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Siemens Process Automation
End-user Summit- 2011 Experience. Technology. Community
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SIMATIC PCS 7
SIEMENS Answer for
global Trends
Dr. Stefan Bamberger
Head Product Management
Process Automation
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Industry Sector2011-08-10/11
INEOS Phenol Production Site, Germany
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Industry Sector2011-08-10/11
Decisive Factors for economical Production Challenges in Process Industries
Operation with highest
availability
Maintain safe and
secure productioncondition
Safety
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Industry Sector2011-08-10/11
Decisive Factors for economical Production Challenges in Process Industries
Operation with highest
availability
Maintain safe and
secure productioncondition
Safety
Reproducible quality of products
Increasing flexibility and productivity
Minimizing life-cycle costs, low maintenance costs
Quality
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Industry Sector2011-08-10/11
Decisive Factors for economical Production Challenges in Process Industries
Operation with highest
availability
Maintain safe and
secure productioncondition
Safety
Reproducible quality of products
Increasing flexibility and productivity
Minimizing life-cycle costs, low maintenance costs
Quality
Efficient use of
resources
Complying with
regulations
Environmental Protect.
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Industry Sector2011-08-10/11
Digital Enterprise
Is Our Long-Term Vision
Engineering
Commissioning
Operation
Design & Modernization
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Industry Sector2011-08-10/11
SIMATIC PCS 7 is the Interoperability Platform in the Plant
Process Control System
PM QM
OP1
OP2
MP
TM
ERP
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Industry Sector2011-08-10/11
SIMATIC PCS 7 for ALL sizes of Application in more than 21 industry segments
Norsk
Hydro ASA,
Norway
38,000 I/O
6 redundant OS Servers
4 Engineering Systems
Roche Products AG,
Switzerland
5,000 I/O
2 redundant OS Servers
1 redundant Archive-Server
3 Engineering Systems
BERTRAM Electronics,
Germany
648 I/O
SIMATIC PCS 7 Box
automates space flight
simulation system
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Industry Sector2011-08-10/11
Fushun Refinery / Ethylene, China High Scalability with strong Process Integration
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Industry Sector2011-08-10/11
Bohrinsel in der Nordsee
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Industry Sector2011-08-10/11
Protect Investments
Market entry
1979Estimated
end 2020
Migrationpaths
SIMATIC S71994
1997 SIMATIC PCS 7
1980 1990 2000 2010 2020
Teleperm
M
TI505/PCS/OSx
APACS / Quadlog
2030
41
years
SIMATIC S5 !!
3rd
party Systems
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Industry Sector2011-08-10/11
SIMATIC PCS 7
Continuous DCS Innovation
based on Totally Integrated Automation
PCS 7
V6
PCS 7
V7
PCS 7
V8
Totally Integrated
Automation
Flexible Redundancy
Safety Matrix
Batch
Route Control
Web OS
Alarm Management
Plant Asset Management
Advanced Process
Control
PA / FF Redundancy
Digital Plant @ PCS 7
PROFINET incl.Redundancy
Scalable archiving and
reporting
Windows 7
Endof2
011
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Industry Sector2011-08-10/11
On the way to the Digital Plant Bridging the gap within the Engineering Workflow!
Asset & Change
Management
PCS 7
Process Control System
PROFIBUS
AS
ES OS PCS 7
Digital Engineering
Basic
Engineering
Installation &
CommissioningProcess
Design
Plant Life Cycle
Detail
EngineeringOperation &
Maintenance
Modernization
& Upgrade
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Industry Sector2011-08-10/11
Comprehensive Integration with Comos for all Industries
Basic Features forCont. Industries
Enhanced Features
Complex Features
for Batch Industries
Transfer of PCS 7 libraries to Comos
Bi-directional exchange of CFC charts
Hardware engineering
Plant hierarchy
Symbol table
Messages
Control logic
Sequential functioncharts
Simatic Hardware Catalogue in Comos available
Plausibility & consistency checks
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Industry Sector2011-08-10/11
Condition-based and predictive Maintenance through Asset Management and Performance Monitoring
Customerbenefit
Effort and Complexity
Plant Asset ManagementPerformance Monitoring
PDM
SITRANS F
SIPART PS
PCS 7 Servers
Maintenance Station
Scalance
SIMATIC I/O cards
S7-400 AS
COMOS MRO
PumpMon
Maintenance Station
B.data
Powerrate
Integrated TIA solution to keep complexity down
Reduction of maintenance and life-cycle cost Extension to Performance Monitoring
Self-diagnosticsStatus information
Maintenance alarms
KPIs
Performance alarms
KPIs
Maintenance alarms
Performance alarms
SIPAT
Extended services
Customer Benefits:
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Industry Sector2011-08-10/11
PCS 7
Engineering
real time
Comos
MRO
Plant Asset
Management
Cyclic and on event
Cyclic and on event
ERP (e.g. SAP)
Integrated Plant Asset Management Data flow between Comos
and PCS 7
Comos
PCS 7
Plant Asset
Management
Real timePCS 7 OS
Realtime
Process
Real
time
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Industry Sector2011-08-10/11
SIMATIC PCS 7 goes Energy Efficiency PCS 7 Powerrate
Increased energy efficiency with SIMATIC PCS 7
Powerrate integrated into SIMATIC PCS 7 (Option)
EM demo model available (for PCS 7 and WinCC)
Pumpmon block saves energy by stabilization of working point
APC Library to reduce energy consumption by 3-10%,
increase yield by 2-10% and flow by 1-5%
Perfect fit for automation of green technologies
E.g. Solar, Poly-silicon, Bio-gas, Bio-ethanol,
Desalination, Waste gas treatment, waste combustion,
Sustainability = Energy efficiency and more
Reduced emissions and less waste by optimized Processes
through SIPAT, PCS 7 APC, PCS 7 Route Control
Introduced on
HMI 2010
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Industry Sector2011-08-10/11
PCS 7 Powerrate Overview
Electrical energies via:
Circuit Breakers, Multifunction meters, Motor Management
Systems, Motor Starter, ...
Non-electrical energies via:
Field Devices (o/420mA, HART, Profibus PA, FF)
PCS 7
Controller
Identify / Measuring
with
SIMATIC PCS 7 and
SIMATIC powerrate
ET200S
Motor Starter
PROFIBUS
SIMOCODE pro
Motor
ManagementSENTRON 3WLCircuit Breaker
SENTRON
PAC3200
Multifunction- Meter SINAMICSMotor Management
PROFIBUSPA
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Industry Sector2011-08-10/11
Reducing operating costs by efficient use of resources
Soft Sensor
Neural Nets
PIDTuningAdaptive
Control
ControlPerformanceMonitoring
GainScheduling
high
APC Methods
Fuzzy Control
Dynamic Modeling
low
APC Engineering
OperatorTraining
Simulator
leanexternal
MPClean
external
MPC
high
low
complexity
complexity
Online Optimization
embedd
ed
interfaced
Advanced Process Control
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Industry Sector2011-08-10/11
SIMATIC PCS 7 TeleControl in typical Oil & Gas Applications
Remote Terminal Units in Oil-
& Gas
Metering stations in pipelines
& gas networks
Valve stations in pipelines
Wellhead monitoring and
automation incl. Emergency Shut
Down (ESD)
- Gas Well
- Oil Well
- Gas injection wells
- Water injection wells
These applications require integration of both local automation and
distributed automation stations
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Industry Sector2011-08-10/11
SIMATIC PCS 7 TeleControl in Water & Wastewater ApplicationsRemote Terminal Units in
Water-
& Waste Water:
Control of pump stations
Rain Water Buildings
Reservoir Buildings
Valve Stations in Pipelines
These applications require integration of both local automation and
distributed automation stations
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Industry Sector2011-08-10/11
PCS 7 TeleControl Merge of DCS and TeleControl
Philosophy to serve combined Industries
SIMATIC PCS 7 OS Clients
TeleControl
OS-Server(dedicated ordouble channel)
Engineering
Station
PCS 7
OS-Server(redundant)
AS 41x FH
ET 200M
ET 200M
ET 200M
ET 200M
AS 41xTCP/IP
WAN Router
central
SINAUT TIM
Modem
widely distributed
TeleControl
remote stations
PR
OFIBUS
WAN
WAN ET 200S
S7-300
S7-400
3rd
party
RTU
Modbus
Modem
TCP/IPserial
S7-300
S7-400S7-400
ET 200S
S7-300
SINAUT ST7 IEC 870
3rd
party
RTU
SIMATIC PCS 7SIMATIC PCS 7 TeleControl
TCP/IP
WAN Router
WAN
S7-300
S7-400
DNP V3
3rd
party
RTU
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Industry Sector2011-08-10/11
Conventional Remote I/O Remote I/O
for Zone 1E/AE/A
BUS BUS
Ex-CouplerRS 485-IS
Zone 0
Zone 1
ET 200M
ET 200iSP
E/A
Sub distribution
Trends on Field Level From conventional to distributed Configurations
Minimal wiring and
material overhead
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Industry Sector2011-08-10/11
First in World, Failsafe Periphery for Installation in Ex-Zone 1 / 21 up to SIL3SIMATIC ET 200iSP-F
Failsafe IO-Modules for installation
up to Ex-Zone 1 / 21; up to SIL 3 Digital Input Modul 8 F-DI NAMUR
Digital Output Modul 4 F DO
Analog Input Modul 4 F-AI HART
+ Line monitoring in Ex area up to the sensor / actuator+ Benefit in terms of SIL-Calculation, because of integrated Ex-Barriers+ Mixed installation with standard modules (on standard TM )+ Complete portfolio
Failsafe modules for direct Zone 1 installation
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Industry Sector2011-08-10/11
SIMATIC PCS 7 Fieldbus TechnologiesFully support of PROFIBUS & FFAS 41x HF
PROFIBUS PA
PA-Link
Foundation Fieldbus H1
FF-Link
No more market entry barriers
PCS 7 customers are free to choose their favorite
fieldbus according to preferred instrumentation
Seamless integration of complete FF
functionality
No need of 3rd party components
Siemens provides complete fieldbus infrastructure
(incl. power conditioning & field distribution)
Outstanding scalable FF redundancy options
FF-H1 link master redundancy (2x IM)
Redundant power conditioning (2x Coupler)
Ring redundancy (unique selling point)
Further improvement of decentralizedapproach
High speed backbone for fieldbus is PROFIBUS andwill be PROFINET in future
Key Benefits:
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Industry Sector2011-08-10/11
Homogeneous Integration of Field level Asset protection via future-proof Technology
PROFINET
Customer Benefits:
Lower Engineering cost
Comprehensive diagnostics and easier commissioning Proxy concept ensures investment protection and backward compatibility
PROFIBUS
DP
PROFINET
ERP
MES
Ethernet backbone
HART
PROFIBUS
PA
FF H1
Customer Benefits:
DCSPCS 7
HART
PROFIBUS PA
FF H1
PROFIBUS DP
PROFINET
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Industry Sector2011-08-10/11
PROFINET @ PCS 7 The Future of Fieldbus
Infrastructure
IE / WSN-PA LINK
SITRANS TF280
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Industry Sector2011-08-10/11
EDGE
GPRS
GSM
3G/4G
Aging &Storage
YeastPropagation
Mashing
Lautering
Brew Kettles
Fermentation
HeatExchangers
Filling Line
Filtration
Level
Flow
Pressure
Positioner
Temperature
Machine Vision
Proximity switch
Fail safe sensors
RFID
Examp
le:Bre
wery
IWLAN
WirelessHART
Temperature
WirelessHART
Pressure
WirelessHART
Adapter
WirelessHART
Gateway
Wireless technology for Process Automation
Wireless
HART
IndustrialWireless LAN
Wireless
WAN
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Industry Sector2011-08-10/11
Physical Security- Physical access to facilities and equipment
Policies & procedures-Security management processes-Operational Guidelines
-Business Continuity Management & Disaster Recovery
Security cells & DMZ-Secure architecture based on network segmentation
Firewalls and VPN-
Implementation of Firewalls as the only
access point to a security cell
System hardening- adapting system from default to secure
User Account Management-
Administration of operator und user
rights (role based access control)
Patch Management
Malware detection and prevention-
Anti
Virus and Whitelisting
Potential Threat
DCS
Defense in Depth because you should not rely on just one measure
Industrial Security via Defense in Depth
Strategy
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Industry Sector2011-08-10/11
Siemens Strong Partner for a life time The 3 P
of Excellence
Always
RUN
a changing
System
!
Professional Services:Dedicated Industry Know-
How
Exchange of experience
across industries
Partners since 150 years
Project Execution:World-wide presence
Standardized processes
Power of a major enterprise
Excellent Products: Leading technology
In-house development
In-house production
One-stop supplier
Seamless integration
Support of Standards
Openness, Investment protection
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Industry Sector2011-08-10/11
BASF, China, 3 P of Excellence
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We wish you a successful meeting!
Dr. Stefan Bamberger
PCS 7 Product ManagementI IA AS PA PRM
E-Mail: [email protected]
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