Latest developments in Control & Safety Systems - KIVI Latest control... · Latest developments in Control & Safety Systems 1 ... CENTUM F-Bus COPS 1975 ... CENTUM CS 3000 R3 VP FCS(FIO)

11/17/2017

1

| KIVI | November 2017 |

© Yokogawa Europe Solutions B.V.

Latest developments in

Control & Safety Systems

1

Hidekazu Matsuura

Elbert van der Bijl

November, 2017



Industrial Automation Portfolio – Control Domain

Page.2

Information Management System

Operation Efficiency

Improvement Package

Integrated Production

Control System Safety Shutdown

Management System

Network Based

Control System

Robust Quality

Estimator

Multi-Variable Model

Predictive Control

Operational Efficiency Asset Management

Advanced Control Information Management

Production Control and Safety Management

Production

Management

Asset Management and

Operational Efficiency

Production Control and

Safety Management

Training Simulator System

Training Systems

Terminal Automation System Plant Resource Manager

Network Based

Control System

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Agenda

3

1. IA Trend and Customers’ Challenge

2. Latest Technology: DCS and SIS

3. Agile Project Execution

4. Cyber Security Approach



4

IA Trend and Customers’

Challenge

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IA Treads – Global Mega Trend and Industry Trends

Emissions reduction

Natural disasters

Energy rebalancing

Environmental Economic

Growth of emerging economies

Industrial reorganization

Reinforcement of energy security

Political

Geopolitical power balance

Electricity deregulation

Resource nationalism

Technological

Internet of Things (IoT)

Human augmentation

Cloud computing

Big Data

Multiple

feedstock

Aging

assets

Shortage of

skilled workers

Safety & Environmental

regulations

Cyber

Security

Demand

response

Wireless

intelligence

Product

traceability

Digitization &

Networking

Industry trends

Social

Globalization

Demographic Changes

Motivating younger

generations

Global

megatrends

Open Architecture

(IIoT, OPC-A, NAMUR, etc)



Market Trends Hype vs. Reality

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Technologies Enabling Digital Transformation

Pervasive

Sensing

Security

Platform

Advanced

Manufacturing

Technology

Connectivity

Augmented

Workforce

Cognition

TECHNOLOGY

TRENDS



Digital Twin

Digital Replica

of physical

assets,

Process &

systems

KBC & BAKER

HUGHES(GE) 19th

Sept

“For 1st time O&G

customers can build

Digital twin of a

Plant, refinery or

Rig with KBC’s

Petro-SIM”

Source: GE Digital

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Open Process Automation Forum

Open Process Automation Forum

is part of The Open Group

www.opengroup.org

ExxonMobil selected The Open Group

The Open Group is a non-profit, global consortium for IT standards

9



ExxonMobil Automation Vision

real-time service bus

DCS

DC

N

PLC Machinery

Monitoring

Safety

Systems Wireless

Gateway Analyzer

App A App B

Operations Platform

High-Availability, Real-Time

Advanced Computing Platform

Manufacturing

OT Data Center

(L1 L3 Functions)

Distributed

Control Node

(L1 L3 Functions)

Enterprise

IT Data Centers

(L4 Functions)

Existing

New

Legend

Business Platform

Transactional

Computing Platform

DC

N

RTAC Platform

External

Data Centers

(L4 Functions)

Electrical

Systems

Real-Time OT Services

• Abnormal Event

Detection

• Procedural Automation

• Advanced Control

• Process Optimization

Legacy

Device/Network

Gateway

Core

Real-Time

Functions

Cloud Services

• Predictive Maintenance

• Global Data Analytics

• Remote Operations

• Fleet Services

• I/O Processing

• Regulatory Control

• Logic Solver

• Application Hosting

Transactional IT Services

• Planning & Scheduling

• Enterprise Data Analytics

Source: ExxonMobil

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OT and IIoT

Can you imagine cloud computing replacing our traditional controllers!



Design Build Operate Maintain Optimize Expand Upgrade

Project execution Managing uncertainty, project complexity, late changes, cost overruns, and

deploys. The challenges are even greater when the lack of manpower and

technical resources are factored in.

Plant

lifecycle

Customers’ Challenges and Concerns

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Efficiency - Reduce OPEX

- Enhance productivity and efficiency

- Increase yield

- Improve energy efficiency

Human Reliability - Overcome shortage of skill, or skilled workforce

- Reduce human errors

- Retain and transfer knowledge

Sustainable operation

Availability - Reduce unplanned outages

- Manage aging assets

- Ensure start-up/shut-down procedure

Safety & Security - Reduce abnormal situations

- Improve cyber security

- Adopt to environmental regulations

- Enhancement of products

Plant

lifecycle





Lifecycle extension •Shorter technology cycle results in multiple generation system compatibility

issues and higher cost to maintain

•High OPEX to maintain obsolete system & components

•High CAPEX to upgrade systems

•Downtime due to system upgrades

Plant

lifecycle



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Plant

lifecycle



Automation

Suppliers

Results in higher OPEX & gaps between solutions and services throughout the plant lifecycle.

Some problems cannot be solved without considering an integrated approach.

Automation

Suppliers Automation

Suppliers

Automation

Suppliers

Automation

Suppliers Automation

Suppliers

Automation

Suppliers



How do we help our customers achieve and sustain optimum

performance throughout the entire plant lifecycle?

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Plant

lifecycle



Integrated approach

Issues & challenges

Products . Solutions . Services

• Pursue Long-term partnership with customers based on a shared vision.

• Deliver sustainable plant lifecycle solutions, right from the beginning.



2. Latest Technology to

Distributed Control System (DCS) and

Safety Instrumented System (SIS)

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Long Term Support & Migration

Full support Full

Support

Maintenance

Support

0 year 10 year 15 year 20 year

ICS

EOPS

CFCS/CFCD

BCV ENGS

EWS HIS PICS

ENG

CFFS

EFCS/EFCD

FCS(NIO)

HIS

AD Suite

1983

1993

2001 2005 2008

2011 2014

CENTUM

F-Bus

COPS

1975

CFCS2/CFCD2

COPS2/COPSV

CENTUM V

HF-Bus

250 Kbps Dual Redundant Token Pass

1Mbps Dual Redundant

Token Pass

1988 CENTUM-XL

V net

10 Mbps Dual Redundant Token Pass

CENTUM CS

FCS(RIO)

1998 CENTUM CS 3000

FCS(RIO) FCS(FIO)

Vnet/IP

1Gbps Dual Redundant

CENTUM CS 3000 R3

FCS(FIO)

AVR

HIS

CENTUM VP

[Release 5]

HIS ENG

[Release 6]

FCS(FIO)

Full Lifecycle Support for Customers’

Legacy Systems

The migration path for each legacy

system is always taken into

consideration before a new system is

released



Advanced Operation

System Agility

Sustainable Plant

An advanced operation that empowers

operators to make smarter decisions.

System agility that provides flexibility,

adaptability and extensibility to cater for

plant upgrading or extension needs, in

tandem with changes in plant operations

and business exigency.

Optimum system performance throughout

the entire lifecycle of the plant.

Smart Engineering

A new engineering ecosystem that

delivers certainty and confidence.

Enablers to Solve Customers’ Challenges

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CENTUM VP R6 – New Release Components

Next Generation

Smart I/O

Integrated Engineering

Environment

Field Validation

Tool

Centralized Engineering Smart I/O Field Device Adjustment Tool

Yokogawa’s agile project execution model

Parallel implementation

Application development

Field

Wiring Shipment HW FAT

SAT

Flexible binding Smart engineering

Design

Decoupling

Applicable period



Yokogawa’s ICSS System Architecture

Distributed Control System (DCS) Safety Instrumented System (SIS)

Plant Asset

Management

Plant

Information

Management

3rd party system

Subsystems

Real Time

Control Network

(Vnet/IP)

Unified

Gateway

Station

Engineering

Station Human Interface

Station

Integrated Control and Safety System (ICSS)

Traditional I/O System Smart I/O System Traditional I/O System Smart I/O System

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Yokogawa’s Smart I/O Solution

Yokogawa Smart I/O is designed with fewer components.

A single module can be configured to support AI/AO/DI/DO

An optional signal conditioner can be plugged in to support a wide range of I/O

signal types (to DCS Only)

The backplane allows I/O redundancy by design, resulting in a smaller footprint

Smart I/O module • 16 I/O channels

• Signal: AI/AO/DI/DO

• Software configurable

• HART 7 support

• Full redundancy

Signal conditioner

(optional) •Wide range of I/O

•Pulse, relay, DO, etc.

Termination block



Comparison between Traditional and Smart I/O System

Term

inal B

oard

T

erm

inal B

oard

Field Cables

(Multicore)

Duct

Terminals

Marshalling – Traditional I/O System

Field Cables

(Multicore)

Duct

Sm

art

IO

S

mart

IO

Marshalling – Smart I/O System

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Field Validation Tool – FieldMate Validator

Field device parameter

setting

• Smart I/O System setting

• I/O assignment

• Validate configuration

• Loop Check

• Accuracy & Function Check

Step 1

Step 2

Binding

Facilitate early completion of field work without requiring the entire system

to be ready at site.

Enable flexible binding with DCS at any stage of SAT.



3. Agile Project Execution

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Yokogawa’s Proposed New Project Execution

Conventional

Execution Design Configuration

Application

& Hardware

FAT

Field

wiring

Ship &

Install

Agile Project EXecution

The class module effect Smart I/O Solution

effects Field Device Adjustment Tool

effects

Increasing quality and

Reduce waste

Reducing risks of

handover slippage

Late Start

Site Activity (incl. Loop check)

Design Configuration

Manufacturing

& Hardware FAT Ship &

Wire

Loop

Vali-

dation

SAT Application

FAT

Site

Activity



Yokogawa’s agile project execution model

Decoupling

Parallel implementation

Application development

Field

wiring Shipment HW FAT

SAT Design

Module engineering

Bulk engineering

Change management

Auto Doc generation

Flexible binding

Asset

Management System

Historian

MES

Solution Packages

FieldMate Validator

Inte

gra

tio

n

SMART IO

Yokogawa repository (Module Library)

Applicable period

Engineering Server (Automation Design Suite Master Database)

A

Smart Engineering

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4. Cyber Security Approach



Yokogawa Security Lifecycle

Yokogawa provides the solutions to implement a comprehensive security lifecycle

based on the “defense in depth” strategy.

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Plant Security Lifecycle Service Portfolio

Security

Assessment

Secure

Network

Design

Antivirus Implementation

Firewall

Software

Backup Service

OS Patch

Management

Malware

Inactivated

Service

Security

Incident

Response

Network

Healthiness

Check

Assessment

and Analysis

Design and Implementation

Host Based

Security Network

Security Situational

Awareness

Unidirectional

Gateway

Security

Awareness

Training

SOC

(Managed

Service)

Next Gen

Firewall OS hardening/

USB Port lock

User/PC Setting

Management

IPS / IDS

Yokogawa Security Solutions and Services Project Based Reference

Operation Support

Respond and

Recovery

Validation

Support

Audit Antivirus

Update

OS Patch

Update

Application

Whitelisting

Update

Security

Information

Service

Network

Monitoring

System

Virus Check

Service

Security

Update

Backup Recovery System



Thank you for your attention!

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Documents

Latest developments in Control & Safety Systems - KIVI Latest control... · Latest developments in Control & Safety Systems 1 ... CENTUM F-Bus COPS 1975 ... CENTUM CS 3000 R3 VP FCS(FIO)