictive maintenance, reducing routine maintenance work. Jeff Hogan, Power Station Technicians Supervisor of Eraring Energy said, "The upgrading of field instrument is still in progress but PRM has provided access from our workshop to all smart instruments on site. When a plant problem occurs we are able to verify the validity of reading and configuration settings of the associated instrument within a couple of minutes. A great diagnostic tool which enhances the Yokogawa CS3000 System."

System Configurations and Details

) Distributed control system: CENTUM CS3000 R3

Burner management system: CENTUM CS3000 R3

Plant information management system: Exaquantum

Integrated plant resource management system: Plant Resource Manager (PRM)

Simulator: TechComm full-replica training simulator

Field devices: EJA series electronic pressure transmitters, GD series gas density meters

Project includes: Full functional requirements design, control system software development

factory acceptance, installation, commissioning & tuning

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Education