Yokogawa DCS System Maintenance Procedures - Inst Tools

25/10/21 21:13 Yokogawa DCS System Maintenance Procedures - Inst Tools
Yokogawa DCS System

Maintenance Procedures - Inst
Tools
In this article, we discussed the Yokogawa
DCS system maintenance procedures.
Here we covered the Yokogawa Centum VP

distributed control system checks which
include field control station, server, power
supply modules, CPU battery, HIS
engineering and operator stations, Sequence
of Events (SOE) server, OPC Server, the plant
resource manager (PRM), redundancy checks,
Node interface unit, ESB bus, Vnet IP, and IO
modules.
Table of contents
https://instrumentationtools.com/yokogawa-dcs-system-maintenance-procedures/?fbclid=IwAR2op2WixAgydE4ie1vfugHU5PfrLcfT… 1/31
Test Equipment
General Checks of FCS
DCS Project Details Checks
DCS Server System Environment Checks
Yokogawa DCS System
Power Supply and other Checks
CPU Battery & PW482 Checks
HIS Engineering and Operator station,
SOE Server, OPC Server, PRM checks
Redundancy Checks of Power Supply
Module
Redundancy Checks of 24V DC Power
Supply Unit
Redundancy Checks of CPU
Module of Node Interface Unit (NIU)
Redundancy Checks of Node Interface Unit
(NIU) Communication Card FIO
Redundancy Checks of ESB Bus

Redundancy Checks of Vnet I/P Bus
Redundancy Checks of IO Modules
Online Maintenance Function
Function Key Assignment Checks
Event Viewer
Plant Resource Manager (PRM) Checks
OPC Communication using Generic
Subsystem Gateway (GSGW)
Test Equipment
Hand tools,
Digital Multimeter.
General Checks of FCS

Here FCS stands for Field Control Station in
Yokogawa Centum VP DCS system.
We will do the general checks of FCS on a

monthly basis.
1. Domain Number and its healthiness.

2. FCS Number and its healthiness.
3. HIS Number and its healthiness.
4. Integrated system and its healthiness
check.
The below list shows some of the integrated

systems in a DCS system.
a. Prosafe RS systemb. PRMc. OPC Serverd.

SOE Viewere. Time master HIS0364
DCS Project Details Checks

We will do the project details checks on a
monthly basis.
1. Project Name
2. Project Size in GB
3. Project Path
4. Set back path
5. CENTUM VP project software application
backup in media (DVD, external HDD)
DCS Server System Environment Checks

We will do the DCS server system
environment checks on a weekly basis.
1. Room temperature
2. Relative humidity
3. Dust deposition or Ingress
Yokogawa DCS System

We will do the field control station checks
on a monthly basis.
1. Model Number and serial number

2. Number of nodes
3. Communication load average
4. Tuning parameters saving successful
5. CPU idle time
6. Visual checks of all cards (CPU, CP, PS,
ESD, IO, Terminal board etc.)
7. Vnet/IP bus status
8. FFTDU status (Fan Failure and
Temperature Detection Unit)
Power Supply and other Checks

We will do the power supply and other checks
on a monthly basis.
1. Measure L-N, L-E & N-E AC voltages of

both Left & Right feeders from UPS.
2. Measure DC voltage for both Left & Right
feeder supply.
3. Measure DC voltage at Analog and Digital
terminal board.
4. Proper grounding and welding of panel.
5. Proper earthing of panel, instrument
earthing.
6. FAN status.
7. Panel Filter status.
8. Room temperature
9. Relative humidity
10. Dust deposition or ingress
CPU Battery & PW482 Checks

We will do the CPU battery & PW482 checks
on a quarterly basis.
1. Battery expiry date of Left & Right CPUs.

2. Measure Voltages of Left & Right CPU
Battery.
3. Measure voltages of PW482, at all left and
right nodes.
HIS Engineering and Operator station,

SOE Server, OPC Server, PRM checks
We will do the HIS Engineering and Operator
station, SOE Server, OPC Server, PRM checks
on a monthly basis.
1. Domain, Station Number

2. Model, Serial Number
3. Visual checks
a. VI701 network cardb. Event viewer statusc.

FAN statusd. CPU performancee. Hardware
healthiness
Vnet/IP Bus 1 & 2 IP address, subnet mask,

default gateway
Server PC OS and service pack details
Server Antivirus license and patch update
status
CENTUM VP license ID checks.
Server RAM, virtual memory size, hard disk
size and free space.
Data storage device floppy drive, DVD
drive, DAT drives status.
Equalize to all HIS.
CENTUM VP project application backup
status.
Report generation, alarm and trend status
checks
PRM, field instrument on network and data

read & write status.
HIS input power L-N, L-E, N-E.

Module
We will do the redundancy checks of the
power supply module on a yearly basis.
The purpose of this test is to verify the CPU is

not affected if any one of the node power
supply fails.
1. Switch off all left/right sides of power

supply module by switching off the
corresponding MCB.
2. Check system alarm message displayed on
the operator station (HIS) and the Station
status display window in ENGG/HIS.
https://instrumentationtools.com/yokogawa-dcs-system-maintenance-procedures/?fbclid=IwAR2op2WixAgydE4ie1vfugHU5PfrLcf… 10/31
3. Check for any spurious action in I/O

modules.
4. Repeat the above steps for both of power
supply modules.
5. Remember, the other power supply module
will still function normally as observed in
the Station Status Display in operator
station (HIS).
Ready lamp on the CPU will still be ÖN”. No

spurious action should be observed at the I/O
during the test.
Redundancy Checks of 24V DC Power

Supply Unit
We will do the redundancy checks of the 24
volts dc power supply unit on a yearly basis.
1. Check that failure of one power supply does

not affect the terminal and the relay board.
2. Switch off anyone incoming 24V DC MCB

to the Diode ’O’ ring unit in marshalling
cabinet.
3. Check if the relays and terminal board’s
power is not interrupted in marshalling
cabinet.
4. Repeat the same for other 24V DC MCB to
the Diode ’O’ ring unit.
Redundancy Checks of CPU

Yokogawa distributed control system CPU on
a yearly basis.
Test 1
The purpose of this test is to ensure that all

components automatically boot up when
going from a ‘stop’ environment to an
‘operating environment.
a. ‘Power on’ each component individually.

‘Power off’ all the components individually.
b. Each component boots up automatically.

System start time will be displayed on the
System Alarm Panel of the HIS which is not
currently under test.
Test 2
The purpose of this test is to verify that the

standby CPU becomes ‘active’ when the active
CPU fails and that all loop data remains the
same after switchover.
The control shall be transferred promptly and

correctly to the standby CPU as observed
through the “Control Station Status Panel”
displayed on the ENGG station and operator
station (HIS). No spurious action should be
observed at the I/O during the test.
a. Stop the active CPU by activating the

START/STOP button.
b. Check the system alarm messages displayed

on the operator station (HIS) and the Station
Status Display.
c. Repeat 1 & 2 for other CPUs after the FCS

resumes from COPY mode.
d. Repeat the above procedure for other FCS

CPUs in the network.
e. Check for any spurious action in I/O in the

trend panel.

Module of Node Interface Unit (NIU)
power supply module of the node interface
unit (NIU) on a yearly basis.

NIU is not affected if any one of the node
power supply modules fails.
Switch off all left/right sides of the power

supply module by switching off the
corresponding MCB.
Check system alarm message displayed on the

operator station (HIS) and the Station Status
Display window in ENGG/HIS.
Check for any spurious action in I/O.
Repeat the above for both sides of the power

supply modules.
Remember, the other power supply module

will still function normally as observed in the
Station Status Display in Operator Station
(HIS). Ready lamp on each I/O card will still
be ‘ON’.
No spurious action should be observed at the

I/O during this test. During this test, all the
power supply units powered by the respective
incoming feeders will be switched off.
Redundancy Checks of Node Interface

Unit (NIU) Communication Card FIO
We will do the redundancy checks of node
interface unit (NIU) communication card FIO
on a yearly basis. Here FIO stands for
Fieldnetwork I/O.

control function is not disrupted even if one of
the NIU communication cards (SB401) fails.
Remove one of the NIU communication cards

from the slot.
Check the system alarm messages on the

operator station.
Note: Use a proper star(+) screwdriver to

remove the NIU card
Remember, the other SB401 communication

card will work correctly as observed through
the “Station Status Display” window.
Redundancy Checks of ESB Bus

We will do the redundancy checks of the ESB
bus on a yearly basis.

control function is not disrupted even if one of
the communication modules fails
Remove one of the ESB bus coupler

connectors.
Check the system alarm messages on the

operator station
Note: Use a proper star (+) screwdriver to

remove the NIU card
The other EC401 communication Bus will

work correctly as observed through the
“Station Status Display” window.
Redundancy Checks of Vnet I/P Bus

We will do the redundancy checks of the Vnet
i/p bus on a yearly basis.
The purpose of this test is to ensure that

failure of one of the inter-station
communication V-net/IP has no effect on the
normal highway communication.
1. Disconnect anyone V-net/IP Bus (Bus 1).

2. Check the system alarm messages display
on the operator station HIS and status
change in System Status Overview window.
3. Force a tag from the HIS and observe the

I/O changes.
4. Perform the above procedure again with
the second bus, after restoring the ‘failed’
bus.
5. Check the system alarm messages display
on the operator station and status change
in System Status Overview window.
6. Force a tag from the FCS and observe the
I/O change in HIS.
7. Remember, the HIS/ENGG station can still
monitor the change in data from the Field
Control Station (FCS) without any
disturbance.
Redundancy Checks of IO Modules

We will do the redundancy checks of the IO
modules on a yearly basis.
Test 1

failure of one of the I/O modules does not
affect the I/O signals.
a. Select an Analog I/O signal.
b. Monitor the values of a particular tag in

HIS.
c. On the Station Status Display window in

HIS, check the two modules being displayed
in Green and Yellow.
d. Pull the module which is active.
e. Observe the system alarm, the tag value,

and the Station Status Display Window in
HIS.
Note: Use proper star (+) screw driver.
f. Remember, the System alarm should post

the module failure alarm. The Station Status
Display Window should show the module
status in red, indicating failure and the one
that has taken over in green. No change in Tag
data should be observed.
Test 2
The purpose of this test is to verify the

functionality of the load/save utility in the
HIS (with Engineering function), thereby
ensuring that the configuration data is
transferred via the V-Net/IP.
a. Call up the load/save utility panel in HIS

(with Engineering function) and select the
Appropriate Field Control Stations (FCS) or
Human Interface Stations (HIS).
b. Perform the Load function
c. Perform the Save function.
d. Remember, Loading/ saving of the database

should be done without any error messages.
Online Maintenance Function

We will do the online maintenance function
checks on a yearly basis.

Online Maintenance Function is operative.
a. Open a Control drawing for loops or logics.
b. Select a loop or sequence table to be

modified
c. Perform modifications as required.
d. Perform Online Download.
e. Ensure that the FCS functionality is

uninterrupted.
f. Ensure that the modifications are

downloaded to the FCS by doing a functional
check of the modifications.
g. Remember, Field Control Stations (FCS)

should not stop the normal
control/monitoring functions, also the
modification made in the database should be

reflected correctly in the FCS.
Function Key Assignment Checks

We will do the function key assignment checks
on a yearly basis.

functions of operator keys are navigating to
the operator windows correctly as per
assigned functions.
Reference: Function key Worksheet filled.
a. Press the Function key on the operation

keyboard.
b. Check the respective screen/panel is

opened.
c. Confirm that the LED flashes if there is an

alarm in the corresponding screen.
d. The navigation of all operator windows is

correct with respect to the operation
keyboards.
Event Viewer
We will do the event viewer checks on a yearly
basis.
The purpose of this test is to verify the

functionalities of the package are working
correctly.
a. Check the Category Sort window with a

display of Status change, Alarm notifies,
Alarm recovery, Operation record, and Others.
b. Check the Message display window with a

display of all the Historical messages per day
in chronological order of time.
c. Check the Point ID Window with the display

of tag names along with the number of alarms
that had come for that particular tag
represented.
Plant Resource Manager (PRM) Checks

We will do the plant resource manager
(PRM) checks on a yearly basis.
To demonstrate the basic functions of the

PRM components: PRM, Server, PRM Client
and Filed Communications Server.
a. Check the Registration of HART devices.
b. Device details update.
c. Device parameter manipulation from PRM,

Change the Block Mode of the AI block for one
of the devices to out of service and confirm

that the alarm appears on the device to ensure
communication. Return the block mode of the
AI device after the check.
d. Remember, after plug and play operation,

Manual Registration all the HART devices,
which are in network, and are alive, should
appear on the PRM device list respectively.
e. Device details update, after this operation,

device details should get updated of PRM.
OPC Communication using Generic

Subsystem Gateway (GSGW)
We will do the OPC communication using
generic subsystem gateway (GSGW) checks on
a yearly basis.

subsystem signal tags are defined properly in
the DCS and its values are updated correctly.
a. Change the tag data of subsystem from the

subsystem OPC Server.
b. Ensure that the change is reflected on the

DCS side by calling the tag faceplate in the
DCS.
c. Check the graphics whether the updating

has taken place.
Check for OPC hardware or OPC hardware or

OPC link failure alarm by simulating a failure.
Reference: Yokogawa
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Read Next:
DCS Troubleshooting
Commissioning of DCS System
DCS Control System Spares
Yokogawa DCS Architecture
DCS System Layout
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25/10/21 21:13 Yokogawa DCS System Maintenance Procedures - Inst Tools

Yokogawa DCS System

Here we covered the Yokogawa Centum VP

Redundancy Checks of ESB Bus

General Checks of FCS

We will do the general checks of FCS on a

1. Domain Number and its healthiness.

The below list shows some of the integrated

a. Prosafe RS systemb. PRMc. OPC Serverd.

DCS Project Details Checks

DCS Server System Environment Checks

Yokogawa DCS System

1. Model Number and serial number

Power Supply and other Checks

1. Measure L-N, L-E & N-E AC voltages of

CPU Battery & PW482 Checks

1. Battery expiry date of Left & Right CPUs.

HIS Engineering and Operator station,

1. Domain, Station Number

a. VI701 network cardb. Event viewer statusc.

Vnet/IP Bus 1 & 2 IP address, subnet mask,

PRM, field instrument on network and data

Redundancy Checks of Power Supply

The purpose of this test is to verify the CPU is

1. Switch off all left/right sides of power

3. Check for any spurious action in I/O

Ready lamp on the CPU will still be ÖN”. No

Redundancy Checks of 24V DC Power

1. Check that failure of one power supply does

2. Switch off anyone incoming 24V DC MCB

Redundancy Checks of CPU

The purpose of this test is to ensure that all

a. ‘Power on’ each component individually.

b. Each component boots up automatically.

The purpose of this test is to verify that the

The control shall be transferred promptly and

a. Stop the active CPU by activating the

b. Check the system alarm messages displayed

c. Repeat 1 & 2 for other CPUs after the FCS

d. Repeat the above procedure for other FCS

e. Check for any spurious action in I/O in the

Redundancy Checks of Power Supply

The purpose of this test is to verify that the

power supply modules fails.

Switch off all left/right sides of the power

Check system alarm message displayed on the

Check for any spurious action in I/O.

Repeat the above for both sides of the power

Remember, the other power supply module

No spurious action should be observed at the

Redundancy Checks of Node Interface

The purpose of this test is to verify that the

Remove one of the NIU communication cards

Check the system alarm messages on the

Note: Use a proper star(+) screwdriver to

Remember, the other SB401 communication

Redundancy Checks of ESB Bus

The purpose of this test is to verify that the