Flyer Simatic PCS7 eng - Siemens€¦ · __Flyer_Simatic_PCS7_eng.indd 2Flyer_Simatic_PCS7_eng.indd...

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New Perspectives with SIMATIC PCS 7 Process Control System simatic PCS 7

Transcript of Flyer Simatic PCS7 eng - Siemens€¦ · __Flyer_Simatic_PCS7_eng.indd 2Flyer_Simatic_PCS7_eng.indd...

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New Perspectives withSIMATIC PCS 7 Process Control System

simaticPCS 7

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With over 10 years in the marketplace and thousands of

installations worldwide, the innovative SIMATIC PCS 7 process

control system has become a proven automation platform

for a wide variety of industries. The uniquely scalable

architecture, powerful engineering tools and comprehensive

asset management capabilities allow you to operate a plant

more cost-effectively and effi ciently over the entire life cycle,

from design and engineering, installation and commissioning

and training through to operation and maintenance.

SIMATIC PCS 7 is more than just a Distributed Control System (DCS). It can take you beyond the limits of your current process automation system, for example, by help-ing you to integrate your electrical infrastructure directly into the DCS, or by using common hardware and enginee r-ing tools for process automation, discrete control (high-speed logic), process safety and batch.

SIMATIC PCS 7 can also address the complete automation of secondary, upstream and downstream processes, such as waste water treatment or the distribution of power to a production location. Because of this versatility and functionality, SIMATIC PCS 7 is a key component of our Totally Integrated Automation (TIA) solution.

SIMATIC PCS 7 – more than just a process control system

With the release of SIMATIC PCS 7 V7.0 we are addressing the business issues that are critical to maintaining and building up your competitive advantage, such as reduc-ing total cost of ownership (TCO), protecting your auto-mation assets, increasing the availability of your plant, optimizing the performance of your process, supporting management of your safety life cycle, providing a path to modernize your existing installed systems, and minimiz-ing engineering costs during the whole plant life cycle!

SIMATIC PCS 7 – Takes you beyond the limits – 7 excellent ways to help make your company more successful

Minimizing the costs of the entire plant through Integration of batch, route control, safety, IT security, plant asset management, and fi eld instruments com- patible with PROFIBUS and FF as well as drives

Delivering higher Performance by maximizing system reliability and availability

Continuous technology Innovation – the best of to-day‘s technology and tomorrow‘s, combined together so that you can adopt it at your own pace and never be left behind

Maximizing system Scalability from 100s of I/O points to more than100,000 I/O points – from laboratories up to large multi-unit plants

Reduced risk through integrated Process Safety with fl exible modular redundancy (FMR) and comprehensive IT Security

Protection of automation investments through step-by-step Modernization of Siemens and third-party sys-tems

A Global Network of Experts and Solution Partners providing service and support locally

SIMATIC PCS 7 – Takes you beyond the limits!

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Human Machine Interface (HMI)

Scalable and fl exible system architectures based on Client-server

Redundancy for both real-time data and archives

Online modifi cation / Remote access via Internet / intranet

Smart Alarm Management ✪ Full OPC Support ✪ Comprehensive Security Concept including virus scanning software ✪

Controllers and I/O

Innovated Powerful controllers with multiple scan rates down to 10 msec ✪

Redundancy (controller, I/O module, fi eld and plant bus)

Hot swapping (insertion and removal of modules during operation)

Extension/modifi cation during operation

I/O modules for hazardous areas

Time stamping on the module level down to 1 msec ✪ Common hardware platform for Process Safety

Easy integration of intelligent fi eld devices/drives

Maintenance free pc-based controller for smaller applications ✪ Innovated SIMATIC PCS 7 BOX for economic solutions for labs,

pilot plants and process OEMs ✪

Communication

Fast Ethernet and PROFIBUS DP/PA

Fiber optic switching technology

Online expandability

Interfaces to MODBUS, AS-i and FF ✪ Wireless monitoring and operation with MOBIC ✪

Exceeding the Requirements of the Process Automation Market: SIMATIC PCS 7 – more than just a process control system

Engineering

Central, system-wide high-performance engineering system

CAE/CAD connection/ bulk engineering with import/export functions ✪

Advanced Process Control functionality ✪ Central parameterization of intelligent fi eld devices using the

integrated SIMATIC PDM engineering tool

Software simulation and testing

Change Management (Version Trail, Change Log, etc.) ✪ Concurrent (multi-user) engineering capability ✪ Support of major control languages (Ladder, Structured Text, CFC,

SFC) with creation of user-specifi c function blocks

Asset Management

Central, system-wide visualization, diagnostics and maintenance of all process control components including mechanical assets ✪

Overview of the entire maintenance workfl ow

Complete traceability and documentation of status changes and maintenance orders

Condition and Plant Performance Monitoring ✪

Batch

Tightly integrated into the engineering system and HMI

Unit- and equipment-independent recipes

Dynamic Unit Allocation

Hierarchical recipes according to ISA S 88.01

Scalable from small to very large plants – single-user system or in client-server architecture

Redundancy

21 CFR Part 11, Audit Trail, access protection, electronic signature

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SIMATIC PCS 7 – Takes you beyond the limits!

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Improved Change Management for minimizing project risk and maximizing traceability

Minimizing costs and project risk are key goals for the Design and Engineering phase. To help users achieve these goals, SIMATIC PCS 7 has added several tools for change management. They compliment the pre-existing set of powerful engineering tools and allow users to comply with industry regulations and practices such as FDA 21 CFR Part 11 or GAMP. These include:

Security and Access control

Confi guration Change Log

Version Trail

Version Management

The SIMATIC LOGON product, which is now included as standard in each Engineering Station (ES), leverages MS Windows security to provide a common login/password for access to the PC, the engineering environment, the HMI, and for the batch system. It provides access control for the engineering environment ensuring that only au-thorized users can make confi guration changes.

A comprehensive Change Log provides traceability of en-gineering changes made to the controller, HMI, batch management or Route Control confi gurations. This change log keeps track of logons/logoffs and downloads, as well as project/library changes for elements created in CFC, SFC, and for the hardware confi guration. Version control tools are also available to maintain a complete version trail for projects, libraries, multiprojects, and for batch recipes, formulas and libraries. Additionally, the Version Cross Manager can be used to perform a thor-ough comparison between two versions of a confi gura-tion to highlight any differences that exist between cor-responding function blocks, CFCs, SFCs, hardware confi guration, alarms, or within the plant hierarchy.

Confi guration Time reduced for automation of material transport processes

SIMATIC Route Control (SRC) can be used for the automa-tion of material transport processes such as is common in Food & Beverage or pharmaceuticals. In addition to pro-viding control, monitoring and diagnostics of the pro-cess, SIMATIC Route Control has been extended to add centralized engineering capabilities, which minimizes du-plication of engineering, as well as the support of “Route templates” which can be defi ned during manual opera-tion and saved for future use.

Bulk Engineering Tools increase engineering productivity

To minimize engineering costs, the bulk engineering tools available in SIMATIC PCS 7 have been enhanced. The Process Object View, which is a spreadsheet-style editor with powerful fi ltering capability, allows engineers to make confi guration changes to multiple objects such as motors, valves and control loops at the same time, thus improving productivity. Additional tabs have been added to support confi guration of “smart alarming”, con-fi guration of alarm groups, hierarchy folder (for OS area, picture names for OS, picture order), equipment proper-ties (used in the plant hierarchy) or shared declarations (enumerations, units, equipment properties).

Additional capabilities have also been added for exporting and importing of selected parameters for manipulation within MS Excel or CAE tools. The import-export assistant (IEA), which is a tool for cloning control modules, SFCs, and entire process areas, has been enhanced through defi nition of sampling time in the IEA fi le, change of block instance names, or block group for “smart alarm hiding”.

Design and Engineering

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SIMATIC PCS 7 Box provides a comprehensive and economical solution for small-scale processes, pilot plants, laboratories and process OEMs

SIMATIC PCS 7 Box, which combines the best of both PLC and DCS capabilities into a single compact industrial PC, has been enhanced to provide greater fl exibility for hy-brid applications. Targeted at small process automation systems consisting of 10s to 100s of I/O points, it uses the same software and hardware as a “full-blown” SIMATIC PCS 7 system, ensuring that technology can be seamless-ly transferred from lab to pilot plant to production. The on-board controller is now available in two forms; a rugged hardened controller in a PCI Slot form factor and a new “soft” controller that runs on the Box PC Processor. Hardware can be added or modifi ed while the system is online (CiR). To maximize availability, the operation of the Slot-type Controller is independent of the Box PC (operating system and power supply). Its comprehensive functionality includes:

Operator Station and/or Engineering Station

MS-SQl-based Historian

Hard Controller (WinAC Slot CPU 416) or Soft Controller (Win AC RTX).

PROFIBUS and Ethernet interfaces (built-in)

S88 Batch & Recipe Management (SIMATIC BATCH)

Asset Management / Maintenance Station capability

Tools for Confi guration / Troubleshooting of smart fi eld devices (PDM)

Advanced Process Control

This unique offering allows use of the same families of remote I/O (ET 200M, ET 200ISP and ET 200S) as a stan-dard PCS 7 system. Although SIMATIC PCS 7 Box is desi-gned for use as a single station system, it can also be easily integrated into a PCS 7 Client-server architecture.

Maintenance-Free, PC-based Controller provides new options for process automation

The new SIMATIC PCS 7 AS RTX, a PC-based automation station based on the SIMATIC Microbox, is ideal for pro-cess OEMs and other hybrid applications. The system is maintenance-free as it comes without fans or any other moving parts such as hard disk drives. The AS RTX pro-vides integrated Ethernet and PROFIBUS connectivity for connecting to the System Bus and to I/O devices.

The system does not require a dedicated HMI since it is confi gured remotely from the Engineering System. The operating system, Windows XP Embedded, is installed on a special Flash RAM module. This industrial grade Flash module is designed for applications which demand a high degree of reliability, and features an integrated Manage-ment Controller that signifi cantly prolongs its useful life.

New High Performance Controllers enable incre-ased throughput and capacity at no additional cost

With version 7 we also offer new higher-performance controller models with all Automation Systems (SIMATIC S7-414, -414FH, -416, -417, and -417FH). Each control-ler contains at least 50% more memory (to hold additio-nal confi guration) and has achieved a 40% reduction in its execution rate (providing plenty of capacity for expan-sion). Integrated Ethernet connectivity has been added to the standard 414 and 416 controllers to make them eas-ier to confi gure and more economical (no CP 443-1 is required). Additionally a redundant controller capable of being used for both process control and as a Safety Inst-rumented System (SIS), the SIMATIC S7-412FH, has been introduced to provide an economical, rugged and power-ful offering for smaller systems.

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Advanced Process Control Capability helps optimize product yield and quality while minimizing con-sumption of energy & raw materials

Most users of process automation are being driven to con-tinuously improve operational effi ciency. Many have found that Advanced Process Control (APC) provides signi-fi cant potential for achieving this goal. Depending on the problem or objective, different APC methods are optimum. With the introduction of SIMATIC PCS 7 V7.0, a compre-hensive set of new embedded APC capabilities have been provided. These include PID Optimization, Model Predic-tive Control, Fuzzy Control, Neural Networks, and Control Performance Monitoring. APC functionality consists of PCS 7 function blocks which run in the controller along with pre-built faceplates for operation and monitoring through the HMI. This implementation makes it very easy for the user to engineer their application and also elimi-nates the need for interfaces.

PID Optimization

PID Gain Scheduling (automatic parameter adjustment)

Butterworth low pass fi lter

Override Control

Smith Predictor

Standard PID control blocks feature a new function for calling the PID Tuner (auto-tuning tool) directly from its associated faceplate within the HMI

Model Predictive Control (MPC)

Embedded multivariable Model Predictive Control for up to 4 process variables, 4 manipulated variables, and one disturbance variable (4 x 4 x 1)

Engineering tool and faceplate for monitoring / interaction

Fuzzy Control and Neural Networks

Wizard-based tool helps defi ne the algorithm, which can then be downloaded to run in the controller

Engineering tool and faceplate for monitoring / interaction

Control Performance Monitoring (Siemens Patent)

Automatic monitoring of control performance and deviation of a PID Loop

Traffi c light symbol for easy performance indication

Faceplate displays Control Performance Index, Standard Deviation of PV, Mean value of Control Error, Mean value of manipulated variable

In addition to the embedded capabilities for APC which run natively in the PCS 7 AS controller, 3rd party packages are also available that can be seamlessly integrated into PCS 7.

Schnitt (Klapper)

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Concurrent Engineering Capabilities reduce time to confi gure and test applications

A signifi cant productivity boost can be achieved by lever-aging SIMATIC PCS 7’s new multi-user engineering capabili-ty. These enhancements allow multiple engineers to work effectively on a single application at the same time, thus allowing confi guration & commissioning tasks to be com-pleted quicker and more cost-effectively.

CFC and SFC confi guration can now be edited by mult i- ple users at the same time in parallel, without additional administrative work.

Several users can work on the same chart. Simultaneous write-access to the database is avoided by the system.

The project is located at a central workstation. Multiple access is possible via Engineering Clients.

Data consistency is assured by the system.

A single CFC chart can be tested online by one user while at the same time it is being confi gured by another user (from a separate workstation)

Connectivity to Plant Engineering Tools (CAE/CAD) minimizes the time it takes to go from P&ID design to complete confi guration

Signifi cant reductions in project cost and schedule can be achieved by linking the output of CAx engineering tools di-rectly to SIMATIC PCS 7’s engineering toolset. With the in-troduction of the SIMATIC Markup Language (SML), XML-based confi guration fi les can now be exchanged directly between PCS 7 and these plant engineering tools. Thanks to a new interface within PCS 7, a seamless exchange of data is possible, minimizing mistakes and ensuring that re-entry of data is not required. In particular users can now:

Copy data directly from a hardware planning tool to the HW Confi g tool of SIMATIC PCS 7

Transfer information from a P&ID scheme of an object- oriented planning tool to create the plant hierarchy and to confi gure individual CFC instances

Schnitt (Klapper)

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PROFIsafe ensures a cost-effective safe communication to smart fi eld devices

PROFIsafe enables TÜV-certifi ed SIL 3, safety-related communication in parallel to the standard communica-tion via one PROFIBUS PA cable between controller and smart fi eld devices like SITRANS P.

The redundant PROFIBUS PA supports the Flexible Modu-lar Redundancy concept of process safety: use redundan-cy only where it is required. This allows us to match the requirements of each Safety Instrumented Function (SIF).

Easy integration of Fieldbus FOUNDATION instruments

In addition to the well-established international fi eldbus standards such as PROFIBUS and HART, SIMATIC PCS 7 now supports connections to the Fieldbus FOUNDATION protocol via fi eldbus interface modules. Users benefi t from central engineering, detailed diagnostics, and inte-gration into our plant-wide asset management system.

Redundant PROFIBUS PA provides increased availability and reliable safety functionality for mis-sion-critical instrumentation and control elements

To make it practical for users with mission-critical appli-cations to leverage digital fi eldbus technology, Siemens has introduced an integrated redundant fi eldbus archi-tecture at the H1 level for PROFIBUS PA. This architecture provides a new level of system availability by ensuring that control is not interrupted in the event of fi eldbus communication faults such as short circuits, wire breaks, loss of bus terminator, or failure of the DP/PA coupler.

Through the use of new patented technology, Active Field Splitters (AFS) and Active Field Distributors (AFD) can be used to create scalable, fault-tolerant ring archi-tectures for PROFIBUS PA. To maximize availability, con-fi guration changes such as repairs and replacements, the addition of new fi eld devices, and extensions to the digi-tal fi eldbus can be made with the system online. All de-vices connected to the network can be monitored with SIMATIC PDM giving a complete view of the installed fi eld devices.

The advantages of this scalable solution are:

Avoidance of unscheduled plant downtime through higher availability

Lower installation and commissioning costs

Ability to expand the network during runtime

Visualization of diagnostics through the SIMATIC PCS 7 Plant Asset Management system

Installation and Commissioning

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Marshalling Termination Assemblies reduce installation costs and startup time

Standard Marshalling Termination Assemblies (MTA) are now available as a means of providing fast and easy connection to the fi eld level. Designed to prevent wiring faults and reduce installation efforts/costs, these termi-nation assemblies come with individual blown-fuse indi-cation and redundant power connections. They can be used with redundant or non-redundant I/O.

Redundant HART I/O offers easy way to leverage asset management

A new model of ET 200M high-density HART I/O cards are available for connection to redundant AI and AO. These new I/O modules, which are integrated seamlessly into the SIMATIC PCS 7 asset management system, support di-rect access to user-selectable secondary and tertiary HART variables. Key features include:

ET 200M 8 AI / 8 AO - (0/4-20 mA HART)

Remote Firmware update via the Engineering Station

Cyclic access of HART secondary variables, on a per- channel basis, for operation and control

New Interface Modules support Sequence of Events & Time Stamping

A new Interface module (IM 153-2 HF) has been intro-duced to support advanced functionality such as high accuracy time stamping for sequence of events (SOE) recording as well as providing the ability to install 12 I/O modules per rack.

12 Modules per Rack

Time Stamping (SOE) for standard and fail safe Digital Input modules

Cyclic HART secondary variables support

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Advanced Alarm Management helps minimize unplanned downtime and achieve Operational Excellence

One of the most common causes of unplanned down-time is a failure to respond effectively during plant distur-bances and process upsets. With the release of PCS 7 V7.0, Siemens has set a new in-dustry standard for “out-of-the-box” alarm management capabilities, which enables operation teams to maximize production rates and product quality.

Alarm suppression by tag or process area with a dedi-cated display showing all suppressed alarms

Ability to add operator comments to the historical alarm log

Ability to confi gure corrective actions and document operational best practices for online viewing by the operator

Identify and correct “nuisance” alarms by analyzing a built-in alarm frequency display

Compare actual performance to key performance indi-cators (such as number of alarms active for > 24 hours)

Read-only notifi cation of alarms in neighboring process areas

State-based “smart” alarming

Alarm “shelving”

State-based Alarming (Smart Alarm Hiding)

To help hide alarms from the operator when they are not meaningful, a state-based alarm system has been created to allow alarms to be hidden dynamically based on specifi c process and equipment conditions.

For example there may be known scenarios where the alarms generated by specifi c devices, individual pieces of equipment, or entire operating units are not meaningful. Presenting alarms to the operator during these condi-tions may overload an operator, obscure the seriousness of the situation, or make it diffi cult to take proper correc-tive action.

The system allows simple defi nition of plant/equipment states that are then available globally throughout appli-cation. The alarm hiding “fi lter” can be defi ned easily and intuitively in the Process Object View via a checkbox. In the event that a defi ned plant condition occurs (such as a compressor trip), the corresponding diagnostic alarms (such as low speed, low oil pressure, high oil temperature) are hidden from the operator view, but stored in the his-torical archive.

Alarm shelving capability helps operators navigate alarm fl ood conditions

Alarm shelving is a capability defi ned in industry stan -dards such as EEMUA 191 and NAMUR whereby opera-tors can manually hide an alarm on a temporary basis. It provides an important means for allowing operators to work more effectively during plant upset conditions. A central timer monitors how long the alarm has been “on the shelf” and places it back in the operator’s view when the time has elapsed. A comprehensive list of “hidden alarms” is provided to show alarms that have been hidden automatically based on smart alarm hiding techniques and manually based on operator shelving.

Redundant Central Archive Server ensures data integrity and access for long-term historical data

In V7.0, the Central Archive Server (CAS) can now be implemented redundantly, ensuring the availability and access to long-term storage of all plant data including alarms, events, process data and batch data. Historical data can be easily exported from the CAS into an MS Excel, CSV fi le for further processing and data analysis.

Operation

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Protecting Automation Assets from Cyberspace Threats (Industrial Security)

The introduction of Internet technology and open stan -dards for communication in plant networks, along with the use of Microsoft Windows operating systems, have increased the danger of hacker attacks on automation and process control systems. This has made IT security one of the most important topics in process automation today. With the release of Version 7, Siemens offers a robust and comprehensive approach to industrial security, including:

Installation of virus scanning software on all PCs

Effective management of Microsoft security patches

Creation of a secure network infrastructure using SCALANCE S security modules for VPN tunneling and encrypted data transfer

User Management and access control (such as pass-word expiration, monitoring the number of login fail-ures, etc.) using SIMATIC LOGON

Automatic confi guration of Windows Firewall and reg-istry using the SIMATIC Security Confi gurator

Implementation of a “Defense in Depth” strategy based on best practices defi ned in the PCS 7 security manual. “Defense in Depth” advocates the creation of a nested security architecture by division of the plant into secure and closed security cells with clearly defi ned and moni-tored access points.

“Open PCS 7“ interface enables easy data ex-change with auxiliary systems

The Open PCS 7 interface in version 7 of SIMATIC PCS 7 makes it easier to exchange process data with higher-level management execution systems and information / supervisory systems. Installable on a PCS 7 OS client or on a stand-alone PC, this package facilitates access to process data because it can serve as a single information access point.

The following standard interfaces are included:

OPC DA – process values (real time)

OPC HDA – process values (historical)

OPC A&E – alarms/events (real time)

OPC H A&E – alarms/events (historical)

A new optional advanced reporting package is available for creating customized reports. It leverages MS SQL and Crystal reports for the creation of reports based on stan-dard templates or from custom reports created with Crys-tal reports designed. Reports can be exported to PDF– fi le format for distribution and storage.

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Integrated Plant Asset Management system allows for monitoring and supervising of all critical assets

In version 7, our integrated plant asset management system has been extended to add user-defi nable plant equipment assets (such as tanks, heat exchangers, centrifuges, distillation columns, etc.) to the list of plant assets that can be easily monitored. Now users can im-plement preventive and predictive maintenance strate-gies, which are proven to be more cost-effective, for all of the critical assets in a plant, including:

Transmitters and Valve Positioners

Motors, Pumps and Drives

Analyzers

PC’s (Servers, Clients, Historians, etc.)

DCS Hardware (controllers, I/O modules, etc.)

Networking Equipment (switches, etc.)

Plant equipment assets (user-defi nable)

Maintenance

User-defi ned logic can be created to designate specifi c plant equipment for monitoring by the asset manage-ment system. This means that faceplates and symbols will be automatically created within the HMI to allow plant personnel to easily visualize and monitor the as-set’s operating performance. Special summary displays are provided for viewing of asset alarms.

A new document management system supports the stor-age and display of up to 10 different fi les (DOC, PDF, MPG, AVI, etc.) for each device. This allows information such as user manuals, standard operating procedures, wiring diagrams, P&IDs or help fi les to be called up from the central maintenance station.

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Modernization and Upgrade

Strategies for modernizing existing systems

Modernization and upgrade of aging, installed automa-tion systems is one of the top challenges faced by end users today. ARC has estimated that worldwide over $65 billion worth of installed process automation systems have reached the end of their useful life. With such a high investment in installed systems, it is no wonder that control system migration strategies are fast becoming one of the most important considerations for enabling increased plant performance and for evaluation of suppliers.

Based on direct feedback from end users, Siemens has developed the industry’s most comprehensive strategy for migration and modernization. This allows you to up-grade to newer technology in a stepwise fashion, to max-imize Return on Assets (ROA), and to modernize at a pace which is best for your plant.

The scope of products, tools and services available to the market from Siemens and our global network of Solution Partners includes:

HMI Connectivity

HMI Application Conversion

Enhanced Batch Management

Engineering Library

Controller Application Conversion

Control Network Gateways

I/O Gateways

I/O Interfaces

Field Termination Assemblies

With SIMATIC PCS 7 we are able to offer comprehensive migration solutions for third-party control systems suchas ABB, Emerson, Honeywell, and even more!

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Siemens AG

Automation and Drives

www.siemens.com/automation

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Current information about SIMATIC PCS 7

www.siemens.com/simatic-pcs7

The information provided in this brochure contains merely general descriptions or characteristics of performance which in case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract.

All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.

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