SIMATIC PCS 7 Positioning e

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Automation and Drives

SIMATIC PCS 7vs.

SCADA / PLC

A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 1Copyright Siemens AG 2002

All Rights Reserved

Overview

Technical

Differentiation

Economical

Differentiation

Summary

Differentiation

SIMATIC PCS 7versus

SCADA / PLC


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SIMATIC PCS 7vs.

SCADA / PLC


All Rights Reserved

Overview

Technical

Differentiation

Economical

Differentiation

Summary

HardwarePC / OS

HardwareAS

HardwareEthernet

S

o

f

tw

a

r

e

DCS

HardwareHighway

SoftwareHMI

Integration Engineering/ Services

SoftwarePLC

Integration Engineering/ Services

SoftwareHighway

SCADA/PLC

HardwarePLC

Overview SCADA + PLC vs. DCS

n xEngineering Environment

n xIntegration Overhead

1 xEngineering Environment

0 xIntegration Overhead


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SIMATIC PCS 7vs.

SCADA / PLC


All Rights Reserved

Overview

Technical

Differentiation

Economical

Differentiation

Summary

Changed cost structures require newprocess control solutions

Engineering

Commissioning

Cost development

Hardware

Increased complexity of the automation task

Missing repetition of applications

To much different media


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SIMATIC PCS 7vs.

SCADA / PLC


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Overview

Technical

Differentiation

Economical

Differentiation

Summary

Priorities in DCS solutions compared withSCADA/PLC solutions

DCS SCADA/PLC

Control Capabilities:

Process I/O A AMultivariable Regulatory Control A C

Complex Interlocking A B

Sequencing B C

Recipe Handling A D

Batch Process Control B D

User Interface:

Ease of Configuration (links & displays) A C

Ease of Operator Use A CEase of Creating Custom Displays A C

Cost:

Hardware C A

Installation A C

Application Programming A B

Additional Considerations:

Ease of Expansion (interactive functions) A DFlexibility A C

Redundancy A C

Reliability A B

Hardware Maintainability A B

Software Maintainability B C

Prio: Prio:

Prio: Prio:

Prio: Prio:

Prio: Prio:

A: highest Prio

A t ti d D i


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SIMATIC PCS 7vs.

SCADA / PLC


All Rights Reserved

Overview

Technical

Differentiation

Economical

Differentiation

Summary

Special requirements to DCS solutions

Longer term of use of plants in process industry

longer innovation cycles,

longer availability of spare parts

Safety requirements demand high availability of the control system

redundancy

distribution of technological tasks on different controllers

redundant communication links

continuous self check of the control system

fast diagnostic functions

in case of failure:

DCS keep in RUNPLC force in STOP



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SIMATIC PCS 7vs.

SCADA / PLC


All Rights Reserved

Overview

Technical

Differentiation

Economical

Differentiation

Summary

Comparison of SIMATIC PCS 7 with aSCADA / PLC solution

Component engineering

Database for each component

Multiple data entries

Individual programming tools

Individual communication modesl

System engineering

Central database

Data are entered once

Uniform engineering tool

Uniform communication

I/O

Net

PLC

BatchSCADA

....

Field dev.

Cross-configuring

Centralengineering

system

AS I/O

NetOS

Batch

Field devices

BLEPCS 7



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SIMATIC PCS 7vs.

SCADA / PLC


All Rights Reserved

Overview

Technical

Differentiation

Economical

Differentiation

Summary

automical generation

Classical SCADA / PLC solution SIMATIC PCS 7 solution

1 timen times

ES

Comparison of SIMATIC PCS 7 with aSCADA / PLC solution



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SIMATIC PCS 7vs.

SCADA / PLC


All Rights Reserved

Overview

Technical

Differentiation

Economical

Differentiation

Summary

Low integration effort:Less errors, increased process reliability

Uniformity notensured

Additional efforton the users side

High integration effort

Uniform functions

System performancewithout additionaleffort

Alarms/ messages

Redundancy

DocumentationUser access rights

Customer Support

Combined system fromvarious control suppliers

Process Control SystemSIMATIC PCS 7

Diagnostics

Low integration effort

Alarms/ messages

Redundancy

DocumentationUser access rights

Customer Support

Diagnostics



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SIMATIC PCS 7vs.

SCADA / PLC


All Rights Reserved

Overview

Technical

Differentiation

Economical

Differentiation

Summary

Comparison combined vs. system technique

Integration work necessary Integrated overall system

Individual components withfunctional scope that is notcoordinated

Frequently from varioussuppliers

Functional extensions in thecomponents for systemperformance

Individual components withcoordinated functional scope

From a single source

System functions are includedin the individual components

Combined system from

various control suppliers

Process Control System

SIMATIC PCS 7

Individual quality assurance foreach component

Individual product documentation

Individual function tests forcomponents, integration testin each project

Uniform quality assurance forthe entire system

Uniform documentation

All components qualified byfunction & system test



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uto at o a d es

SIMATIC PCS 7vs.

SCADA / PLC


All Rights Reserved

Overview

Technical

Differentiation

Economical

Differentiation

Summary

Base: ET 200iS

plus

PCS 7 spec. funct.

SIMATIC PCS 7: standard components plusprocess control specific add ons

ES

OS-Client

AS AS

Net

OS server

BATCH flex ib le

Base: Step 7

plus

PCS 7 spec. funct.

Base: S7-400

plus

PCS 7 spec. funct.

Base: WinCC

plusPCS 7 spec. funct.

Base: standard

Net comp.

Base: standard

Net comp.

Base: WinCC

plus

PCS 7 spec. funct.

Base: PA comp.

plus

PCS 7 spec. funct.

Base: standard

fail safe

Office LAN EthernetPCS 7 spec.

Batch package

@PCS 7 /

OPC server

Base: standards

plus

PCS 7 spec. funct.

PCS 7plus

add ons

Base: ET 200M

plus

PCS 7 spec. funct.

PCS 7plus

diagnostics



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SIMATIC PCS 7vs.

SCADA / PLC


All Rights Reserved

Overview

Technical

Differentiation

Economical

Differentiation

Summary

Certified Add-Ons

Added value of SIMATIC PCS 7 ...functions as system behavior

Systemwide time synchronisation of all participants

Central plantwide message system and alarm acknowledgement (acknowledge at source)

More Advanced Process Control

Interfaces to SAP, PI etc.

Pre-configured integration of field devices (PDM, CFC, faceplates)

Integrated Batch package for discontinous processes

Pre-configured, tested system components, order of bundles by separate MLFB-No.

Redundancy on all levels

Automatical system diagnostics for OS, AS and I/O modules

Defined startup / restart behavior

Safe and fast commissioning and safe operation of the plant (tested standards)

Life beat monitoring of all participants


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SIMATIC PCS 7vs.

SCADA / PLC


All Rights Reserved

Overview

Technical

Differentiation

Economical

Differentiation

Summary

Pre-defined faceplates, overview displays, graphics, keyset,... for cost effective engineering

Textuell programming based on SCL for complexe calculations and formulas.

Differentiated user access rights

Import-/Export-Assistent for efficient bulk engineering, use of Ratio as well

Automatical creation of area specific overview displays

Automatical creation of display hierarchy from plant hierarchy

Safe signal processing, even in stress situations (driver concept)

Libraries with: functions, faceplates, diagnostics and messages, but also

pre-wired chart templates for easy engineering

Added value of SIMATIC PCS 7 ...functions for engineering

Automatical creation of OS areas and automatical assignment of messages to OS areas

Faceplate Designer: user specific functions and faceplates can be created easily

Technological view and palnt hierarchy (Name scheme): object oriented configuring insted of programming

Pre-configured message, alarm and acknowledgement system (without engineering overhead)

Graphical configuration of sequential function charts (SFC), automatical creation of SFC visualization

Copy of CFC / SFC constructs: all internal connections stay preserved

PLC and control system SW can be engineered on the same system

Object/TAG oriented process data management

User specific libraries for administration of own functions, templates, ...

AMS (Asset Management System) for field bus oriented field devices e.g. transmitter + drives !



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SIMATIC PCS 7vs.

SCADA / PLC


All Rights Reserved

Overview

Technical

Differentiation

Economical

Differentiation

Summary

Added value of SIMATIC PCS 7 ...functions for installation, commissioning, service

More diagnostics/displays for operators and maintenance staff

(limits, times, interlockings, sequential function charts,...) - automatically

Fast installation due to pre-installed and tested devices

Autotune function

Support of intelligent field devices with 74% less wiring, 93% less space in control room and

80% less overhead for commissioning and AMS functionality. To check a field device maintenance staff

has no longer to go into far away located or dangerous areas to check the devices.

Integrated documentation instead lots of single documents

Automatical system diagnostics for OS, AS and I/O modules

Exchange of modules under power (hot replacement)

Failure strategy for I/O modules (maintain value, alternative value)

Uniform HW diagnostics

Display with life beat monitoring of all participants

In case of problems one system responsibility



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SIMATIC PCS 7vs.

SCADA / PLC


All Rights Reserved

Overview

Technical

Differentiation

Economical

Differentiation

Summary0

10

20

30

40

50

60

70

80

90

100

Investment and life cycle costs SCADA/PLC vs. PCS 7

2. Network

7. Service 1. HW

8. System SW

4. Application SW

3. Installation5. Commissioning

6. Training

SIMATIC PCS 7

SCADA / PLC



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SIMATIC PCS 7vs.

SCADA / PLC


All Rights Reserved

Overview

Technical

Differentiation

Economical

Differentiation

Summary

Solution with S7 + WinCCSolution with SIMATIC PCS 7

System-Hard-/Software: 53%

Appl.-Eng., install., comm.: 47%

total: 100%

Comparison of project costs(hardware, licenses, appl.eng., installation, commiss, ...)

Example plant with ca. 3.000 Control Loops

Configuration:

3.000 Control Loops

4 operator stations

1 engineering station

6 controllers

7.500 I/O channels

Configuration:

3.000 Control Loops

4 operator stations

1 engineering station

6 controllers

7.500 I/O channels

System-Hard-/Software: 50%

Appl.-Eng., install., comm.: 61%

total: 111%

:11%

Control Loop: Measuring, Motor, Control PID, Valve ...



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SIMATIC PCS 7vs.

SCADA / PLC


All Rights Reserved

Overview

Technical

Differentiation

Economical

Differentiation

Summary

Break even point SIMATIC PCS 7 vs. S7 / WinCC

# Control Loops

Costs

S7 / WinCC

PCS 7

Break even point

Contents & assumptions:

- Conti plant

- system hard- & -software

- application engineering

- installation & commissioning

- training

- ratio AI/AO to DI/DO:

50% zu 50%

100 1.500 7.500 15.0003.000

11%:3%

:17%

:11%

ca. 250ControlLoops



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SIMATIC PCS 7vs.

SCADA / PLC


All Rights Reserved

Overview

Technical

Differentiation

Economical

Differentiation

Summary

Graphical configuration

Pre-defined function block libraries

Pre-defined OS faceplates

Pre-defined overview displays/softkey sets

Uniform AS / OS configuration

Automatical generation of messages

Automatical generation of system diagnostics

Automatical scan of messages after startup

Cost savings in engineering

0

20

40

60

80

100

engineering effort

SCADA PCS 7


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SIMATIC PCS 7vs.

SCADA / PLC


All Rights Reserved

Overview

Technical

Differentiation

Economical

Differentiation

Summary

Optimally adapted function scope

Worldwide system competence

System technology from a single source

System approach reduces engineering costs

Low integration effort minimizes risk of errors and

accelerates the engineering process

Unifrom system functions ensure high process reliablity

Highly economical over the entire life cycle

These criteria speak in favour of SIMATIC PCS 7 ...


SIMATIC PCS 7 Positioning e

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