The Process Control System for all industry sectors SIMATIC PCS 7. simatic PCS 7

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1 The Process Control System for all industry sectors SIMATIC PCS 7 simatic PCS 7

2 Be more competitive in your industry sector With Totally Integrated Automation Incessant competitive pressure is forcing companies to keep increasing their productivity and shortening their time to market. Soaring costs also require continual optimization of both engineering and process. A high level of investment security is an important factor in this never-ending cycle. Totally Integrated Automation (TIA) makes an important contribution toward solving this problem. TIA supported by the sector-specific know-how and experience of our specialists combines business objectives with Siemens products and systems for process-oriented, productionoriented and hybrid industries. TIA forms the basis for the implementation of sector-specific automation solutions, tailored to meet customer-specific requirements. Totally Integrated Automation makes Siemens the only provider to offer a complete line of matched products, systems and solutions for all sectors covering everything from incoming goods to outgoing goods from the field level over the production management level to the ERP level. As a result, TIA makes a very important contribution towards optimizing production sequences and reducing complexity, and thus to increasing productivity, both manufacturing and process automation production while also ensuring a high degree of investment security. The result is an increase in the total value of ownership, making your business more competitive. No matter how you look at it, your company will profit from TIA all the way down the line: higher machine cycle times, a noticeable increase in availability, the very highest product quality, and all while reducing your time to market. Totally Integrated Automation is based on the Siemens principle of continuous further development and consistent improvements in services and applications know-how, all of which is directed toward the needs and demands of a wide variety of industrial sectors. 2

3 Shorten your time to market Thanks to TIA, you can do your engineering in an integrated development environment. This unique method of integration pays off by making design, configuration, operation and testing faster, effectively reducing the time between planning a production line and getting the new products to your customers. A higher degree of investment security Totally Integrated Automation offers you the opportunity to tread new production paths while adopting an integrated development environment. You also profit from the continued development of TIA. Existing engineering know-how can continue to be used. Partial modernization efforts or plant expansions can be completed without system breaks, allowing you to secure your investment over the entire life cycle. Today and for the future. Reduce complexity The smaller number of software blocks required in integrated systems reduces the complexity both in engineering and in plant maintenance and operation. One example: integrated engineering STEP 7 for PLC (software and hardware controller) and SIMATIC PCS 7 process control system reduces time and costs while making use of existing and valuable know-how. Reduce life cycle costs Reduce costs in every phase of the life cycle! Two of the many examples: thanks to the integrated engineering system, less time is needed for plant engineering and implementation. And the use of standard components reduces overhead for spare-parts warehousing and service and maintenance. Increase productivity Whether you want to implement a small application or have to plan a sophisticated, complex production line, the TIA solution platform includes all the components you need, from the smallest sensor over the process control system to an MES solution for interfacing the plant level to the corporate management level. TIA is scalable and expandable over the entire production workflow, allowing it to be adapted to suit any requirement. 3

4 Part of Totally Integrated Automation: SIMATIC PCS 7 The process control system for all industry sectors Being able to respond flexibly and quickly to new market demands without having to halt plant operations is a major prerequisite for success in the process industry. The future-oriented SIMATIC PCS 7 process control system, a component of Totally Integrated Automation, can help you do just that. Its benefits are already apparent in the design and engineering phases, but are also a major factor in the installation and commissioning phases as well as during operation and maintenance. SIMATIC PCS 7 thus provides optimum support over the entire life cycle of your plant. And because our efforts toward continuous further development include close attention to system compatibility from generation to generation, even modernization is as easy as pie, and that ensures a high degree of investment security. Including the demands of tomorrow in today's system: that is the quality of our state-of-the-art process control system. SIMATIC PCS 7 a control system for all industry sectors SIMATIC PCS 7 is the integrated, homogeneous automation solution for all industry sectors, whether process, production or hybrid industry and regardless of whether manufacturing or process automation production is involved. The concept on which it is based, as well as its architecture, make it possible to operate a plant costeffectively and efficiently over the entire life cycle, from planning, engineering, commissioning and training over operation to service and maintenance. SIMATIC PCS 7 handles not only process engineering tasks in the primary production process, but also the automation of all secondary, upstream and downstream processes, such as waste water treatment or the distribution of power to a production location. SIMATIC PCS 7 the process control system in Totally Integrated Automation As state-of-the-art process control system, SIMATIC PCS 7 forms an integrated and homogeneous all-in-one system with typical process engineering features. SIMATIC PCS 7 at a glance Based on standard SIMATIC hardware and software components Modern, distributed client-server architecture Scalable from small laboratory system to plant group with 60,000 measuring points For all applications: continuous and batch applications For all sectors: process, production and hybrid industries Powerful HMI system with integrated archive based on SQL server Central, plant-wide engineering system based on IEC Flexible and easy integration of field devices and drives based on PROFIBUS Homogeneous, integrated safety technology, TÜV*-certified up to AK6 resp. SIL3 Hybrid operation of standard and fail-safe applications, high-availability and fail-safe applications possible on the same programmable controller Enhanced availability thanks to redundancy at all levels SIMATIC BATCH modular batch system according to ISA S and FDA 21 CFR Part 11 Interface to MES/ERP level via SIMATIC IT Framework * German Technical Inspectorate 4

5 Horizontal integration Horizontal integration means using the same standard hardware and software components in the primary process and in the upstream and downstream processes. The result is a noticeable reduction in engineering, hardware, spare parts warehousing, logistics and personnel training costs. Vertical integration For the user, integrated communication from the MES level to the field level and integration in the IT landscape via SIMATIC IT Framework means integration of production and business processes short response times to changes in the market high availability thanks to transparent information flow, e.g. for maintenance optimized warehouse logistics and supply chain management over the entire life cycle of the plant Exceeding the requirements of the process automation market SIMATIC PCS 7 a true modern DCS HMI Multiuser-capable HMI components Large quantity frameworks Client-server architecture Redundancy Online modification AS, I/O modules, I/O Hot swapping (insertion and removal of modules during operation) Expansion / modification during operation I/O modules for hazardous zones Redundancy (controller, modules and PROFIBUS) Integrated fail-safe technology Integration of intelligent field devices/drives Communication Fast Ethernet and PROFIBUS DP/PA Fiber-optic switching technology Redundancy (system and field bus) Online expandability Engineering Central, system-wide, high-performance engineering system Bulk engineering with import/export functions Comprehensive, efficient engineering with graphical and PLT-oriented tools Central parameterization of intelligent field devices using the integrated SIMATIC PDM engineering toolset Software simulation and testing Tracking function Distributed, parallel engineering Batch Equipment-neutral recipes Hierarchical recipes according to ISA S 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 Full integration in HMI system and in the engineering system 5

6 Investment security and cost-efficiency Over the entire life cycle of your plant With SIMATIC PCS 7, you can protect your investment and profit from future developments because PCS 7 provides: The scalability you need Its flexibility for plants of any size is one of the major advantages of SIMATIC PCS 7. The integrated system platform can be flexibly used for both small applications as well as extremely large plants configuration or groups of larger plants. SIMATIC PCS 7 is thus particularly suitable for standardization at one specific production location. Integrated control system platform, i.e. reduces expansion costs thanks to reusable applications engineering, personal know-how, even replacement parts Optimum adaptation to the size of the relevant plant, i.e. no need for expensive reserve capacities; as the plant configuration grows, the control system grows with it Open architecture Integration in the existing infrastructure of the company (from IT level to sensor technology) means above all the protection of investments already made! Economical automation means integrated, factory-wide automation. SIMATIC PCS 7 is based on the latest, most innovative standard technologies, such as Windows, OPC, PROFIBUS and Fast Ethernet. This makes it possible to integrate devices and systems from other manufacturers, and makes SIMATIC PCS 7 open to the world of information technology. Uncompromising compliance with international industrial standards Easy, fast integration of other software packages at the plant control level Cross-vendor interchange of process data from different Windows applications possible Web-capable thanks to the use of interface standards Interfaces for the import/export of data using higherorder planning tools Ethernet with TCP/IP communication Integration of intelligent sensors/actuators via HART, PROFIBUSDP/PA Creation of user blocks using user-friendly high-level languages AS-Interface for integrating simple actuators/sensors Stand-alone systems Production facilities Various plants of a production site 6 Scalable from small applications (~160 process objects) to the distributed system in client/server (~ 60,000 process objects)

7 Integration in the IT world with SIMATIC IT For plant owners, today's information technology (IT), process data management and production-planning systems are important levers for cost reduction and process optimization. The merging of process automation systems with MES systems and ERP systems (such as SAP/R3) is therefore gaining in importance. Thanks to its open and integrated system platform, SIMATIC PCS 7 provides the prerequisite for vertical integration of the process automation, plant control and corporate management levels. Integration & synchronization of all business processes with the SIMATIC IT technology platform Integration of control level to MIS/MES level via SIMATIC IT Integration of vendor-neutral IT products Problem-free integration in the existing IT landscape The result: shorter response times and more transparency form the basis for more reliable decisions! Company-wide process data availability 7 and OPC Process data and archive data are made available throughout the entire company without regard to location. All process data can be visualized, analyzed and post-processed on any desktop. Open for own client-server applications Integration of third-party products 7

8 SIMATIC PCS 7 system architecture The SIMATIC PCS 7 process control system provides everything you need for process automation and it does so as an integral component of Totally Integrated Automation. All components are perfectly matched and integrated to build up a homogeneous control system: The flexible and user-friendly engineering system is an universal tool for all configuration tasks and for all components of the process control system. The HMI system is the window to the process. Operating personnel and plant personnel can track the process, modify recipes or batch sequences and change current values. Office LAN SIMATIC PCS 7 BOX OS/ES OS/ES (Single Station) OS Single Station (Multi-VGA) Engineering Station ES SIMATIC PDM Engineering Toolset OS Clients SIMATIC BATCH Clients SIMATIC IT Framework Components OS-LAN Box PC OS-Server (redundant) Batch-S (redund Industrial Ethernet / Fast Ethernet DP AS 417 AS 416 AS 414 OS AS 414F AS 417F DP/AS-Interface DP/EIB PROFIBUS DP DP/PA-Link ET 200M Ex-I/O HART PROFIBUS PA OP PROFIBUS DP ET 20 Fail-S ET 20 DP/PA-Link PROFIBUS DPiS ET 200iS PROFIBU ET 200X ET 200S

9 PROCESS FIELD BUS The SIMATIC PCS 7 automation systems provide all the functions required to solve automation and control tasks at different performance and security levels. Recipe-controlled batch processes can be implemented easily with SIMATIC BATCH, making a flexible solution possible for virtually any task from simple single-line/ single-product processes to complex multi-line/multiproduct processes. SIMATIC PCS 7 utilizes industrial Ethernet and PROFIBUS standards for communication. Ethernet SAP R/3 Internet/ 7 / OPC-Server INTERNET Office LAN Plant Information Ethernet Plant Maintenance PROFIBUS I/O interface and excellent links to field devices SIMATIC PCS 7 is optimized for the integration of distributed field devices in the process control system, and depends on PROFIBUS technology to make this possible. PROFIBUS is simple, rugged and reliable, and is used worldwide in all sectors of the process and production industries and in hybrid industries for input and output logistics as well as for primary and secondary processes. PROFIBUS-PA is used for the implementation of intrinsically safe applications in hazardous areas. DP/PA link modules and coupler make it possible to use a combination of PROFIBUS-PA and PROFIBUS-DP. erver ant) Fast Ethernet In addition to lower procurement costs, lower service costs and problem-free replacement of field devices, PROFIBUS technology offers many other important advantages, such as Reduced configuration costs thanks to easy, centralized field device engineering (PROFIBUS-DP/PA and HART) with SIMATIC PDM, including cross-vendor H H AS 414H AS 417H Lower service costs thank to less wiring, a less complex plant structure and simplified diagnostics 0M afe 0M PROFIBUS DP ET 200M with CP 341 DP/PA-Link Y-Link Modbus, serial interface PROFIBUS PA User-friendly integration of existing field devices in SIMATIC PCS 7 systems for more investment security S PA COx, NOx,... 9

10 SIMATIC BATCH Flexible automation of batch processes In the process industry, discontinuous processes, generally referred to as discrete or batch processes, are assuming increased importance, one reason being ever shorter product life cycles. For this reason, today's new plants are normally multi-purpose plants, i.e. conceived and implemented as batch plants. The automation of such a process is extremely flexible; the production know-how lies in the sequences, or recipes. The economic and technological obligation to utilize these plants flexibly therefore requires their control systems to be extremely flexible as well. The SIMATIC PCS 7 process control system provides a great solution for all the demands of batch automation: SIMATIC BATCH. The SIMATIC BATCH batch package is based on SIMATIC PCS 7 and has a modular structure. Thanks to its flexible scalability, it can be used equally well in plants of any size, which is why it is available as single-user system or in modern client-server architecture; the batch server can also be configured for high availability. Process-oriented recipe generation Simple, fast, with minimum errors the hierarchical recipe structure according to ISA S is displayed on the plant model: Subrecipe procedure for controlling process/production in a subplant Recipe operation/recipe function for fulfilling the industrial task/function using technical equipment Subplant-neutral recipes An integrated class concept supports user-friendly generation of neutral recipes for subplants. Only one recipe (!) is required for similar subplants, which minimizes engineering and brings a number of advantages to bear when it comes to validation. Users are offered various strategies for subplant allocation, allowing them to choose the perfect solution for their plant. This ensures flexible, optimum utilization of the plant capacity. 10

11 User library (ROP) for recipe operations This library provides user-friendly support for the management of recipe operations. Library recipe operations can be included as reference in recipe procedures, making it possible for them to be modified centrally. This reduces engineering overhead and, above all, validation overhead (which is important in the case of plants which require validation). Resolving the reference allows the recipe operation to become a fixed component of the recipe procedure, also making it independent of subsequent centralized modification. Integration of SIMATIC BATCH For the user, the total integration of SIMATIC BATCH in the plant's visualization system means user-friendly handling, safe operator guidance and a fast response to process disturbances. A comprehensive batch report (XLM-based archive) ensures production transparency. The total integration of SIMATIC BATCH in the SIMATIC PCS 7 engineering system makes the engineering data reusable and, above all, centrally modifiable. Once entered, engineering data are always available and need not be re-entered. This saves valuable time and minimizes errors. The link to the host IT level (MIS/MES) is supported by a standard interface in SIMATIC IT Framework; the open API interface also opens the way to customer-specific expansions. 21 CFR Part 11 compliance Validation In the interest of upholding quality standards as well as due to obtaining marketing and legal requirements, the need for plant validation is increasing. Reproducible production, especially in multi-product or multi-stream environments, is of particular importance. SIMATIC BATCH supports you with a number of functionalities according to 21 CFR Part 11. Audit Trail (offline and online) provides the user with logs for changes in recipes, changes in recipe operations, changes made during production and operator entries at the unit control level, making it possible to reproduce production processes whenever necessary. Access protection is provided by a Windows 2000-based central user manager. An electronic signature enables paperless production. Production documentation is also paperless thanks to the archiving of production data in a system-neutral format (XML). Optimum adaptation to plant requirements A client-server architecture allows optimum adaptation to plant requirements. A redundant batch server ensures high availability; no batch data are lost, and automatic matching of batch data is easily accomplished. 11

12 Migration Switching made easy Installation of the basis for process control systems means a big investment in hardware and applications software as well as valuable and complex know-how on the part of operators and maintenance personnel. The objective of a transitional strategy for subsequent generations, also known as migration, must therefore be the modernization of the existing basis step by step and without any system breaks. At the same time, investments must be protected over the long term. Based on 20 years of experience in process automation, Siemens offers optimized migration solutions for transitioning to SIMATIC PCS 7, allowing users of previous Siemens control systems and non-siemens control systems alike to take advantage of everything Totally Integrated Automation has to offer for their processes. This includes a reduction in time to market, a high degree of investment security and higher productivity. Migration products and services In addition to hardware and software components, the extensive line of migration products also includes services for the conversion of applications software, onsite conversion, or the migration of an entire plant. They present and discuss migration options, analyze the plant in question, do consulting and prepare a detailed quotation. One important customer demand is minimizing the duration of downtimes. This requires precise planning. Our specialists therefore organize and coordinate the problem-free execution of all activities together with the customer. As "know-how provider", the applications software represents a large portion of the overall investment volume, making the quality of the conversion to the new system world an important criterion for a migration's economical success. The state-of-the-art migration tools developed by Siemens guarantee invariable software quality, reliability and reproducibility. It is now also possible to develop migration concepts for non-siemens process control systems, allowing users of those products to profit from the migration solutions for transitioning to SIMATIC PCS 7 and thus from the many advantages of Totally Integrated Automation for their processes. The success of a migration is determined largely by A technical solution which is optimally matched to customer requirements and to the individual circumstances of the plant in question A high-quality, fast, on-schedule conversion of that solution Siemens has been proving its competence for many years, completing numerous migration projects successfully. Our specialists have many years of experience in engineering, commissioning and service, both at home and abroad. 12

13 Optimizing migration over the entire life cycle of your plant: Design and Engineering Installation and Commissioning Operation Maintenance Modernization and Upgrade Online support The comprehensive, Internet-based information system. Available around the clock, it provides information on everything from product support over service and support to shop support tools. Technical support Competent help with technical questions and a wide variety of services for our products and systems. Technical consulting Help with planning and devising a concept for your project; for everything from actual analysis and target definition over consulting services for products and systems to development of the automation solution. Configuration and software engineering Help with the configuration and development of appropriate services for everything from configuring to conversion of an automation project. On-site service On-site commissioning and maintenance services an important prerequisite for ensuring availability. Repairs and replacement parts We provide comprehensive repair and replacement part services to ensure the highest degree of operational safety and reliability during the operating phase of a machine or automation system. Optimization and modernization To increase productivity or reduce project costs, we offer top-quality services for every facet of optimization and modernization. 13

14 Process safety safety as you need In the process industry, safety enjoys the very highest priority. Siemens is one of the few providers of automation systems to offer totally integrated safety and control in one process automation system. An integrated system continuously executes self-tests and performs self-diagnostics, while operating in order to ensure the necessary safety. After all, a process without interruptions always has the highest priority. Siemens has been developing and implementing programmable electronic systems for process safety for more than 20 years. These include emergency shutdown systems, furnace management systems and fire and gas detection systems, to name only a few. The demands for specific degrees of safety, redundancy, input-output counters, communication, and so on are different for every project. It is for this reason that Siemens offers a variety of certified products, which can be configured to meet the requirements of your particular application. Process safety products from Siemens are userfriendly, just as they should be. You don't have to waste even one thought on integration problems. Our products provide simple, low-cost, innovative options for ensuring high safety and availability of your plant. Our products provide state-of-the-art, integrated self-test technology. There is no need for complicated manual test or evaluation software in order to satisfy certification requirements. In addition, our safety systems are a component of Siemens Totally Integrated Automation. That means that we can offer you exceptionally problem-free integration of industrial safety and control. For example: Safety Integrated the safety component in Totally Integrated Automation Steeling humans, machines and plants against potential dangers requires a complete concept and a line of products for every situation, regardless of whether safety requirements are simple or highly complex. "Safety Integrated" from Siemens provides a uniform safety chain for standard automation systems and one which is integrated throughout all levels, in discrete production as well as in process and hybrid industries. For example: automation systems from SIMATIC PCS 7 to SIMATIC S7-400FH Among programmable safety systems, SIMATIC S7-400FH guarantees the highest possible degree of safety and availability. Using it in conjunction with the SIMATIC PCS 7 process control system, enables the implementation of powerful and flexible solutions for integrated control and safety applications. Engineering STATION ES OS-LAN PROFIBUS PA OS-Server (redundant) Industrial Ethernet / Fast Ethernet PROFIBUS DP AS 414FH AS 417FH DP/PA-Link ET 200M Fail-Safe ET 200M OS Client Process safety from Siemens: A high degree of efficiency thanks to a reduction in hardware and installation overhead Safety technology and standard automation integrated into a single, all-in-one system Fail-safe communication using standard field buses A minimum of engineering overhead thanks to the use of standard software, even for fail-safe technology Effective, fast diagnostic functions for the highest machine and plant availability Products, systems, solutions and services all from a single source

15 Services Those who opt for the SIMATIC PCS 7 process control system can depend on fast, reliable, firstclass service worldwide. Regardless of which service you might need, the right contact is available quickly and without a lot of red tape anywhere in the world. The right training customized to your exact needs The right training helps when it comes to using the process control system most efficiently and quickly. Whether you are "switching over" from the PLC world, just want to enter the world of process automation or are already experienced in this field, we can provide you with target group-oriented, professional training. In our training centers in over 60 countries worldwide, you can familiarize yourself thoroughly with the SIMATIC PCS 7 system or expand your current know-how. And regardless of whether you visit a standard course or a special user-specific course, SIMATIC training courses bring quick qualification and extensive know-how straight from the manufacturer modularly structured and very practical. Or if you wish so, you can choose to have system specialists provide you with hands-on training right in your own plant. Our services include: Consulting services Consulting in all facets of automation Support services Hotline Configuration and commissioning support Questions regarding documentation Provision of service tools Service on demand Service whenever needed 24-hour service Holding of personnel / Dispatching of personnel Replacement part service Replacement parts for all products Worldwide replacement parts delivery, including express delivery Repair service Modernization service Competent consulting services for conversions and expansions Plant modernization Maintenance service Service and maintenance 15

16 PUBLICIS For the latest information on SIMATIC PCS 7: Web support: Interactive catalog on the Internet: Subject to change without prior notice 03/04 Order No. E20001-A170-P280-X-7600 Dispo C8471 MK.AS.PS.XXXX WS Printed in Germany Siemens 2004 Siemens Aktiengesellschaft Automation and Drives Industrial Automation Systems P. O. Box Nuremberg Germany SIMATIC, WinAC and STEP are trademarks of Siemens. Other designations used in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owners. The information in this brochure contains 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. Availability and technical specifications are subject to change without notice.