Course Details

Objective

By end of course participants will be able to understand

• Understand the Architecture of the CENTUM CS 3000: Gain a comprehensive understanding of the system architecture, components, and how they interact in process automation.
• Operate the CENTUM CS 3000 System: Learn how to navigate and operate the system effectively, including the user interface, control modes, and monitoring features.
• Perform Routine Maintenance: Understand routine maintenance procedures, such as hardware checks, software backups, and system upgrades.
• Troubleshoot and Diagnose Issues: Learn how to identify and troubleshoot common issues in the system, including signal loss, controller malfunctions, and communication errors.
• Configure and Manage System Parameters: Learn how to configure system settings, controllers, and alarms to optimize performance and maintain system integrity.
• Implement System Upgrades and Modifications: Understand how to perform software upgrades, configuration changes, and system modifications safely without disrupting operations.
• Ensure System Reliability and Safety: Develop the skills to maintain and optimize system performance to ensure the reliability and safety of plant operations.

Content

Day 1: Introduction to Yokogawa CENTUM CS 3000 DCS

• Overview of DCS and CENTUM CS 3000
  • Introduction to Distributed Control Systems (DCS) and their role in process automation
  • Key features of the Yokogawa CENTUM CS 3000 system
  • DCS architecture: controllers, operator stations, I/O modules, and field devices
  • Overview of CENTUM CS 3000 hardware and software components
• System Architecture and Configuration
  • Understanding the system layout: Controllers, communication network, field devices
  • How the CENTUM CS 3000 integrates with other systems in the plant (SCADA, PLC, etc.)
  • Role of the Human-Machine Interface (HMI) in system operation
• System Network and Communication
  • Understanding the communication protocol: FIO, FCS, HMI, and LAN
  • Network topology and communication redundancy
  • Data flow and control loops

Day 2: Operating the Yokogawa CENTUM CS 3000

• Navigating the Operator Interface (HMI)
  • Introduction to the Yokogawa CENTUM CS 3000 graphical user interface (GUI)
  • Customizing operator screens and navigating system views
  • Accessing and interpreting real-time process data (trends, alarms, and diagnostics)
  • Setting up user access controls and permissions
• Control and Monitoring Functions
  • How to operate control modes: Automatic, Manual, and Cascade control
  • Understanding interlocks, alarms, and events management
  • Reviewing historical data and process logs
  • Managing process variables, controllers, and setpoints
• Executing Control Actions
  • Creating and adjusting control strategies for field devices
  • Manipulating control loops, tuning controllers, and optimizing process performance
  • Managing start-up, shutdown, and emergency procedures

Day 3: Routine Maintenance of CENTUM CS 3000

• Preventive Maintenance Procedures
  • Identifying components that require regular maintenance (controllers, power supplies, network components)
  • Scheduled tasks: System backups, data logging, and archival processes
  • Cleaning and calibrating sensors, actuators, and controllers
• Software Management
  • Backing up and restoring system configurations and data
  • Software patching and version management
  • Handling updates and managing system libraries
• System Diagnostics and Health Checks
  • Tools for assessing system performance and stability
  • Monitoring CPU, memory, and network usage
  • Checking system logs for anomalies and failures
  • Identifying and addressing potential failure points in hardware and software

Day 4: Troubleshooting CENTUM CS 3000

• Diagnosing Communication Issues
  • Troubleshooting network connectivity issues between controllers, I/O modules, and HMIs
  • Resolving signal loss or errors in communication between devices
  • Investigating issues in system communication protocols (Modbus, OPC, etc.)
• Troubleshooting Control Loops
  • Diagnosing problems in feedback loops, PID controllers, and actuators
  • Analyzing loop tuning parameters and resolving instability
  • Identifying common causes of control loop malfunctions (sensor failure, wiring issues)
• Troubleshooting Hardware Failures
  • Identifying hardware malfunctions: I/O module failures, power supply issues, and CPU errors
  • Using diagnostic tools to pinpoint issues in physical components
  • Techniques for isolating and repairing faulty modules
• Alarm and Event Troubleshooting
  • Identifying and responding to system alarms and events
  • Troubleshooting alarm triggers and correcting false alarms
  • Interpreting diagnostic information from event logs

Day 5: System Upgrades, Configuration, and Advanced Troubleshooting

• System Configuration and Modifications
  • Configuring new controllers, I/O points, and field devices
  • Modifying control loops, setpoints, and control strategies for process optimization
  • Adding new devices to the DCS network
• Upgrading CENTUM CS 3000 System
  • Performing software upgrades and hardware replacements without downtime
  • Managing system backups and recovery during upgrades
  • Verifying system integrity post-upgrade
• Advanced Troubleshooting Techniques
  • In-depth troubleshooting of complex issues: controller misbehaviors, network faults, and I/O errors
  • Using Yokogawa diagnostic tools to monitor system performance
  • Case study analysis: Resolving real-world issues based on past experiences
• Best Practices for System Optimization
  • Optimizing system performance for higher availability and reliability
  • Implementing redundancies and fault-tolerant designs for critical processes
  • Ensuring safety and regulatory compliance in DCS operations

NOTE:

Pre-& Post Tests will be conducted.

Case Studies, Group Exercises, Group Discussions, Last Day reviews, and assessments will be carried out.

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Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. You will also be encouraged to raise your questions and to share in the development of the right answers using your analysis and experiences.  Tests of the multiple-choice type will be made available daily to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

• 30% Lectures
• 30% Workshops and work presentation
• 20% Group Work& Practical Exercises
• 20% Videos& General Discussions