Automation and Drives OSEA Totally Integrated Automation SIMATIC. Process Automation. Exceeding requirements of a DCS

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Roy Fisher
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1 and Drives OSEA SIMATIC Process Exceeding requirements of a DCS

2 Siemens your DCS supplier Process Reliability of a major enterprise More than 150 successful years of SIEMENS One of worldwide leading

platform (one stop shopping) In-house development and production of all components (field devices, I/O, Controller, Operator & Station,

..) SIMATIC PCS 7 Minimum solution cost with no compromise The DCS in on Quality Homogenous system, full integration of Remote-I/O,

2 2 Siemens your DCS supplier Process Reliability of a major enterprise More than 150 successful years of SIEMENS One of worldwide leading companies in electro-technology and electronics Complete solution from a single source Optimal solution for all industries based on a single platform (one stop shopping) In-house development and production of all components (field devices, I/O, Controller, Operator & Station, Batch, MES,...) SIMATIC PCS 7 Minimum solution cost with no compromise The DCS in on Quality Homogenous system, full integration of Remote-I/O, transducer, drives, motor starter & protection, positioner, weighing systems,... Seamless integration of production level and enterprise resource planning level Integration of primary & secondary processes and inbound and outbound logistics as well Siemens your reliable DCS supplier

3 Process SIMATIC PCS 7 The process control system in

Vertical integration Enterprise resource planning (ERP)

PCS 7 Industrial networks Actuators (motors, drives) and

3 3 Process SIMATIC PCS 7 The process control system in SIMATIC PCS 7 - the DCS in Horizontal integration Vertical integration Enterprise resource planning (ERP) MES system (SIMATIC IT Framework) SIMATIC S7 / SIMATIC PCS 7 Industrial networks Actuators (motors, drives) and sensors Auxiliary processes: EV, HVAC, building services automation,... Corporate management level Production management level Plant control level Process control level Field level

4 4 Process SIMATIC PCS 7 is based on components from SIMATIC PCS 7 comprises: SIMATIC HMI SIMATIC PCS 7 SIMATIC software SIMATIC industrial PCs SIMATIC controllers SIMATIC NET Components SIMATIC DP

Low-voltage switchgear MIS / MES components

were extensively system tested Siemens as

5 SIEMENS One stop shopping - all from a single source Process Totally Integrated One stop shopping - all from a single source All PCS 7 system components (I/O, controller, network, HMI, engineering, batch) Standard PLCs and text displays Field devices, analyzers, compact controllers Drives, drive controls Low-voltage switchgear MIS / MES components Services and much more... One contact partner Products are perfectly compatible with each other and were extensively system tested Siemens as world market leader in automation has experience and expertise Worldwide service and support for all components 5

6 6 Process SIMATIC PCS 7 - system architecture From the perspective of technology direction, SIMATIC PCS 7 conforms closely to ARC s CPAS model, and has rapidly advanced its technology SIMATIC PCS 7 Setting a new standard of integration! position in the marketplace. SIMATIC PCS 7 BOX OS Single Station (multi VGA) Station SIMATIC PDM Toolset January 2005 OS OS LAN OS server (red.) Industrial Ethernet / Fast Ethernet Office LAN SIMATIC BATCH Clients WEB client SAP R/3 Ethernet SIMATIC IT Framework Components Internet/ intranet Fast Ethernet Batch / archive 7 / OPC Server Office LAN Plant Information Ethernet Plant Maintenance PROFIBUS DP DP/AS-I Instabus EIB ET 200X DP/EIB ET 200S AS 417 AS 416 AS 414 PROFIBUS DP DP/PA Link PROFIBUS DP Zone 2 ET 200M Ex I/O HART OP Profibus PA Zone 1 OS ET 200iSP PROFIBUS DP AS 414 F/FH AS 417 F/FH ET 200M Fail-safe ET 200M DP/PA link PROFIBUS PA PROFIBUS DP AS 414 H AS 417 H ET 200M DP/PA link PROFIBUS PA Y link COx, NOx,...

7 7 Redundancy at all levels Process Redundant OS Special Features Redundant Servers Redundant communication Redundant controller Redundant I/O Redundant Link FieldBus Redundant PROFIBUS Redundant IM Without additional

8 Process Predefined I&C function blocks with standard OS faceplates and symbols (e.g. Motor, Valve, Control PID) SIMATIC PCS 7 System (ES) centrally integrated OS User OSfaceplates Asset Management BATCH flexible recipe editor Special Features PCS 7 SIMATIC Manager uniform database for process safety systems for network/ communication/hardware of automation function of user function blocks SIMATIC PDM for field device parametrization 8

9 Process Special Features SIMATIC PCS 7 - central, system-wide engineering system

system Common database and optimally matched graphic tools Multi-project engineering for

of plant data from higher-order CAE tools Working with processrelated objects such as

9 9 Process Special Features SIMATIC PCS 7 - central, system-wide engineering system Central, system-wide integrated hardware and software configuration with one engineering system Common database and optimally matched graphic tools Multi-project engineering for separating large plants into multiple subprojects (with branch & merge support) Transfer of plant data from higher-order CAE tools Working with processrelated objects such as motors, valves, PID controllers Central dialog for translating and loading all AS, OS and batch modifications

data over time and location OPC standard interfaces DA, HDA, AE,

10 Process Simatic PCS 7 V 7.0 OpenPCS 7 Special Features Central station hides distribution of data over time and location OPC standard interfaces DA, HDA, AE, HAE Access to process values and alarms and events Sources / Sources are OS and destinations are CAS OS and CAS 10

11 11 SIMATIC PCS 7 V7.0 Integrated Plant Asset Management Process Monitoring Diagnostics Maintenance Request Maintenance, Task Special Features Plant Asset Management Online, real time functions of the integrated Plant Asset Management Systems of PCS 7: 1.) Monitoring of the components 2.) Message generated on status change 3.) Display of diagnostic information 4.) Creation of maintenance request 5.) Tracking of the maintenance activities Implementation per International Standards (NAMUR recommendations NA 64 and NE 91)

12 12 SIMATIC PCS 7 V7.0 Integrated Plant Asset Management Process Separation of Process and Maintenance Information Monitor & control & notify OS Notify & diagnostic & request MS Special Features Prozessereignis Diagnostic event hierarchical / cyclic

13 13 SIMATIC PCS 7 V7.0 Integrated Plant Asset Management Process Special Features Free choice of field devices (all suppliers) The integration into the Asset Management System depends on intelligence of the device The manufacturer of the device determines the amount of information for his device MS Only the manufacturer knows the asset management capabilities of his device Compliance with international standards and specs determines the integration effort conventional, e.g. 4 20mA Profile, e. g. RIO Profile, e.g. PB PA, FF HART PB - Slave PB PROFIBUS FF - Foundation EDD Electronic Device Description MS Maintenance Station RIO Remote I/O PA Process

14 14 Process SIMATIC PCS 7 V7.0 Integrated Plant Asset Management Asset Management functionality can be integrated into the OS or stand-alone The Maintenance Station Special Features OS MS... AS 1 AS 2 AS n Maintenance Station integrated in Operator station OS... C 1 OS C n MS OS Clients with access to maintenance area (pictures, messages, faceplates) S 1... S n MS... AS 1 AS 2 AS n Maintenance Station has additional functionality - direct online access to PDM and hardware configuration tool AS System C Client MS Maintenance Station OS Operater Station

15 Integrated Plant Asset Management Overview OS Client 1 Process OS Client 2 OS / Batch Client 3 + OS / Batch Client n... Special Features OS Server F... OS / Batch Server AS 1 AS 2 AS 3... AS n A 15

16 16 Process Integrated Plant Asset Management Hierarchical Structure S7-400 and Profibus Network status and selection of underlying hierarchy ET200M Station diagnosis symbol of the component Profibus Assets V6.1 Faceplates for intelligent device

17 17 Interface to supervisory systems Process EAM Enterprise-Asset-Management ES Station MS Maintenance Station OS Operator Station EAM / SIMATIC IT Special Features Asset Hierarchy Maintenance Info EAM Info Process ES MS OS

18 18 Levels of Integrated Control & Safety Process ENG HMI ENG INTERFACED DCS Gateway SIS ENG HMI INTEGRATED DCS SIS Fail-Safe ENG HMI COMMON DCS SIS

19 Levels of Integrated Control & Safety

HMI SIMATIC S7-400FH SIS Fail-Safe COMMON

19 19 Levels of Integrated Control & Safety Process ENG HMI SIMATIC S7-400FH ENG INTERFACED DCS Gateway Gateway SIS INTEGRATED DCS SIMATIC PCS 7 ENG ES & OS HMI SIMATIC S7-400FH SIS Fail-Safe COMMON SIMATIC PCS ENG 7 ES & OS SIMATIC HMI S7-400FH DCS SIS Std. I/O

Process Fail-safe automation embedded in the DCS SIEMENS: Over 20 Years experience in failsafe-technology Fail-Safe Integrated Control & Safety System (ICSS) Solution Use of SIMATIC S7 standard

20 Process Fail-safe automation embedded in the DCS SIEMENS: Over 20 Years experience in failsafe-technology Fail-Safe Integrated Control & Safety System (ICSS) Solution Use of SIMATIC S7 standard components for fail-safe application Flexibility for different availability and safety levels per safety function Standard and fail-safe functions can be mixed in the same controller and on the same PROFIBUS-DP Configuration of standard and fail-safe functions with the same engineering tool PROFIBUS DP S7-400FH ET 200M ET 200M ET 200M PROFIBUS DP S7-400F ET 200M F-I/O ET 200S F-I/O ET 200M F-I/O S-I/O redundant F-I/O AK1 - AK6 (DIN) SIL1 - SIL3 (IEC) F tool provides support for approval by (TÜV*) (compare function, checksum, access protection, F signature to OS) *German Technical Inspectorate 20

21 Plantwide Integration Operator Station Clients 7 / OPC Server Station ES OS Single Station OS-LAN Fast Ethernet OS server (redundant) Service Batch server (redundant) Industrial Ethernet / Fast Ethernet S7-PLC s SIMATIC PCS 7 SIMATIC PCS 7 SIMATIC ES & OS Distributed Safety SIMATIC S7-400FH PROFIBUS-DP DP/AS-I MODBUS ET 200X ET 200S ET 200M DP/PA Link PROFIBUS-PA Y Link Analyzer DP/AS-I PROFIBUS-DP Fail-Safe PROFIBUS-DP DP/PA Link Drives/Motors 21

22 Process SIMATIC PCS 7 Integrated Safety Applications B+B Operator Station Radio or WLAN Power Management Emergency Shutdown / Process Control System Fire & Gas Wellhead 22

23 23 Flexible Modular Redundancy TM Process DI Fail-Safe

24 24 Flexible Modular Redundancy TM Process DI Make any component redundant Fail-Safe

25 25 Flexible Modular Redundancy TM Process DI Make any component redundant Physically separate redundant resources DI Fail-Safe

26 26 Flexible Modular Redundancy TM Process DI DI Make any component redundant Physically separate redundant resources Mix and match redundancy Fail-Safe

27 27 Flexible Modular Redundancy TM Process Dual DI DI Make any component redundant Physically separate redundant resources Mix and match redundancy Fail-Safe Simplex Triple

28 Flexible Modular Redundancy TM Process Fail-Safe DI DI Simplex Dual Make any component redundant Physically separate redundant resources Mix and match redundancy Tolerate multiple faults with no impact on safety Triple Aircraft 28

29 29 Flexible Modular Redundancy TM Process Fail-Safe DI DI Ultimate flexibility to choose the redundancy levels to fit the Safety Instrumented Function (SIF) Mix and Match to meet the goals of the application Dual CPU/IO safety is not dependant on redundancy All components are SIL3-capable Simplex Redundancy only for availability Triple IO and Field Device redundancy can be matched to: Target Safety Performance Maximize availability Minimize cost

30 30 SIMATIC PCS 7 TOP 10 Points Process 1 SIMATIC Platform 2 One Stop Shop 3 TIA Concept 4 Scalabilty 10 Continuous Development PCS7 continuous research & development, based on clear roadmap/strategy World Market Leader high quality standard, worldwide logistics and support all components developed and manufactured by Siemens covering all automation tasks from raw material to packing, from field to ERP level from 100 to I/O s from PCS 7 Box to large client-server plants with 100 s of controllers 8 9 High-performance engineering Single point of entry (Process Object View) Integration of customer specific libraries Integrated Asset management Automatic generation of diagnostic screens Easy fault analysis and repair tracking 7 Redundancy at all levels Operation System IE Communication System I/O Systembus I/O modules 5 Integrated Technology Same hardware S7-400 Flexible Modular Redundancy (FMR) Safety Matrix 6 True decentralized architecture with Systembus Profibus World No.1 fieldbus Integration of Remote I/O s, motors, drives, analyzers, intelligent field devices etc. HART, FF, PA

31 SIMATIC PCS 7 has all features of a modern Distributed Control System Process Plant engineering with central overview of all relevant project data (Process object view) Integrated Asset Management

31 31 SIMATIC PCS 7 has all features of a modern Distributed Control System Process Plant engineering with central overview of all relevant project data (Process object view) Integrated Asset Management Bulk engineering with import/export functions Configuration of intelligent field devices Software simulation and testing Modification tracking Distributed, concurrent engineering HMI components Windows-based intuitive GUI High capacity Client server architecture Central archive server Redundancy Online reconfiguration Communication AS, I/O modules, I/O Fast Ethernet Online reconfiguration and expansion Fiber optic switching technology Redundancy (controller, modules and Profibus) Redundancy (system and field bus) Integrated Safety Online expansion Integration of intelligent field devices / drives Large range of I/O modules

32 and Drives SIMATIC PCS 7 T I A SIMATIC Thank you Process Exceeding requirements of a DCS

SIMATIC PCS 7 Process Control System New Perspectives for Increased Productivity 2005 Highlights. simatic PCS7

SIMATIC PCS 7 Process Control System New Perspectives for Increased Productivity 2005 Highlights simatic PCS7 PROCESS FIELD BUS Performance, Flexibility, Scalability, Security. Ready for new challenges.