SIMATIC PCS 7: Perfect Use Content

Transcription

1 SIMATIC PCS 7: Perfect Use Content SIMATIC PCS 7: Overview Control Module Technology SIMATIC PCS 7: Plant Asset Management Added Value SIMATIC PCS 7 and SIEMENS Fielddevices Page 1

2 SIMATIC PCS 7: Overview January 2019

3 SIMATIC PCS 7 Overview Content Process Automation Positioning Our Portfolio What did we learn? Overview: SIMATIC PCS 7 V9.0 Market and Competitors What did we learn? Page 3

4 SIMATIC PCS 7 Overview Content Process Automation Positioning Our Portfolio What did we learn? Overview: SIMATIC PCS 7 V9.0 Market and Competitors What did we learn? Page 4

5 1. Process Automation Automation Landscape FA: Factory Automation Example: Automotive Application for PLC / HMI (SCADA*) Welding Robot * Sequence Control and Data Aquisition PA: Process Automation Example: Chemical Plant Application for DCS PLC Reactor HA: Hydrid Automation Example: Brewery Application for PLC / HMI and DCS** ** Digital Control System Stock Boiler Filling Stock PLC / HMI DCS PLC / HMI PLC / HMI Page 5

6 1. Process Automation Characteristics of PA, FA and HA Automation Characteristics Production Visibility of the product during production Automation functionality Typical industries Process Automation (PA) Manufacturing Stuff Product seen after completely produced Combination of regulatory (loop) control and (sequential) control Chemical and Pharma (Batch) Oil and Gas Paper and Cement Power Utilities Page 6

7 1. Process Automation Characteristics of PA, FA and HA Automation Characteristics Production Visibility of the product during production Automation functionality Typical industries Process Automation (PA) Manufacturing Stuff Product seen after completely produced Combination of regulatory (loop) control and (sequential) control Chemical and Pharma (Batch) Oil and Gas Paper and Cement Power Utilities Page 7

8 1. Process Automation Characteristics of PA, FA and HA Automation Characteristics Process Automation (PA) Factory Automation (FA) Production Manufacturing Stuff Manufacturing Things Visibility of the product during production Automation functionality Product seen after completely produced Combination of regulatory (loop) control and (sequential) control Product seen through whole production (Assembly processes) Speed logic control, on/off (binary) Typical industries Chemical and Pharma (Batch) Oil and Gas Paper and Cement Power Utilities Automotive Electronics Machine building Aerospace Page 8

9 1. Process Automation Characteristics of PA, FA and HA Automation Characteristics.. Process Automation (PA) Factory Automation (FA) Hybrid Automation (HA) Production Manufacturing Stuff Manufacturing Things Visibility of the product during production Automation functionality Product seen after completely produced Combination of regulatory (loop) control and (sequential) control Product seen through whole production (Assembly processes) Speed logic control, on/off (binary) Combination of PA and FA Typical industries Chemical and Pharma (Batch) Oil and Gas Paper and Cement Power Utilities Automotive Electronics Machine building Aerospace Page 9

10 1. Process Automation Industries The Industries can be segmented in Process Automation (PA), Hybrid Automation (HA) and Factory Automation (FA) Page 10

11 1. Process Automation Automation Pyramid A DCS together with Fielddevices are important parts of the Automation Pyramid 2 Page 11

12 1. Process Automation Important Trend of the Automation Pyramid: Openness Field and DCS are coming more and more together through Openness, as a result of all the Forcing Factors from Process, Field and DCS We as SIEMENS can offer the strong concept SIMATIC PCS 7 and Integrated SIEMENS Field devices, that supports this trend This is a real Competitive Advantage in the market 2 1 Forcing Factors Page 12

13 1. Process Automation Forcing Factors for Openness From Process Maintenance to keep in function or to repair, aging and wear down plant / machines Preventive Maintenance: Operation and / or functional test From Field Need of field devices with extended functionality (Coriolis, Intelligent Positioner,..) Powerful fieldbus technology Central access to connected field devices Seamless integration in Plant Asset Management From Process Control Need of field devices with extended functionality (Coriolis, Intelligent Positioner,..) Full integration of field devices beyond 4 20mA Minimizing Total Cost of Ownership based on Plant Asset Management Page 13

14 SIMATIC PCS 7 Overview Content Process Automation Positioning Our Portfolio What did we learn? Overview: SIMATIC PCS 7 V9.0 Market and Competitors What did we learn? Page 14

15 2. Positioning SCADA, DCS, DCS Full Blown PLC / HMI (SCADA) SCADA Classic SCADA extd. = SCADA Classic + Libraries for PLC / HMI DCS DCS Classic DCS extd. = DCS Classic + Historian + Assetmanagement + Energy Control + Power Control + Route Control +.. DCS Full Blown: SIMATIC PCS 7 DCS extd. + PLC/HMI- Functions (Low Cost driven) Page 15

16 1. Process Automation DCS in Industries Page 16

17 1. Process Automation DCS in Industries Page 17

18 1. Process Automation DCS in Industries DCS Classic and DCS Extd. Page 18

19 1. Process Automation SIMATIC PCS 7 in Industries DCS Full Blown: SIMATIC PCS 7 also for Hybrid Automation Page 19

20 3. Positioning DCS and SCADA: System Features SCADA Multiple manufactures for PLC, Communication, HMI and PC (not Siemens) Programming based on IL, Ladder, FBD, SFC, ST Strong in binary and digital Functionality Highest Processing Speed Redundant System Components are optional Basic Batch Package optional Single supplier DCS Configuration based on Standard SW (PID, Faceplates,..) Strong in analog Functionality Medium Processing Speed Redundant System Components are a Must Powerful Batch Package Page 20

21 3. Positioning DCS and SCADA: Application Cost A first step of Positioning is given by the System Features as shown before A second step of Positioning (the most important one) within a Project is given by the Application Cost (depending on the Characteristics ) The Application Cost are dominated more and more by the Total Cost of Ownership (TCO) Page 21

22 3. Positioning TCO: High Priority Phases High Priority High Priority Page 22

23 3. Positioning System HW, System SW and Engineering Cost System HW equal The cost for System SW can be higher than the cost for SCADA But in the engineering phase, the increased cost for System SW, will be compensated or even reduced through the powerful and from customer required functionality Purchase Cost Engineering Cost E System-SW System- SW P System- HW System- HW SCADA DCS SCADA DCS Delta Total = Delta E Delta P Page 23

24 3. Positioning Calculated Projects CONTI Standard : Delta Total = Delta E Delta B = positive = 19% CONTI Extended : Delta Total = Delta E Delta B = positive = 26% BATCH Standard : Delta Total = Delta E Delta B = positive = 38% BATCH Extended : Delta Total = Delta E Delta B = positive = 47% Page 24

25 SIMATIC PCS 7 Overview Content Process Automation Positioning Our Portfolio What did we learn? Overview: SIMATIC PCS 7 V9.0 Market and Competitors What did we learn? Page 25

26 3. Our Portfolio Comprehensive Portfolio for DCS-Applications SIEMENS has a comprehensive Portfolio for DCS applications: SIMATIC PCS 7 together with SIMIT, COMOS and the SIEMENS Fielddevices Page 26

27 3. Our Portfolio SIMATIC PCS 7 V9.0 Page 27

28 3. Our Portfolio TOP 10 Highlights and 4 Key Factors for our Customers % SIMATIC, PROFIBUS- and PROFINET Platform 2. TIA Concept. Upstream, Mainstream and Downstream 3. One Stop Shop. All components from SIEMENS 4. True decentralized architecture through PROFIBUS and PROFINET 5. Scalability. From PCS 7 Box to Client / Server 6. Integrated Engineering through Technological User Interfaces, powerful libraries, Control Modules, Plant Automation Accelerator (PAA), COMOS and SIMIT 7. Redundancy at all levels 8. Integrated Fail Safe Technology based on Safety Matrix 9. Plant Asset Management, Energy Control, Power Control 10. Powerful Batch- and Route Control Package Cost Reduction Invest Protection 1-6 Safety Plant Availability 7 Plant / Process Performance Page 28

29 SIMATIC PCS 7 Overview Content Process Automation Positioning Our Portfolio What did we learn? Overview: SIMATIC PCS 7 V9.0 Market and Competitors What did we learn? Page 29

30 4. What did we learn? ü ü ü ü ü ü ü The different categories of Process Automation are shown The openess of the Automation Pyramid is driven by the Process, the Field and the Process Control A Positioning of DCS and SCADA can be made by System Features and Application Cost Result of calculated Applications Cost for projects: The use of SIMATIC PCS 7 is the best solution SIEMENS has a comprehensive Portfolio for DCS- applications: SIMATIC PCS 7 together with SIMIT, COMOS and the SIEMENS Field Devices, thanks to the SIMATIC platform The roadmap and the strong ongoing development of SIMATIC PCS 7 is shown The TOP 10 Highlights and the 4 Key Factors for customer s need verify the power of SIMATIC PCS 7 Page 30

31 SIMATIC PCS 7 Overview Content Process Automation Positioning Our Portfolio What did we learn? Overview: SIMATIC PCS 7 V9.0 Market and Competitors What did we learn? Page 31

32 5. Overview: SIMATIC PCS 7 V9.0 Content System Components 5.1 Engineering Station (ES) 5.2 Operator Station (OS) 5.3 Automation System (AS) 5.4 PROFIBUS and PROFINET 5.5 Security 5.6 Process Device Manager (PDM) 5.7 Maintenance Station (MS) Technology Components 5.8 Process Historian (PH) and Information Server (IS) 5.9 SIMATIC BATCH 5.10 SIMATIC Route Control 5.11 Safety Integrated 5.12 SIMATIC PCS 7 TeleControl 5.13 SIMATIC PCS 7 PowerControl Support & Service 5.14 Migration 5.15 Lifecycle Management Page 32

33 5. Overview: SIMATIC PCS 7 V9.0 Content System Components 5.1 Engineering Station (ES) 5.2 Operator Station (OS) 5.3 Automation System (AS) 5.4 PROFIBUS and PROFINET 5.5 Security 5.6 Process Device Manager (PDM) 5.7 Maintenance Station (MS) Page 33

34 5.1 Engineering Station (ES) Engineering Functionality Engineering tools Import and export to Cax SIMATIC PDM also as standalone product available Page 34

35 5.1 Engineering Station (ES) Continuous Function Chart (CFC) Page 35

36 5.1 Engineering Station (ES) Continuous Function Chart (CFC) Page 36

37 5.1 Engineering Station (ES) Sequential Function Chart (SFC) Standard Elements (Step, Transition, Jump,...) Automatic Generation of OS Visualization Different Modes of Operation Modification in Run Page 37

38 5.1 Engineering Station (ES) The Library concept Advanced Process Library (APL) Standard library for all industries Technological function blocks Channel drivers Block icons and faceplates Standard drive integration APC with look & feel of APL Industry Library Industry specific blocks Block icons and faceplates with look & feel of APL PCS 7 HVAC PCS 7 panel integration S7 package unit integration Page 38

39 5.1 Engineering Station (ES) Advanced Process Library (APL) Ease of use Ergonomic symbols and task-oriented faceplates Uniform representation of state information Unified operation modes (auto, on, manual, local, out-of-service) Adaptable & scalable functionality Feature parameter Modular functionality Integrated maintenance functions and simulation Advanced Process Control (APC) integrated Page 39

40 5.1 Engineering Station (ES) Industry Library (IL) Easy integration of package units with S7-300 (in CFC Engineering) Visualization of package units on PCS 7 OS APL look & feel PCS 7 HVAC functionalities Page 40

41 5.1 Engineering Station (ES) Logic Matrix Reduction of engineering effort for interlocks and shutdown logic Editor in the form of Safety Matrix Improved efficiency compared to interlock engineering on CFC level Bulk Editing / Engineering Automatic visualization in OS Page 41

42 5.1 Engineering Station (ES) Plant Automation Accelerator (PAA) Shorter project durations through consistent data synchronization between engineering and automation Increased engineering efficiency through Change Management and controlled "Mass Data Engineering" Consistent documentation throughout the entire lifecycle Reusability of the as-is documentation for migrations, plant extensions and new-builds Control Modules for "Technological Engineering" Page 42

43 5.1 Engineering Station (ES) SIMIT: Merging of the Real World and the Digital World Page 43

44 5. Overview: SIMATIC PCS 7 V9.0 Content System Components 5.1 Engineering Station (ES) 5.2 Operator Station (OS) 5.3 Automation System (AS) 5.4 PROFIBUS and PROFINET 5.5 Security 5.6 Process Device Manager (PDM) 5.7 Maintenance Station (MS) Page 44

45 5.2 Operator Station (OS) Overview OS Page 45

46 5.2 Operator Station (OS) Effective operator guidance Staight- forward Display Hierachy and Segmented Screen layout Page 46

47 5.2 Operator Station (OS) Complete user interface Pre- configured pictorial representations Graphic displays, curve display, alarm list,... Symbols, Faceplates Information based color schema Graphics Enhanced functions Acknowledgement of messages right in the graphics themselves Multi-screen technology (1-4 monitors) Symbols Face Plates Page 47

48 5.2 Operator Station (OS) Effective alarming Alarm management tools providing high operator efficiency Better Alarm Analysis Alarm number by type Frequency of alarms Alarm source Export functionality Fast Response to Alarms Alarm Prioritization User-specific settings Excel-style sorting/filtering Online Help Page 48

49 5.2 Operator Station (OS) Scalable archiving Full integrated in PCS 7 Scalable and centralized storage of process data in real time Open System ODBC OLE DB ADO.NET Page 49

50 5.2 Operator Station (OS) Web client: Remote monitoring and control Providing a secure remote interface for a broad range of applications Monitoring and Control via the Internet / Intranet Web Client as thin client Complete plant overview Advanced security with User-specific password User-specific rights Firewall technology Page 50

51 5.2 Operator Station (OS) Integration of mobile services via WinCC Web UX Flexible access to important plant data Ease installation and configuration Secured plant information as a basis for decisions Device independent use of smartphones, tablets and other mobile devices Zero Client installation Supported functionality Alarm visualization and alarm acknowledge Some important tag (key performance indicators) visualization on IO field and Trend Page 51

52 5.2 Operator Station (OS) Virtuliazation Reduced number of Servers, reduced Network- Components, reduced Space Reduced Energy- Cost Reduced Maintenance- Cost PCS 7 System-Software independent of Hardware- Innovation by VMware Cloud Computing- Architecture Page 52

53 5.3 Overview: SIMATIC PCS 7 V9.0 Content System Components 5.1 Engineering Station (ES) 5.2 Operator Station (OS) 5.3 Automation System (AS) 5.4 PROFIBUS and PROFINET 5.5 Security 5.6 Process Device Manager (PDM) 5.7 Maintenance Station (MS) Page 53

54 5.3 Automation System (AS) Portfolio: Scalable in function and performance For highest standard AS: Standard AS H: High availability AS F: Failsafe AS H/F For compact solutions SIMATIC PCS 7 Box CPU 410E CPU 410SIS Page 54

55 5.3 Automation System (AS) CPU 410-5H: Scalable Controller for PA Flexible Performance according to number of Process Objects (PO) Expanding in steps of 100 PO s, even at runtime Single, Redundant, Failsafe Robust Proven ruggedness of SIMATIC Coating on the board Cost optimized One single HW- platform, adaptable to use 4 Ethernet Ports Reduced and simplified spare part management No reserves needed. Pay what you use Page 55

56 5. Overview: SIMATIC PCS 7 V9.0 Content System Components 5.1 Engineering Station (ES) 5.2 Operator Station (OS) 5.3 Automation System (AS) 5.4 PROFIBUS and PROFINET 5.5 Security 5.6 Process Device Manager (PDM) 5.7 Maintenance Station (MS) Page 56

57 5.4 PROFIBUS and PROFINET I/O- Architecture Page 57

58 5.4 PROFIBUS and PROFINET SIMATIC Compact Field Unit (CFU) 8 x PROFIBUS PA 8 x DI / DO, free configurable Extended Temperature (- 40 / +70 ). Conformal Coating Automatic addressing for PROFIBUS PA devices through PA- profiles Page 58

59 5.4 PROFIBUS and PROFINET ET 200SP HA 56 Modules per Station. High channel density per module (32 channels) Application specific modules Extended temperature (- 40 / +70 ). Conformal Coating Connecting technology: Push- Clip without special tool Page 59

60 5.4 PROFIBUS and PROFINET Active Field Distributor for EX (AFDiSD) High power trunk solution for EX (PA and FF-H1) Robust IP66 housing for outdoor Live monitoring and diagnostic of physical layer data Support of remote control of spurs from ES / MS M SIMATIC PA Link SIMATIC AFDiSD [Ex ia] spurs Diagnostic according to NE107 Page 60

61 5.4 PROFIBUS and PROFINET PROFINET: Network Structures Highest flexibility in network structures Page 61

62 5.4 PROFIBUS and PROFINET PROFINET: Invest protection Page 62

63 5. Overview: SIMATIC PCS 7 V9.0 Content System Components 5.1 Engineering Station (ES) 5.2 Operator Station (OS) 5.3 Automation System (AS) 5.4 PROFIBUS and PROFINET 5.5 Security 5.6 Process Device Manager (PDM) 5.7 Maintenance Station (MS) Page 63

64 5.5 Security Trends impacting security More network connections than ever before Cloud Computing approaches Increased use of mobile devices Wireless technology Reduced personnel requirements The worldwide and remote access to remote plants, remote machines and mobile applications The Internet of Things The physical world is becoming an information system. Page 64

65 5.5 Security Security chain as strong as its weakest points Security can fail at many points Employee Smartphone Laptops PC workstations Network infrastructure Mobile storage devices Tablet PC Computer center Policies and guidelines Printer Page 65

66 5.5 Security The Defense in Depth Solution A set of functions together with Defense in Depth is the key to resolve security problems PCS 7- documentation for all security aspects Page 66

67 5.5 Security SIMATIC PCS 7 Application: Security you trust User Authentication Network Segmentation Firewalls VPN Tunnels Virus Scanning Patch Management Page 67

68 5. Overview: SIMATIC PCS 7 V9.0 Content System Components 5.1 Engineering Station (ES) 5.2 Operator Station (OS) 5.3 Automation System (AS) 5.4 PROFIBUS and PROFINET 5.5 Security 5.6 Process Device Manager (PDM) 5.7 Maintenance Station (MS) Page 68

69 5.6 Process Device Manager (PDM) Overview SIMATIC PDM (Process Device Manager) Effective service tool and commisioning station for smart field instruments SIMATIC PDM MS (Maintenance Station) Stand alone station for monitoring and service for smart field instruments

70 5.6 Process Device Manager (PDM) SIMATIC PDM The universal tool for Parameterization Diagnostic Commisioning Device management Can be used As stand alone service tool As central or decentralize service station Integrated in SIMATIC PCS 7 / Step 7 Is the recognized and leading tool for management and diagnistics of smart instruments Supports the future oriented "Field Device Integration" (FDI) Page 70

71 5.6 Process Device Manager (PDM) Access points Integrated in Engineering Station (ES) Stand Alone as a Service Tool on a Mobil Computer x x x x x x x x Page 71

72 5.6 Process Device Manager (PDM) SIMATIC PDM MS Universal and stand- alone Maintenance Station Management and diagnostics of smart field instruments Instrument condition and commisioning overviews Parameter archiving Device management Data export for cloud based applications Has similar functionality like SIMATIC PCS 7 MS Can be used As unit related maintenance station As central maintenance station Integrated in SIMATIC PCS 7 / Step 7 Page 72

73 5. Overview: SIMATIC PCS 7 V9.0 Content System Components 5.1 Engineering Station (ES) 5.2 Operator Station (OS) 5.3 Automation System (AS) 5.4 PROFIBUS and PROFINET 5.5 Security 5.6 Process Device Manager (PDM) 5.7 Maintenance Station (MS) Page 73

74 5.7 Maintenance Station (MS) Integrated Plant Asset Management System (PAMS) Plant asset management increases plant availability Benefits Automatic generation of all Plant Asset Management diagnostic pictures Maintenance Station integrated into Operator Station or as dedicated station Common visualization (symbols, faceplates) of all assets (unified assets) Implementation of NAMUR NA 64 and NE91 Online, Real-time Functions Condition Monitoring of all component Display of diagnostic information (PDM) Creation and tracking of maintenance requests Page 74

75 5.7 Maintenance Station (MS) Unified representation of all Assets Visualization of all assets Display of status change Announcement for maintenance Reporting of the maintenance activities Designed along NAMUR requirements Page 75

76 5.7 Maintenance Station (MS) Unified representation of all Assets Good Simulation local operation Maintenance request (low) Maintenance demand (medium) Maintenance alert (high) Maintenance not in progress Maintenance is requested Maintenance in progress Page 76

77 5. Overview: SIMATIC PCS 7 V9.0 Content Technology Components 5.8 Process Historian (PH) and Information Server (IS) 5.9 SIMATIC BATCH 5.10 SIMATIC Route Control 5.11 Safety Integrated 5.12 SIMATIC PCS 7 TeleControl 5.13 SIMATIC PCS 7 PowerControl 5.14 Energy Management 5.15 Advanced Process Control Page 77

78 5.8 Process Historian (PH) und Information Server (IS) Overview Scalable and centralized storage of process data from multiple projects Real-time storage Reporting system based on Microsoft Reporting Services. Access to office applications Page 78

79 5. Overview: SIMATIC PCS 7 V9.0 Content Technology Components 5.8 Process Historian (PH) and Information Server (IS) 5.9 SIMATIC BATCH 5.10 SIMATIC Route Control 5.11 Safety Integrated 5.12 SIMATIC PCS 7 TeleControl 5.13 SIMATIC PCS 7 PowerControl 5.14 Energy Management 5.15 Advanced Process Control Page 79

80 5.9 SIMATIC BATCH What is SIMATIC BATCH? Easy graphical recipe generation and charge planning Hierarchical recipes according to ISA 88 Interaction with Route Control Page 80

81 5.9 SIMATIC BATCH TOP 10 Highlights and 4 Key Factors for our Customers 1. Unique Selling Point: Integrated BATCH & Route Control Unique in the DCS- World 2. Modular architecture in Hardware and Software 3. Full integrated into ES and OS 4. Importing and exporting of master recipes, formulas and library objects 5. High availability through redundant Servers and / or Automation System 6. Unit independent recipes 7. Saving and archiving of data in Process Historian 8. Validation support according to 21CFR Part Flat and hierarchical recipes according to ISA Interfacing with SIMATIC IT or any other MES- System Cost Reduction Invest Protection 1-4 Safety Plant Availability 4,5,6 Plant / Process Performance 7,8 1,4,9,10 Page 81

82 5.9 SIMATIC BATCH Recipe Editor Creation and modification of master recipes and library objects Documentation of master recipes and library objects Plausibility checks Release of master recipes and library objects for test and production ROP RPH ROP Lib. Operator Dialog Command Step Parallel branch Sync line Monitoring Area Transition Alternative branch Loop Jump Page 82

83 5.9 SIMATIC BATCH PC- and / or AS- based PC- based (Chemical Reactor) Batch Server: Recipe Function Recipe Unit Procedure (RUP) Recipe Operation Procedure (ROP) AS: CFC, SFC AS- based (Iced - lolly Production) High Speed Batch Batch Server: Synchronisation of RUP s AS: Recipe Function (RUP, ROP) and CFC, SFC Therefore High Speed from step to step Page 83

84 5.9 SIMATIC BATCH BATCH Control Center (BCC) The BCC is the command center for planning, monitoring and control of a batch process Import of basic project data and updates User rights management Manage master recipes, formulas and libraries Create batches from master recipes and formulas Run batch production and control batches Batch procedure monitoring and diagnose Recipe and batch data reporting and archiving Page 84

85 5.9 SIMATIC BATCH Faceplates in APL Style Symbols and Faceplates for Unit block Equipment Phase block (EPH) Page 85

86 5.9 SIMATIC BATCH Planning Production Orders Planning a large number of production orders and batches in advance Schedule, modify, cancel, delete or release of batches Automatic creation and splitting of batches for a production order Clear presentation of batches through a combination of Gantt chart and table view Variable batch properties like start mode, batch quantity, etc. are adjustable and changeable Page 86

87 5.9 SIMATIC BATCH Reporting Batch Report is used to create reports for recipes and batch data Display and print the report Trends may be monitored for the duration of a batch Reports can be customized through project settings Reporting system based on MS Reporting Services Two types of reports: Batch Report with data for reproduction, certification and compliance (21CFR Part11) Recipe Report with recipe header, material input/output, setpoints,.. Page 87

88 5. Overview: SIMATIC PCS 7 V9.0 Content Technology Components 5.8 Process Historian (PH) and Information Server (IS) 5.9 SIMATIC BATCH 5.10 SIMATIC Route Control 5.11 Safety Integrated 5.12 SIMATIC PCS 7 TeleControl 5.13 SIMATIC PCS 7 PowerControl 5.14 Energy Management 5.15 Advanced Process Control Page 88

89 5.10 SIMAIC Route Control What is SIMATIC Route Control? For manual or automated transportations of materials, liquids or solid goods Automated search of available routes Interaction with SIMATIC BATCH or stand alone Page 89

90 5.10 SIMATIC Route Control TOP 10 Highlights and 4 Key Factors for our Customers 1. Unique Selling Point: Integrated BATCH & Route Control Unique in the DCS- World 2. Integrated, but also without BATCH 3. Full integrated into ES and OS 4. Mapping of route network through partial routes 5. Engineering of routes based on CFC 6. Offline test for completeness, inconsistencies and undesired combinations 7. High availability through redundant servers and / or Automation Systems 8. Test of material compatibilities to avoid undesired mixing 9. Detailed diagnostics of material transport 10.Online changes during commissioning and production Cost Reduction Invest Protection 1-6 Safety Plant Availability 4,7 Plant / Process Performance 6,8,9 1,2,10 Page 90

91 5.10 SIMATIC Route Control Route Control in different Industries (1) Page 91

92 5.10 SIMATIC Route Control Route Control Center Overview of all RC elements and request details Selection of manual / automatic mode Diagnostics of material transport errors caused by locked elements / partial routes / Page 92

93 5.10 SIMATIC Route Control Added Value: SIMATIC BATCH and SIMATIC Route Control Use Case 1 (Separated) System 1 for BATCH System 2 for Route Control Route Control Package realized by Programming Use Case 2 (Integrated) One System, given by SIMATIC PCS 7, for BATCH and Route Control Route Control Package realized by Parameterisation of an algorithm SIMATIC BATCH and SIMATIC Route Control fully integrated Page 93

94 5.10 SIMATIC Route Control Added Value: SIMATIC BATCH and SIMATIC Route Control Ratio Small Size Project : 11% Ratio Medium Size Project : 44% Ratio Large Size Project : 57% Page 94

95 5. Overview: SIMATIC PCS 7 V9.0 Content Technology Components 5.8 Process Historian (PH) and Information Server (IS) 5.9 SIMATIC BATCH 5.10 SIMATIC Route Control 5.11 Safety Integrated 5.12 SIMATIC PCS 7 TeleControl 5.13 SIMATIC PCS 7 PowerControl 5.14 Energy Management 5.15 Advanced Process Control Page 95

96 5.11 Safety Integrated Safety for Process Automation Application example Emergency und Process Shutdown Systems (ESD / PSD) Burner Management Systems Fire & Gas Systems Main industries Oil & Gas Petrochemical Energy Benefit Safety Integrated Fast cost effective Engineering Reduced training effort and costs Reduced cost for spares pooling Integrated Safety Lifecycle Tool (Safety Matrix) Page 96

97 5.11 Safety Integrated Scalable range of controllers (410H/F and 410SIS) Powerful controllers for Process Automation and Factory Automation Based on SIMATIC F Systems Library Physical separation of controllers possible Extremely high-speed processing and communications performance Changes to the configuration during operation Failsafe and high availability versions Hot swapping CPU 410 SIS 4 MB Memory 200 PO s max No restriction for Cycle- time CPU 410 H/F CPU 410 SIS Page 97

98 5.11 Safety Integrated Remote I/O s SIMATIC ET 200M Failsafe modules Scan QR code to learn more about ET200M SIMATIC ET 200iSP Failsafe modules Scan QR code to learn more about ET200iSP Page 98

99 5.11 Safety Integrated Safety Matrix with unique features Configurable Password Protected Secure Operation Engineering station with full online capability Operator station with limited online capability Page 99

100 5. Overview: SIMATIC PCS 7 V9.0 Content Technology Components 5.8 Process Historian (PH) and Information Server (IS) 5.9 SIMATIC BATCH 5.10 SIMATIC Route Control 5.11 Safety Integrated 5.12 SIMATIC PCS 7 TeleControl 5.13 SIMATIC PCS 7 PowerControl 5.14 Energy Management 5.15 Advanced Process Control Page 100

101 5.12 SIMATIC PCS 7 TeleControl Overview Page 101

102 5.12 SIMATIC PCS 7 TeleControl Use of TeleControl Integration of remote stations via tele control protocols into the control system Main applications in Water & Wastewater-, Oil & Gas- and Energy Supply plants Remote stations so called Remote Terminal Units (RTU) are typically wide distributed and mostly with low or medium level of automation SIMATIC PCS 7 TeleControl integrates these RTU s to a homogenous solution Page 102

103 5.12 SIMATIC PCS 7 TeleControl Application: Gas Pipeline Page 103

104 5. Overview: SIMATIC PCS 7 V9.0 Content Technology Components 5.8 Process Historian (PH) and Information Server (IS) 5.9 SIMATIC BATCH 5.10 SIMATIC Route Control 5.11 Safety Integrated 5.12 SIMATIC PCS 7 TeleControl 5.13 SIMATIC PCS 7 Power Control 5.14 Energy Management 5.15 Advanced Process Control Page 104

105 5.13 SIMATIC PCS 7 PowerControl Hierarchy in Power- Supply and Distribution Page 105

106 5.13 SIMATIC PCS 7 PowerControl Products Page 106

107 5.13 SIMATIC PCS 7 PowerControl Operator Station (OS) Integration of medium voltage switch gear plants into SIMATIC PCS 7 Technological Objects for electrical units Feeder, Generator, Motor Transformer etc. Faceplates in APL style Equivalent to Power Rate core functionality Page 107

108 5. Overview: SIMATIC PCS 7 V9.0 Content Technology Components 5.8 Process Historian (PH) and Information Server (IS) 5.9 SIMATIC BATCH 5.10 SIMATIC Route Control 5.11 Safety Integrated 5.12 SIMATIC PCS 7 TeleControl 5.13 SIMATIC PCS 7 Power Control 5.14 Energy Management 5.15 Advanced Process Control Page 108

109 5.14 Energy Management How to optimize Determine, improve and analyze Energy consumption systematically and continuously Consideration of economic, technical and legal aspects in optimization All kinds of energy: electrical and non- electrical See also: DIN 4602, VDI , EN16001 Page 109

110 5.14 Energy Management Operator Station (OS) Page 110

111 5. Overview: SIMATIC PCS 7 V9.0 Content Technology Components 5.8 Process Historian (PH) and Information Server (IS) 5.9 SIMATIC BATCH 5.10 SIMATIC Route Control 5.11 Safety Integrated 5.12 SIMATIC PCS 7 TeleControl 5.13 SIMATIC PCS 7 Power Control 5.14 Energy Management 5.15 Advanced Process Control Page 111

112 5.15 Advanced Process Control Model Predictive Control (MPC): Two Material Destillation From Mixed Liquid to Liquid 1 and Liquid 2 Page 112

113 5.15 Advanced Process Control Model Predictive Control (MPC): Two Material Destillation Manipulated Variable (MV) 1 influences Control Variable (CV) 1 and 2 Manipulated Variable (MV) 2 influences Control Variable (CV) 1 and 2 MPC Goal: MV1 for CV1 Page 113

114 5.15 Advanced Process Control Model Predictive Control (MPC): Two Material Destillation Manipulated Variable (MV) 1 influences Control Variable (CV) 1 and 2 Manipulated Variable (MV) 2 influences Control Variable (CV) 1 and 2 MPC Goal: MV1 for CV1 MV2 for CV2 Page 114

115 5.15 Advanced Process Control SIMATIC PCS 7 Enviroment Page 115

116 5.15 Advanced Process Control Applications MPC max: 10x10 MPC for 2 x 2 application: two-material distillation 3 x 2 application: steel bleaching process 3 x 4 application: cement mill 4 x 4 application: three-material distillation, oven with 4 burners Benefits Less process deviations. Typically 200% Increased yield: 2% - 10% Higher throughput: 1% - 5% Degreased energy consumption: 3% - 10% Page 116

117 5. Overview: SIMATIC PCS 7 V9.0 Content Support & Service 5.14 Migration 5.15 Lifecycle Management Page 117

118 5.14 Migration Overview Page 118

119 5.14 Migration Definition of Migration Activities to transfer a System A to System B System B can be a 100% New System, based on a total different platform, compared to System A System B can also be a Mixture of System Components of System A and System Components of a New System System A System B (Can include components of System A) Page 119

120 5.14 Migration Update and Upgrade (Not Migration) Update and Upgrade of System A through Hardware and/or Software Update of System- SW Done through a Service Pack inside a SW- Version Bug fixing and (Minor enhancements) Upgrade of System- SW Done through a Next Version (from Vn to Vn+1) Bug fixing Additional new functions System A System A+ Page 120

121 Overview: SIMATIC PCS 7 V9.0 Content Support & Service 5.14 Migration 5.15 Lifecycle Management Page 121

122 5.15 Lifecycle Management Life- Cycle Strategies Reactive Strategy with high risk of obsolescence Page 122

123 5.15 Lifecycle Management Life- Cycle Strategies Preventive Strategy with low level risk of obsolescence Page 123

124 5.15 Lifecycle Management Preventive Strategy: Life- Cycle Services (LCS) Services for Operation and Serviceability of plants Life Cycle Services (LCS) are maintaining existing functions of the DCS by minimized costs Standards and recommendations DIN EN 62402: Guidance for Obsolescence-Management NAMUR-Recommendation NE 121 Page 124

125 SIMATIC PCS 7 Overview Content Process Automation Positioning Our Portfolio What did we learn? Overview: SIMATIC PCS 7 V9.0 Market and Competitors What did we learn? Page 125

126 6. Market and Competitors Market Trends (1) Sustainibility Emission, Energy, Water, Wastewater Increasing engineering efficiency over all phases Purchasing in low cost countries System components, engineering, services Communication WLAN, Wireless instruments, remote operation control Process Optimization Process Know- how is expected from system supplier Globalization Market activities Lokalization of services Page 126

127 6. Market and Competitors Market Trends (2) Increased competition Shorter product lifetime, therefore higher production flexibility Integration of all automation levels into one solution Merging of plants on one location One supplier for all automation levels (One Stop Shopping) Local service and support Service is fastest growing of all DCS segments Merger & Acquisitions DCS- Companies Engineering Software. Lifecycle and Service- Contracts Page 127

128 SIMATIC PCS 7 Overview Content Process Automation Positioning Our Portfolio What did we learn? Overview: SIMATIC PCS 7 V9.0 Market and Competitors What did we learn? Page 128

129 7. What did we learn? ü ü ü ü ü ü SIMATIC PCS 7 has a functionality beyond those of a Classical DCS: DCS Full Blown We can offer the powerful integrated Concept SIMATIC PCS 7 and SIEMENS Field Devices This is a real Competitive Advantage in the Market The full basket of integrated functions is given by ü ü ü Basic Functions Technological Functions Customer Support Migration is an important Market for DCS Systems SIEMENS is a mayor player in Global DCS business SIEMENS has the completest spectrum of Automation Systems including DCS, Fielddevices, Analytics,... Page 129