Yokogawa Electric Corporation Nakacho, Musashino-shi Tokyo, JAPAN Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation DCS with long life Yokogawa’s Migration Path October 22, 2015

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Important issues for long life DCS. Using DCS for a long time, the following items become more and more important. –System Deterioration Due to Aging. –Out-of-date Functions. –Increasing System Maintenance Cost. You cannot avoid to renew your DCS to make your total cost lower. HOWEVER......

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… System Deterioration Due to Aging. System deterioration can be generally predicted below. Time Failure rate Required reliability (allowable failure rate) End-of-life cycle Shift toward deterioration cycle Coincident failure cycle Deterioration curve To minimize the fall in plant operation rate (business loss) caused by aging, costly spare parts and maintenance checks are necessary. System failure rate =  i x N i : Parts failure rate N: Number of Parts Based on environmental condition, becomes more due to aging.

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Out-of-date Functions. New technologies are established after introducing the existing systems. –OPC, Fieldbus, Network of MS-Windows, etc. For production systems, there are the increasing requirements, such as below. –Hot link with business domain, such as ERP, PIMS, MES. –Improvement manual operation with AOA software. –Optimization with Fieldbus system and total asset management. –Remote solution for control, operation, and maintenance. To remain in competitive market, it is necessary to catch up with the technology innovation.

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Increasing System Maintenance Cost. Because of the quick innovation of parts, parts manufacturers tend to discontinue supplying. –It occurs frequently especially for DCS basic parts, such as CPU, HDD, IC, etc. The longer time pasts after the release, it becomes more and more difficult to provide the parts of the DCS with reasonable cost. For long term steady DCS operation, it is necessary to consider the supplement ability of maintenance parts.

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… In case of “Scrap & Build”, Advantages: –The latest technologies can be used. –System life becomes longer. Disadvantages: –Full installation cost is necessary at once. –You need to consider your application assets. –How to use is changed suddenly, so particularly operators may feel uncomfortable, at first. Yokogawa’s MIGRATION solution is to minimize disadvantages without missing advantages.

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Key points of Yokogawa's Migration Step by step –Only the portion with shorter life parts can be renewed with remaining other portion. –Divide renewing cost. Reuse the existing assets. –Field cable wiring. –Field devices. –Application database. Shorten stopping time for migration work. –Longer stopping time directly leads to larger loss of your business chance.

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Yokogawa’s Migration Path. CENTUM CS Micro-XL CENTUM V CENTUM-XL

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Yokogawa’s Migration Path. CENTUM V, CENTUM-XL –Migrate to the latest CS3000 R3 system with 3 steps. Step 1 : HMI migration Step 2 : Controller migration Step 3 : I/O portion migration

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Solution with Migration step 1 Ethernet Vnet HIS COPSV, EOPS are no longer necessary. It is not necessary to modify FCS and I/O. HISs works instead of COPSV, EOPS All tag data of the existing FCSs can be operated from HIS. (Read/Write is OK.) Operators need not recognize whether the tag is the existing FCSs’ or CS3000 FCSs’. Operation keyboard and touch panel are available. OPC server All process data is handled as CS3000 data. Operation improvement with AOA function. Seamless connection with PIMS. Audit trail Remote operation Bus converter

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… How to connect. Ethernet Vnet HIS FCSs do not be affected at all. As HF bus is redundant, the communication does not stop when connecting Vnet -- HF bus. Tags are registered in CS3000 builder. Builder Download tag information to each HIS. Process operation is not stopped when connecting HISs.

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Connection without communication stop Terminator HF bus line-1 HF bus line-2 FCS Vnet Bus converter (1) 1 set of HF bus are connected to a bus converter. (2) Remove a terminator of the existing HF bus. (In this case, HF bus line-1 is still working.) (3) Connect the HF bus cable from the bus converter. (4) Remove the other terminator of the existing HF bus. (In this case, HF bus line-2 is still working.) (5) Connect the HF bus cable from the bus converter.

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… What are benefit at Step 1 ? Step 1: HMI Migration –Dramatically reduced the anxiety of parts supplement. HMI includes the shorter life parts, such as CRT, HDD. As CS3000 HMI is based on generic PC, it is easy to supply these parts. –You can utilize the latest Windows technologies. Because CS3000 R3 works on MS-Windows2000 and will be able to work on WindowsXP. –Seamless connectivity with various kinds of the latest business domain systems. HIS (R3 HMI) has OPC interface. Most of MES, PIMS, and CMMS have OPC interface. –Operation improvement with AOA software in HIS. AOA (Advanced Operation Assistance) can improve your manual operation.

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Solution with Migration step 2 Ethernet Vnet HIS It is not need to modify I/O nests, signal conditioners, and field wiring at all. CS3000 FCU has the interface for the I/O bus of CENTUM-XL and V. You can connect the existing I/O nests to CS3000 FCU. Field wiring cables need not changed at all. CS3000 control logics can be connected to XL, V I/O. OPC server FCU is used instead of SCN. Control logics (Loop, sequence) works as CS3000 control function. Much more availablity with Pair&Spare technology. Connected on Vnet.

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Solution with migration Step2 Existing CENTUM-XL (Front)(Rear) (Field) Internal bus

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Solution with migration Step2 (Field) (Front)(Rear) CS3000 XL SCN Internal bus

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Solution with migration Step2 Same Interface connector SI31SI301 (Field) (Front)(Rear) CS3000 Internal bus XL SCN

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Solution with migration Step2 (Field) (Front)(Rear) CS3000 Internal bus ESB bus CS3000 FIO subsystem

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… How to connect. Ethernet Vnet HIS You can change FCUs one by one without affecting other FCSs at all. Builder Download control logics to each FCS. Process operation by other FCUs is not stopped when replacing an FCU. Control loops, Sequence, etc. Control logics Converted as CS3000 application. Control Logics Save

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… What are benefit at Step 2 ? Step 2: Controller Migration –Much Larger application capacity. –Much quicker processing. Short turn around to improve control ability. More control logics can be used. –The batch system complied with ISA S88. –Much more reliability. Pair & Spare mechanism to detect not only the hardware abnormalities, but also software abnormalities, such as the error by transient noise. –Much more number of I/O point. FIO subsystems can be additionally connected. –Much more visualized control logics. Not only decision tables, but logic chart, SFC, are available. The work status of these logics can be displayed on HIS.

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Solution with Migration step 3 Ethernet Vnet HISOPC server Renew I/O portion to R3 FIO subsystem. Front connector of FIO modules is same as existing I/O cards. Field wiring can be remain.

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Hardware continuity (Front)(Rear) Same connector is available. Field wiring is NO CHANGE Field wiring Compatible modules with the existing. Same size as the existing. Controller hardware can be renewed to R3 without changing field wiring. In case of CENTUM V, CENTUM-XL

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… What are benefit at Step 3 ? Step 3: I/O portion Migration –Much more reliability. All modules can be redundant. –Much more number of I/O point. –You can extend the functionality with new technologies. FOUNDATION Fieldbus solution. Remote I/O installation. Connectivity with various types of 3’rd party subsystems. Even at Step 3, you need not rewire the field cables. –Yokogawa will continue supplying the signal conditioners. Migration story completes !

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Yokogawa’s Migration Path. CENTUM CS –Migrate to the latest CS3000 R3 system with 2 steps. Step 1 : HMI migration Step 2 : Controller migration –Integrate with the latest CS3000 R3 system

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Solution with Migration step 1 Ethernet Vnet HIS ICSs are no longer necessary. It is not necessary to modify FCS and I/O. HISs works instead of ICS All tag data of the existing FCSs can be operated from HIS. (Read/Write is OK.) Operators need not recognize whether the tag is the existing FCSs’ or CS3000 FCSs’. Operation keyboard and touch panel are available. OPC server All process data is handled as CS3000 data. Operation improvement with AOA function. Seamless connection with PIMS. Audit trail Remote operation CS FCS EWS

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… How to connect. Ethernet Vnet HISOPC server CS FCS EWS Builder FCSs are not affected at all. Process operation is not stopped when connecting HISs. As Vnet is redundant, the communication does not stop when connecting replacing ICS to HIS. The ICS graphics can be imported into CS3000 HIS Tags are equalized in CS3000 builder.

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… What are benefit at Step 1 ? Step 1: HMI Migration –Dramatically reduced the anxiety of parts supplement. HMI includes the shorter life parts, such as CRT, HDD. As CS3000 HMI is based on generic PC, it is easy to supply these parts. –You can utilize the latest Windows technologies. Because CS3000 R3 works on MS-Windows2000 and will be able to work on WindowsXP. –Seamless connectivity with various kinds of the latest business domain systems. HIS (R3 HMI) has OPC interface without any gateways. Most of MES, PIMS, and CMMS have OPC interface. –Operation improvement with AOA software in HIS. AOA (Advanced Operation Assistance) can improve your manual operation.

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Solution with Migration step 2 Ethernet Vnet HIS As RIO can be used also in CS3000, it is not necessary to modify I/O portion, and field wiring at all. CS3000 FCU has the interface for RIO. You can connect the existing I/O nests to CS3000 FCU. Field wiring cables need not changed at all. OPC server FCU is migrated to the latest one. Control logics (Loop, sequence) works as CS3000 control function.

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… How to connect. Ethernet Vnet HIS You can change FCUs one by one without affecting other FCSs at all. Builder Download control logics to each FCS. Process operation by other FCUs is not stopped when replacing an FCU. Control loops, Sequence, etc. Control logics Converted as CS3000 application. Control Logics Save

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… What are benefit at Step 2 ? Step 2: Controller Migration –Much Larger application capacity. –Much quicker processing. Short turn around to improve control ability. –Much more number of I/O point. –You can extend the functionality with new technologies. FOUNDATION Fieldbus solution.

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Yokogawa’s Migration Path. MicroXL –Migrate to the latest CS3000 system with 2 steps. Step 1 : HMI migration Step 2 : Controller migration

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Solution with Migration step 1 Ethernet Vnet HIS MOPSs are no longer necessary. It is not necessary to modify FCS and I/O. HISs works instead of MOPS All tag data of the existing FCSs can be operated from HIS. (Read/Write is OK.) Operators need not recognize whether the tag is MicroXL’s or CS3000 FCSs’. Operation keyboard and touch panel are available. OPC server All process data is handled as CS3000 data. Operation improvement with AOA function. Seamless connection with PIMS. Audit trail Remote operation Bus converter

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… How to connect. Ethernet Vnet HIS FCSs are not affected at all. If RL bus is redundant, the communication does not stop when connecting Vnet -- RL bus. Tags are registered in CS3000 builder. Builder Download tag information to each HIS. Process operation is not stopped when connecting HISs.

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Connection without communication stop Terminator RL bus line-1 RL bus line-2 FCS Vnet Bus converter (1) 1 set of RL bus are connected to a bus converter. (2) Remove a terminator of the existing RL bus. (In this case, RL bus line-1 is still working.) (3) Connect the RL bus cable from the bus converter. (4) Remove the other terminator of the existing RL bus. (In this case, RL bus line-2 is still working.) (5) Connect the RL bus cable from the bus converter.

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… What are benefit at Step 1 ? Step 1: HMI Migration –Dramatically reduced the anxiety of parts supplement. HMI includes the shorter life parts, such as CRT, HDD. As CS3000 HMI is based on generic PC, it is easy to supply these parts. –You can utilize the latest Windows technologies. Because CS3000 R3 works on MS-Windows2000 and will be able to work on WindowsXP. –Seamless connectivity with various kinds of the latest business domain systems. HIS (R3 HMI) has OPC interface. Most of MES, PIMS, and CMMS have OPC interface. –Operation improvement with AOA software in HIS. AOA (Advanced Operation Assistance) can improve your manual operation.

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Solution with Migration step 2 Ethernet Vnet HIS It is not need to modify most of signal conditioners, and field wiring at all. OPC server Migrate MicroXL FCS to FFCS Control logics (Loop, sequence) works as CS3000 control function. Connected on Vnet. Field wiring cables can be remain. FFCS

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… How to connect. Ethernet Vnet HIS You can change FCUs one by one without affecting other FCSs at all. Builder Download control logics to each FCS. Process operation by other FCUs is not stopped when replacing an FCU. Control loops, Sequence, etc. Control logics Converted as CS3000 application. Control Logics Save

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Hardware continuity (Front)(Rear) Same connector is available. Field wiring is NO CHANGE Field wiring Controller hardware can be renewed to R3 without changing field wiring. Compatible modules with the existing. Same size as the existing.

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… What are benefit at Step 2 ? Step 2: Controller Migration –Much Larger application capacity. –Much quicker processing. Short turn around to improve control ability. More control logics can be used. –The batch system complied with ISA S88. –You can extend the functionality with new technologies. FOUNDATION Fieldbus solution. –Much more visualized control logics. Not only decision tables, but logic chart, SFC, are available. The work status of these logics can be displayed on HIS.

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Operation Continuity CS3000 can provide quite similar operation environment to the existing operation. –Same kinds of screens, such as overview, trend, tuning, and graphic, are available. –Console, touch-screen are available. –Operation keyboard is available. –Operator needs not recognize that each tag belongs to CS3000 or to the existing systems. Operators can smoothly start their work HIS instead of the existing HMI.

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Shorten Stopping Period. We have prepared application conversion procedure Yokogawa inside. –We need not RECREATE your application, such as sequence, control logic, etc. You need not wait for the delivery of FCS before starting your debugging. –Yokogawa has Virtual Test function to debug the control application only with a PC.

Yokogawa Electric Corporation Copyright © by Yokogawa Electric Corporation Proprietary info goes here… Conclusion By Yokogawa’s Migration solution, your DCS will become a dramatically longer life system with much more capability. You can reduce your TCO (Total Cost Ownership).