Siemens - Distributed Control System
Content
Study Title • Executive Overview
Siemens
http://pcs.khe.siemens.com/index_simatic_pcs_7-1075.htm
DCS Offerings
SIMATIC PCS 7, APACS, Teleperm
DCS Business
Siemens AG, headquartered in Munich, Germany, is a major global
automation supplier with activities focused on the areas of
industrial and infrastructure, energy, and healthcare.
In fiscal
year 2009 (ended September 30), the company had over 400,000
employees
in
190
countries
and
revenue
from
continuing
operations of €76.6 billion, roughly the same as the previous year.
In 2008, Siemens regrouped its business into three operating
sectors:
Industry, Energy, and Healthcare.
The Industry sector
and its products and solutions address industry customers and is
made
up
of
six
divisions:
Industry
Automation,
Drive
Technologies, Building Technologies, OSRAM, Industry Solutions,
and Mobility.
The range of offerings at the Industry Automation and Drive
Technologies divisions extends from standard products to system
solutions for energy and automation technologies used in the
manufacturing and processing industries.
These divisions are
responsible for the design and production of a wide range of
industrial
automation
products,
including
PLC,
CNC,
DCS,
industrial PC, electric drives, as well as an array of supporting
software and peripheral products, including low voltage products,
communications products, and programming and operational
software.
Drive Technologies offers products and solutions for
industry ranging from motors and electric drives to mechanical
components including gearboxes.
The Building Technologies division bundles Siemens’ offerings for
building security, automation, and operation – both as a service
provider and a manufacturer of products and systems. Osram’s
product portfolio includes lamps and optoelectronic semiconductor
light sources such as light-emitting diodes, related electronic
control systems, and light management systems.
The Industry
Solutions division is a systems and solutions integrator for the
Copyright " © ARC Advisory Group • ARCweb.com • For Internal Use Only • 1-1
Study Title • Executive Overview
industrial plant market, covering everything from planning to
construction and operation. The Mobility division networks a wide
array of transportation systems to move people and goods
efficiently.
The Energy sector primarily addresses energy providers, but also
industrial customers, particularly in the oil & gas industry.
The
Fossil Power Generation division offers highly efficient products
and solutions for power generation based on fossil fuels. Offerings
range from individual gas and steam turbines and generators to
power plant construction on a turnkey basis.
The Renewable
Energy division bundles Siemens’ activities in the wind energy
market. The Oil & Gas division offers products and solutions for
the extraction, transport and conversion of oil and gas. The Power
Transmission division is a leading supplier of products and
solutions in the high-voltage field.
The specialties of the Power
Distribution division range from solutions for the automation of
power grids to products like medium-voltage switchgear and
components.
Siemens' "Totally Integrated Automation”
Siemens' all-encompassing automation concept is known as
Totally Integrated Automation (TIA). This concept leverages one
class of automation products across all applications. While some
standard components are used to achieve the Totally Integrated
Automation vision, the emphasis remains largely on integration of
Siemens’ products.
TIA is characterized by a three-fold uniformity in software
(configuration
and
programming),
data
management,
and
communication. This is accomplished using common engineering
tools and common hardware, software, and networking interfaces.
In
the
marketplace,
this
strategy
translates
into
common
components applied to a variety of applications formerly served
by application-specific products.
Siemens' industrial automation solutions use the networking
technologies
Ethernet.
from
Profibus
International
(PI)
and
Industrial
Industrial Ether-net is used as the system bus
connecting controllers, HMI servers, and batch servers, and for
inter-controller communication.
At the I/O level, PROFIBUS DP
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Study Title • Executive Overview
serves as the high-speed network, while PROFIBUS PA segments
extend the fieldbus to networked field instruments.
Finally,
PROFInet is Profibus' emerging industrial Ethernet standard that
will
augment
the
Profibus
architecture
as
Ethernet
gains
acceptance at the device level. Profibus also offers applicationspecific profiles to address a wide variety of specific networking
requirements. For HART users, PCS 7 offers integration of HARTcompatible field devices.
SIMATIC PCS 7
SIMATIC PCS 7 is Siemens’ PAS offering that serves as the fulcrum
for all of Siemens’ process industry strategy.
currently
has
worldwide.
over
seven
thousand
SIMATIC PCS 7
reported
installations
Fulfilling the TIA vision of common hardware
infrastructure across application domains, SIMATIC PCS 7 includes
hardware based on the common SIMATIC platform. SIMATIC PCS 7
utilizes common ET200 Series I/O, common PROFIBUS and
Ethernet communications, common configuration, engineering,
operator interface, and a single unified automation database.
The SIMATIC PCS 7 Engineering Station (ES) provides tight
integration and automated data transition between engineering,
configuration, operations, and HMI.
The IEC 61131-compliant
programming tools offer easy engineering of the configuration
logic using a single database, pre-configured library blocks or
custom blocks, statement list, ladder diagram and function blocks.
The ES is based on Siemens’ Step 7 programming software, thus
contains all its strengths in addition to Structured Control
Language (SCL), Process Object view, Continuous Function Chart
(CFC), Sequential Function Chart (SFC), Safety Matrix, and ISA-88
compliant plant hierarchy views.
The Component View in the ES allows for configuration of control
hardware and is typically the view for maintenance personnel or
technicians.
Configuration can be done in standard function
blocks or in SFC.
Users can also create customized function
blocks. The Plant View within ES is the logical view that provides
hierarchical structuring of the plant by process area, unit, or
component.
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Study Title • Executive Overview
The Process Object view in ES is the primary engineering view of
ES and offers a single point of entry. It provides a modular and
object-based graphical view of the engineering process and
provides a device-oriented perspective for configuration. Process
Objects represent devices such as pumps, motors, and field
devices by providing access to context-specific information such
as I/O assignment, control hardware, HMI representation, archives,
function block parameters, alarm priorities, and alarm messages.
ES reduces design costs and startup times by automatically
reusing data from the control strategy configuration during the
creation of the HMI environment. The ability for the operator to
view and interact with SFCs is generated automatically for both
continuous and batch applications. Graphical representations of
faceplates can also be
strategies.
from
the
derived automatically
from
control
Users can automatically generate process graphics
controller
configuration.
Displays
are
automatically with symbols, which are pre-linked.
management
tools
within
ES
include
a
populated
Configuration
central
change
management tool for SFC modifications and an audit trail for
configuration changes.
Security in ES can be linked to the
Windows security scheme to control logon access.
ES also offers concurrent engineering, enabling a whole team of
engineers to work on the same control strategies from multiple,
geographically distributed locations simultaneously.
This allows
for global distribution of engineering tasks and engineering of
multiple projects simultaneously. More important, however, is the
collaborative sharing of engineering best practices in a dynamic
way across multiple plants.
The system automatically guarantees data consistency.
Linking
CAD/CAE tools to Simatic PCS 7 improves data transfer from the
P&ID (Piping and Instrumentation Diagram). The output data of
the CAx tools can be transferred direct to the engineering system
of Simatic PCS 7, which simplifies data exchange, reduces
potential error sources, avoids duplicated entry of data, and cuts
the configuration time.
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Study Title • Executive Overview
OS Provides Common HMI
The common HMI environment for SIMATIC PCS 7 is the Operator
Station (OS), which is based on the standard Siemens SIMATIC
WinCC HMI, with additional features to make it suitable for process
applications and distinguish it from the standalone WinCC HMI
offering.
OS offers customized, contextual operator views and
features a SQL Server-based historian.
The Data Storage compression within OS allows for online
modifications and upgrades, which is consistent with ARC’s CPAS
vision. OS is also designed to reduce operator response times to
abnormal situations.
Alarm status is shown at all times, and
alarms and messages are automatically segregated by process
area.
OS also offers alarm filtering and prioritization through
alarm classes and priorities.
Common Hardware and Control Platform
The common control hardware platform for SIMATIC PCS 7 is the
400 Series of controllers, including the 412, 414, 416, and 417
Automation Stations (AS). These Automation Stations are based
on standard SIMATIC Controllers.
Used as DCSs, the controllers
offer variable scan rates down to 10 milliseconds.
Larger
controllers can execute over 1,000 PID loops in 0.5 seconds and
support online expansion of programming memory. There are two
controller versions for Simatic PCS 7 Box; a rugged PCI slot
version, and a soft controller that runs on the integral PC
processor.
The slot version is equipped with its own operating
system and power supply and offers higher availability.
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Study Title • Executive Overview
ET200M is the primary I/O offering and can be placed in hazardous
areas, including Class 1 Division 2.
Failsafe versions are TÜV-
approved and can be used for SIL 3 applications with the
integrated safety system controllers.
The ET 200S Series I/O is
designed for motor control, starter control, and pneumatic valve
control applications.
The I/O is designed to support distributed
architectures natively, allowing the user full flexibility in choosing
the location for the I/O (Remote I/O).
The HART I/O module
provides redundancy capability for the ET 200M distributed I/O
station.
This has a high channel density for analog inputs and
outputs, supports the connection of HART field devices and is
integrated into the asset management system of Simatic PCS 7.
The IM 153-2 HF interface module for the ET 200M distributed I/O
station offers high-accuracy time stamping for recording the SOE
(sequence of events) and supports the operation of up to 12 I/O
modules in one I/O device.
Common Information Infrastructure
The common communications infrastructure for SIMATIC PCS 7 is
based on the standard PROFIBUS protocol and Siemens’ Industrial
Ethernet backbone. PROFIBUS DP connects remote I/O (including
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Study Title • Executive Overview
HART), drives, and provides an interface to other device networks,
such as AS-i, Modbus and FF.
PROFIBUS PA operates at the
process field device level and provides connectivity for fieldbuscompatible process field instrumentation and intelligent control
valve positioners.
PROFIsafe is also integrated into the system
architecture through Siemens’ safety system offering.
The
Industrial Ethernet control network provides for the specific needs
of a real-time controller on a standard Ethernet backbone.
SIMATIC PCS 7 Supports Multiple Application Domains
A typical process plant requires up to three different types of
control applications, from regulatory control, to sequential control,
discrete control, and safety applications. CPAS incorporates these
functions as well as asset management, advanced control, and
production management.
SIMATIC PCS 7 addresses the needs of process, hybrid, and
discrete applications within a single framework.
The common
hardware platform and common network infrastructure, as well as
the unified 61131 and SFC-based configuration environment, allow
for seamless incorporation of discrete control capabilities, batch,
and safety system applications along with process.
applications
are
supported
with
Siemens’
SIMATIC
Batch
BATCH
application, which serves the purpose of a high-performance basic
batch engine and is fully integrated into PCS 7.
An Advanced
Batch Reporting package enables drafting of customized reports
using MS SQL or Crystal Reports. Reports can be converted to .pdf
file format for forwarding or storage.
Process Safety can be fully integrated in standard PCS 7
Automation Stations. The integration of the safety engineering in
the standard automation means less demand for space, less
hardware and wiring and less work for assembly, installation, and
engineering.
Additional applications, such as those needed for
separate safety controllers due to the substantial integration work
in the DCS, are avoided with the homogeneous integration of PCS
7. Together with SIMATIC PCS 7, powerful, flexible solutions can
be realized for integrated automation and safety applications in an
integrated automation network.
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Study Title • Executive Overview
With the safety matrix, fail-safe functions can be created without
programming skills based on the rules of a cause and effect
matrix.
Flexible Modular Redundancy™ provides scalable, cost
effective solutions that allow users to implement multiple levels of
fault-tolerance exactly where it is needed for their application.
The new Simatic S7-412FH controller can be used both as a faulttolerant standard controller and as an SIS (Safety Instrumented
System).
It is suitable for smaller applications with up to 50 F
(failsafe) I/O.
Advanced control options in SIMATIC PCS 7 include Model-based
multivariable
control
systems,
Operating
point-dependent
regulating parameter control, and Control quality monitoring.
PCS 7 simulation and operator training are accomplished through
the SIMIT process training simulation package.
configuration
tool
automatically
creates
environment directly from the control strategy.
The system’s
the
simulation
For production
management applications, SIMATIC PCS 7 interfaces directly to the
SIMATIC IT Production Suite.
For plant asset management applications, Siemens offers PDM
(Process Device Manager). Using PDM from a central engineering
station, users can parameterize and troubleshoot intelligent field
devices remotely.
PDM serves as the communications basis for
the asset management system and is available either integrated
with SIMATIC PCS 7 or in standalone configurations. PDM reduces
factory acceptance testing (FAT), commissioning, and startup
times. FAT is also facilitated and optimized by using SIMBA which
can simulate the complete behavior of I/O devices (PROFIBUS DP
and PA) on the fieldbus and makes it possible to test automation
functions, like measurement and control loops, and safetyrelevant functions, like emergency shutdowns, before doing it on a
live plant.
Latest Version Release of Simatic PCS 7
Siemens Industry Automation Division introduced version 7.1 of its
Simatic PCS 7 process control system in March of 2009 with
numerous new functions. The primary focus of the latest release
is to help shorten engineering, installation, and commissioning
times,
while
reducing
operating
and
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maintenance
costs.
Study Title • Executive Overview
Automation of key engineering tasks with version 7.1 streamlines
engineering workflow.
Use of centralized visualization schemas
for color palettes, styles, or optical effects enables automatic
propagation of graphical changes to all process pictures.
The
design is configurable in "classical" or "modern" look. Drag and
drop connection of process values between controllers provides
seamless communication setup. Versioning for CFCs and SFCs, as
well as for SFC type enhance change documentation.
Engineering
Checklists
provide
step-by-step
verification
of
engineering steps, described in the new Engineering Compendium
thus reducing FAT and commissioning time.
Forcing of all CFC
parameters allows engineers to test system functionality quickly.
The newly designed operator interface with v7.1 increases
operational efficiency. An optimized color schema and improved
alarm control raises awareness of critical conditions. The alarm
control allows for user-specific adaption of filters, selections, and
sorting during runtime.
New
trending
capabilities
provide
a
high
level
of
data
transparency to enable operators to respond quickly to process
changes. The trend control is individually configurable for tables
and graphic displays and features a combination of several trend
windows.
Representation of process values is done either in
relation to time or to other process values in tabular, curve, and
function windows.
Scaling of the value axis is either linear,
logarithmic, percentage, or even freely configurable.
It’s also been made easier to retrieve and analyze both historical
and live process data. An enhanced Trend Control provides access
and visualization at the Operator Stations. The new Data Monitor
tool provides a direct link to process data from Excel, allowing
users to leverage the power and familiarity of Excel for efficient
analysis and reporting.
New hardware allows more flexible configuration.
High channel
density with ET 200M can be achieved with the 64-channel digital
modules.
ET 200iSP features new EEx e digital output for
switching magnetic valves, DC contactors or pilot lamps and new
four-channel analog input module for resistance measurement.
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Study Title • Executive Overview
The release of v7.1 marks the introduction of a new library in
addition to the Standard Library that was created from the ground
up to provide more comprehensive functionality out-of-the box.
The library supports additional modes of operation such as “local”
and “out of operation,” making it easy to adapt the configuration
to the plant hardware and operational philosophy. Technological
function blocks can be extended with additional analog values and
alarm modules.
I/O signal data quality information is passed
through the configuration and up to the HMI, ensuring that
operators know when a signal is bad, is being simulated, or is
being forced for troubleshooting purposes.
Ergonomic symbols and task-oriented faceplates created for the
new Advanced Process Library provide a consistent look and feel
to the operator and a uniform representation of state information.
Faceplate operation can be easily adjusted to be consistent with
the plant’s operational philosophy, for example, the use of
confirmation steps when energizing a motor.
New interlock
faceplates allow operators to quickly identify the status of
interlock conditions and to navigate to the source of the interlock.
Advanced Process Library blocks support simulation of process
values directly in the faceplate, resulting in faster commissioning.
Siemens Strengthens Migration Capabilities
Siemens has developed a well-thought-out approach to control
system migration for both its own legacy systems and those of its
competitors.
The company offers a stepwise, phased migration
plan that includes a full suite of services, applications, and a
strong set of automated conversion tools that ease the migration
process for end users, while allowing them to retain the functions
and the look and feel of their legacy systems.
investment
considerable.
in
conversion
tools,
for
example,
Siemens’
has
been
The company has spent significant resources on
making it easy for users to convert legacy graphics and faceplates
to the company’s SIMATIC PCS 7 process automation system.
Siemens’ official name for its migration program is Performance
Upgrade. In this phased approach, ten layers address each major
layer of the control system architecture. These ten layers include
HMI Connectivity, HMI Conversion, Enhanced Batch Management,
Engineering Library Conversion, Application Conversion, Control
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Study Title • Executive Overview
Network Gateways, I/O Gateways (PFM), I/O Replacement, I/O
Interfaces (DPIO), and Field Termination Assemblies (FTA).
These ten layers are grouped into three primary phases of
migration that address the three typical phases of a migration
project. Phase I deals with the HMI and batch layer, and includes
HMI
connectivity,
Management.
HMI
Conversion,
an
Enhanced
Batch
Phase II includes the creation and conversion of
engineering libraries, application conversion, and control network
gateways. Phase III includes I/O Gateways, I/O Replacement, I/O
Interfaces, and Field Termination Assemblies.
As part of Siemens’ strategic focus on migration, the company has
developed multiple centers of excellence (COE) for migration that
provide technology, support, and educational resources for end
users considering a migration project.
The primary COE for
migration is located in the company’s Spring House, Pennsylvania
location and is designed to provide global support for migration,
but has particular expertise in migrating the company’s installed
base of Moore APACS systems and 505 systems, the latter which
were the product of the Siemens TI acquisition in the early 1990s.
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Study Title • Executive Overview
Siemens’ Stepwise Migration Path
Siemens also has a COE for migration in Cologne, Germany for
legacy Contronic systems from ABB/Hartmann & Braun. Another
COE for Siemens Teleperm and other competitor systems is
located in Karlsruhe, Germany. While Siemens’ migration centers
of excellence provide technology and services, the most important
thing they provide for end users is assisting them in developing a
real business case for migration and providing the training and
education services that are necessary to realize the vision of the
migration project.
Siemens has a dedicated Project Engineering Team comprised of
experts that already have a record of accomplishment in
delivering successful migration projects. This team also conducts
front-end engineering and design (FEED) studies and provides
consulting services to help customers determine the breadth and
scope of their migration project.
Siemens has also developed
strong relationships with local third-party systems integrators, all
of which are picked, trained, and certified by Siemens specifically
for migration projects, particularly in the North American market.
Finally, the global migration Center of Excellence in Spring House
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Study Title • Executive Overview
is responsible for testing and developing all migration products.
This is consistent with Siemens’ overall approach to the DCS
market.
Partnerships and Acquisitions
In 2008, Siemens acquired innotec GmbH.
The company was
assigned to the Industry Automation Division and changed its
name to Comos Industry Solutions GmbH. Comos is a leading
supplier of lifecycle management systems, especially for plant in
the process industry.
The acquisition will allow the Industry
Automation Division to expand its portfolio for customers in the
process industry. Comos enables Siemens to offer an integrated
software solution, all the way from the planning stage of a
production plant, through operation, right up to modernization and
planning of decommissioning work.
This will help Siemens to
extend its global reach in the market for industrial software.
Key Industries
Siemens is a leader in the power generation industry worldwide,
and its presence in the DCS market for power generation is often
underestimated because so many of its projects are captive
business. Siemens IS’ takeover of US Filter in 2004 provided a set
of technology platforms with high-growth potential based on
added value.
Siemens created a new R&D center in Singapore
and continues to invest to remain a leading technology provider.
The new Siemens IS Water Technologies business unit set up sales
organizations in Northeast and Southeast Asia, the Middle East,
Europe, and South America, with the objective of quickly
expanding the previously US-focused US Filter business into other
world regions. Siemens also has large installed base among many
of the world’s large chemical companies, particularly the large
German end users such as BASF and Bayer. The company also
has a strong presence in the life sciences industry and food and
beverage industry.
The company is a leader in brewing
applications worldwide.
Siemens is probably the leading DCS
supplier for the glass industry and is also strong in cement
applications.
Other core industries for Siemens include oil and
gas, pulp and paper, and metals and mining.
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Siemens
http://pcs.khe.siemens.com/index_simatic_pcs_7-1075.htm
DCS Offerings
SIMATIC PCS 7, APACS, Teleperm
DCS Business
Siemens AG, headquartered in Munich, Germany, is a major global
automation supplier with activities focused on the areas of
industrial and infrastructure, energy, and healthcare.
In fiscal
year 2009 (ended September 30), the company had over 400,000
employees
in
190
countries
and
revenue
from
continuing
operations of €76.6 billion, roughly the same as the previous year.
In 2008, Siemens regrouped its business into three operating
sectors:
Industry, Energy, and Healthcare.
The Industry sector
and its products and solutions address industry customers and is
made
up
of
six
divisions:
Industry
Automation,
Drive
Technologies, Building Technologies, OSRAM, Industry Solutions,
and Mobility.
The range of offerings at the Industry Automation and Drive
Technologies divisions extends from standard products to system
solutions for energy and automation technologies used in the
manufacturing and processing industries.
These divisions are
responsible for the design and production of a wide range of
industrial
automation
products,
including
PLC,
CNC,
DCS,
industrial PC, electric drives, as well as an array of supporting
software and peripheral products, including low voltage products,
communications products, and programming and operational
software.
Drive Technologies offers products and solutions for
industry ranging from motors and electric drives to mechanical
components including gearboxes.
The Building Technologies division bundles Siemens’ offerings for
building security, automation, and operation – both as a service
provider and a manufacturer of products and systems. Osram’s
product portfolio includes lamps and optoelectronic semiconductor
light sources such as light-emitting diodes, related electronic
control systems, and light management systems.
The Industry
Solutions division is a systems and solutions integrator for the
Copyright " © ARC Advisory Group • ARCweb.com • For Internal Use Only • 1-1
Study Title • Executive Overview
industrial plant market, covering everything from planning to
construction and operation. The Mobility division networks a wide
array of transportation systems to move people and goods
efficiently.
The Energy sector primarily addresses energy providers, but also
industrial customers, particularly in the oil & gas industry.
The
Fossil Power Generation division offers highly efficient products
and solutions for power generation based on fossil fuels. Offerings
range from individual gas and steam turbines and generators to
power plant construction on a turnkey basis.
The Renewable
Energy division bundles Siemens’ activities in the wind energy
market. The Oil & Gas division offers products and solutions for
the extraction, transport and conversion of oil and gas. The Power
Transmission division is a leading supplier of products and
solutions in the high-voltage field.
The specialties of the Power
Distribution division range from solutions for the automation of
power grids to products like medium-voltage switchgear and
components.
Siemens' "Totally Integrated Automation”
Siemens' all-encompassing automation concept is known as
Totally Integrated Automation (TIA). This concept leverages one
class of automation products across all applications. While some
standard components are used to achieve the Totally Integrated
Automation vision, the emphasis remains largely on integration of
Siemens’ products.
TIA is characterized by a three-fold uniformity in software
(configuration
and
programming),
data
management,
and
communication. This is accomplished using common engineering
tools and common hardware, software, and networking interfaces.
In
the
marketplace,
this
strategy
translates
into
common
components applied to a variety of applications formerly served
by application-specific products.
Siemens' industrial automation solutions use the networking
technologies
Ethernet.
from
Profibus
International
(PI)
and
Industrial
Industrial Ether-net is used as the system bus
connecting controllers, HMI servers, and batch servers, and for
inter-controller communication.
At the I/O level, PROFIBUS DP
1-2 • Copyright " © ARC Advisory Group • ARCweb.com • For Internal Use Only
Study Title • Executive Overview
serves as the high-speed network, while PROFIBUS PA segments
extend the fieldbus to networked field instruments.
Finally,
PROFInet is Profibus' emerging industrial Ethernet standard that
will
augment
the
Profibus
architecture
as
Ethernet
gains
acceptance at the device level. Profibus also offers applicationspecific profiles to address a wide variety of specific networking
requirements. For HART users, PCS 7 offers integration of HARTcompatible field devices.
SIMATIC PCS 7
SIMATIC PCS 7 is Siemens’ PAS offering that serves as the fulcrum
for all of Siemens’ process industry strategy.
currently
has
worldwide.
over
seven
thousand
SIMATIC PCS 7
reported
installations
Fulfilling the TIA vision of common hardware
infrastructure across application domains, SIMATIC PCS 7 includes
hardware based on the common SIMATIC platform. SIMATIC PCS 7
utilizes common ET200 Series I/O, common PROFIBUS and
Ethernet communications, common configuration, engineering,
operator interface, and a single unified automation database.
The SIMATIC PCS 7 Engineering Station (ES) provides tight
integration and automated data transition between engineering,
configuration, operations, and HMI.
The IEC 61131-compliant
programming tools offer easy engineering of the configuration
logic using a single database, pre-configured library blocks or
custom blocks, statement list, ladder diagram and function blocks.
The ES is based on Siemens’ Step 7 programming software, thus
contains all its strengths in addition to Structured Control
Language (SCL), Process Object view, Continuous Function Chart
(CFC), Sequential Function Chart (SFC), Safety Matrix, and ISA-88
compliant plant hierarchy views.
The Component View in the ES allows for configuration of control
hardware and is typically the view for maintenance personnel or
technicians.
Configuration can be done in standard function
blocks or in SFC.
Users can also create customized function
blocks. The Plant View within ES is the logical view that provides
hierarchical structuring of the plant by process area, unit, or
component.
Copyright " © ARC Advisory Group • ARCweb.com • For Internal Use Only • 1-3
Study Title • Executive Overview
The Process Object view in ES is the primary engineering view of
ES and offers a single point of entry. It provides a modular and
object-based graphical view of the engineering process and
provides a device-oriented perspective for configuration. Process
Objects represent devices such as pumps, motors, and field
devices by providing access to context-specific information such
as I/O assignment, control hardware, HMI representation, archives,
function block parameters, alarm priorities, and alarm messages.
ES reduces design costs and startup times by automatically
reusing data from the control strategy configuration during the
creation of the HMI environment. The ability for the operator to
view and interact with SFCs is generated automatically for both
continuous and batch applications. Graphical representations of
faceplates can also be
strategies.
from
the
derived automatically
from
control
Users can automatically generate process graphics
controller
configuration.
Displays
are
automatically with symbols, which are pre-linked.
management
tools
within
ES
include
a
populated
Configuration
central
change
management tool for SFC modifications and an audit trail for
configuration changes.
Security in ES can be linked to the
Windows security scheme to control logon access.
ES also offers concurrent engineering, enabling a whole team of
engineers to work on the same control strategies from multiple,
geographically distributed locations simultaneously.
This allows
for global distribution of engineering tasks and engineering of
multiple projects simultaneously. More important, however, is the
collaborative sharing of engineering best practices in a dynamic
way across multiple plants.
The system automatically guarantees data consistency.
Linking
CAD/CAE tools to Simatic PCS 7 improves data transfer from the
P&ID (Piping and Instrumentation Diagram). The output data of
the CAx tools can be transferred direct to the engineering system
of Simatic PCS 7, which simplifies data exchange, reduces
potential error sources, avoids duplicated entry of data, and cuts
the configuration time.
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Study Title • Executive Overview
OS Provides Common HMI
The common HMI environment for SIMATIC PCS 7 is the Operator
Station (OS), which is based on the standard Siemens SIMATIC
WinCC HMI, with additional features to make it suitable for process
applications and distinguish it from the standalone WinCC HMI
offering.
OS offers customized, contextual operator views and
features a SQL Server-based historian.
The Data Storage compression within OS allows for online
modifications and upgrades, which is consistent with ARC’s CPAS
vision. OS is also designed to reduce operator response times to
abnormal situations.
Alarm status is shown at all times, and
alarms and messages are automatically segregated by process
area.
OS also offers alarm filtering and prioritization through
alarm classes and priorities.
Common Hardware and Control Platform
The common control hardware platform for SIMATIC PCS 7 is the
400 Series of controllers, including the 412, 414, 416, and 417
Automation Stations (AS). These Automation Stations are based
on standard SIMATIC Controllers.
Used as DCSs, the controllers
offer variable scan rates down to 10 milliseconds.
Larger
controllers can execute over 1,000 PID loops in 0.5 seconds and
support online expansion of programming memory. There are two
controller versions for Simatic PCS 7 Box; a rugged PCI slot
version, and a soft controller that runs on the integral PC
processor.
The slot version is equipped with its own operating
system and power supply and offers higher availability.
Copyright " © ARC Advisory Group • ARCweb.com • For Internal Use Only • 1-5
Study Title • Executive Overview
ET200M is the primary I/O offering and can be placed in hazardous
areas, including Class 1 Division 2.
Failsafe versions are TÜV-
approved and can be used for SIL 3 applications with the
integrated safety system controllers.
The ET 200S Series I/O is
designed for motor control, starter control, and pneumatic valve
control applications.
The I/O is designed to support distributed
architectures natively, allowing the user full flexibility in choosing
the location for the I/O (Remote I/O).
The HART I/O module
provides redundancy capability for the ET 200M distributed I/O
station.
This has a high channel density for analog inputs and
outputs, supports the connection of HART field devices and is
integrated into the asset management system of Simatic PCS 7.
The IM 153-2 HF interface module for the ET 200M distributed I/O
station offers high-accuracy time stamping for recording the SOE
(sequence of events) and supports the operation of up to 12 I/O
modules in one I/O device.
Common Information Infrastructure
The common communications infrastructure for SIMATIC PCS 7 is
based on the standard PROFIBUS protocol and Siemens’ Industrial
Ethernet backbone. PROFIBUS DP connects remote I/O (including
1-6 • Copyright " © ARC Advisory Group • ARCweb.com • For Internal Use Only
Study Title • Executive Overview
HART), drives, and provides an interface to other device networks,
such as AS-i, Modbus and FF.
PROFIBUS PA operates at the
process field device level and provides connectivity for fieldbuscompatible process field instrumentation and intelligent control
valve positioners.
PROFIsafe is also integrated into the system
architecture through Siemens’ safety system offering.
The
Industrial Ethernet control network provides for the specific needs
of a real-time controller on a standard Ethernet backbone.
SIMATIC PCS 7 Supports Multiple Application Domains
A typical process plant requires up to three different types of
control applications, from regulatory control, to sequential control,
discrete control, and safety applications. CPAS incorporates these
functions as well as asset management, advanced control, and
production management.
SIMATIC PCS 7 addresses the needs of process, hybrid, and
discrete applications within a single framework.
The common
hardware platform and common network infrastructure, as well as
the unified 61131 and SFC-based configuration environment, allow
for seamless incorporation of discrete control capabilities, batch,
and safety system applications along with process.
applications
are
supported
with
Siemens’
SIMATIC
Batch
BATCH
application, which serves the purpose of a high-performance basic
batch engine and is fully integrated into PCS 7.
An Advanced
Batch Reporting package enables drafting of customized reports
using MS SQL or Crystal Reports. Reports can be converted to .pdf
file format for forwarding or storage.
Process Safety can be fully integrated in standard PCS 7
Automation Stations. The integration of the safety engineering in
the standard automation means less demand for space, less
hardware and wiring and less work for assembly, installation, and
engineering.
Additional applications, such as those needed for
separate safety controllers due to the substantial integration work
in the DCS, are avoided with the homogeneous integration of PCS
7. Together with SIMATIC PCS 7, powerful, flexible solutions can
be realized for integrated automation and safety applications in an
integrated automation network.
Copyright " © ARC Advisory Group • ARCweb.com • For Internal Use Only • 1-7
Study Title • Executive Overview
With the safety matrix, fail-safe functions can be created without
programming skills based on the rules of a cause and effect
matrix.
Flexible Modular Redundancy™ provides scalable, cost
effective solutions that allow users to implement multiple levels of
fault-tolerance exactly where it is needed for their application.
The new Simatic S7-412FH controller can be used both as a faulttolerant standard controller and as an SIS (Safety Instrumented
System).
It is suitable for smaller applications with up to 50 F
(failsafe) I/O.
Advanced control options in SIMATIC PCS 7 include Model-based
multivariable
control
systems,
Operating
point-dependent
regulating parameter control, and Control quality monitoring.
PCS 7 simulation and operator training are accomplished through
the SIMIT process training simulation package.
configuration
tool
automatically
creates
environment directly from the control strategy.
The system’s
the
simulation
For production
management applications, SIMATIC PCS 7 interfaces directly to the
SIMATIC IT Production Suite.
For plant asset management applications, Siemens offers PDM
(Process Device Manager). Using PDM from a central engineering
station, users can parameterize and troubleshoot intelligent field
devices remotely.
PDM serves as the communications basis for
the asset management system and is available either integrated
with SIMATIC PCS 7 or in standalone configurations. PDM reduces
factory acceptance testing (FAT), commissioning, and startup
times. FAT is also facilitated and optimized by using SIMBA which
can simulate the complete behavior of I/O devices (PROFIBUS DP
and PA) on the fieldbus and makes it possible to test automation
functions, like measurement and control loops, and safetyrelevant functions, like emergency shutdowns, before doing it on a
live plant.
Latest Version Release of Simatic PCS 7
Siemens Industry Automation Division introduced version 7.1 of its
Simatic PCS 7 process control system in March of 2009 with
numerous new functions. The primary focus of the latest release
is to help shorten engineering, installation, and commissioning
times,
while
reducing
operating
and
1-8 • Copyright " © ARC Advisory Group • ARCweb.com • For Internal Use Only
maintenance
costs.
Study Title • Executive Overview
Automation of key engineering tasks with version 7.1 streamlines
engineering workflow.
Use of centralized visualization schemas
for color palettes, styles, or optical effects enables automatic
propagation of graphical changes to all process pictures.
The
design is configurable in "classical" or "modern" look. Drag and
drop connection of process values between controllers provides
seamless communication setup. Versioning for CFCs and SFCs, as
well as for SFC type enhance change documentation.
Engineering
Checklists
provide
step-by-step
verification
of
engineering steps, described in the new Engineering Compendium
thus reducing FAT and commissioning time.
Forcing of all CFC
parameters allows engineers to test system functionality quickly.
The newly designed operator interface with v7.1 increases
operational efficiency. An optimized color schema and improved
alarm control raises awareness of critical conditions. The alarm
control allows for user-specific adaption of filters, selections, and
sorting during runtime.
New
trending
capabilities
provide
a
high
level
of
data
transparency to enable operators to respond quickly to process
changes. The trend control is individually configurable for tables
and graphic displays and features a combination of several trend
windows.
Representation of process values is done either in
relation to time or to other process values in tabular, curve, and
function windows.
Scaling of the value axis is either linear,
logarithmic, percentage, or even freely configurable.
It’s also been made easier to retrieve and analyze both historical
and live process data. An enhanced Trend Control provides access
and visualization at the Operator Stations. The new Data Monitor
tool provides a direct link to process data from Excel, allowing
users to leverage the power and familiarity of Excel for efficient
analysis and reporting.
New hardware allows more flexible configuration.
High channel
density with ET 200M can be achieved with the 64-channel digital
modules.
ET 200iSP features new EEx e digital output for
switching magnetic valves, DC contactors or pilot lamps and new
four-channel analog input module for resistance measurement.
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Study Title • Executive Overview
The release of v7.1 marks the introduction of a new library in
addition to the Standard Library that was created from the ground
up to provide more comprehensive functionality out-of-the box.
The library supports additional modes of operation such as “local”
and “out of operation,” making it easy to adapt the configuration
to the plant hardware and operational philosophy. Technological
function blocks can be extended with additional analog values and
alarm modules.
I/O signal data quality information is passed
through the configuration and up to the HMI, ensuring that
operators know when a signal is bad, is being simulated, or is
being forced for troubleshooting purposes.
Ergonomic symbols and task-oriented faceplates created for the
new Advanced Process Library provide a consistent look and feel
to the operator and a uniform representation of state information.
Faceplate operation can be easily adjusted to be consistent with
the plant’s operational philosophy, for example, the use of
confirmation steps when energizing a motor.
New interlock
faceplates allow operators to quickly identify the status of
interlock conditions and to navigate to the source of the interlock.
Advanced Process Library blocks support simulation of process
values directly in the faceplate, resulting in faster commissioning.
Siemens Strengthens Migration Capabilities
Siemens has developed a well-thought-out approach to control
system migration for both its own legacy systems and those of its
competitors.
The company offers a stepwise, phased migration
plan that includes a full suite of services, applications, and a
strong set of automated conversion tools that ease the migration
process for end users, while allowing them to retain the functions
and the look and feel of their legacy systems.
investment
considerable.
in
conversion
tools,
for
example,
Siemens’
has
been
The company has spent significant resources on
making it easy for users to convert legacy graphics and faceplates
to the company’s SIMATIC PCS 7 process automation system.
Siemens’ official name for its migration program is Performance
Upgrade. In this phased approach, ten layers address each major
layer of the control system architecture. These ten layers include
HMI Connectivity, HMI Conversion, Enhanced Batch Management,
Engineering Library Conversion, Application Conversion, Control
1-10 • Copyright " © ARC Advisory Group • ARCweb.com • For Internal Use Only
Study Title • Executive Overview
Network Gateways, I/O Gateways (PFM), I/O Replacement, I/O
Interfaces (DPIO), and Field Termination Assemblies (FTA).
These ten layers are grouped into three primary phases of
migration that address the three typical phases of a migration
project. Phase I deals with the HMI and batch layer, and includes
HMI
connectivity,
Management.
HMI
Conversion,
an
Enhanced
Batch
Phase II includes the creation and conversion of
engineering libraries, application conversion, and control network
gateways. Phase III includes I/O Gateways, I/O Replacement, I/O
Interfaces, and Field Termination Assemblies.
As part of Siemens’ strategic focus on migration, the company has
developed multiple centers of excellence (COE) for migration that
provide technology, support, and educational resources for end
users considering a migration project.
The primary COE for
migration is located in the company’s Spring House, Pennsylvania
location and is designed to provide global support for migration,
but has particular expertise in migrating the company’s installed
base of Moore APACS systems and 505 systems, the latter which
were the product of the Siemens TI acquisition in the early 1990s.
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Study Title • Executive Overview
Siemens’ Stepwise Migration Path
Siemens also has a COE for migration in Cologne, Germany for
legacy Contronic systems from ABB/Hartmann & Braun. Another
COE for Siemens Teleperm and other competitor systems is
located in Karlsruhe, Germany. While Siemens’ migration centers
of excellence provide technology and services, the most important
thing they provide for end users is assisting them in developing a
real business case for migration and providing the training and
education services that are necessary to realize the vision of the
migration project.
Siemens has a dedicated Project Engineering Team comprised of
experts that already have a record of accomplishment in
delivering successful migration projects. This team also conducts
front-end engineering and design (FEED) studies and provides
consulting services to help customers determine the breadth and
scope of their migration project.
Siemens has also developed
strong relationships with local third-party systems integrators, all
of which are picked, trained, and certified by Siemens specifically
for migration projects, particularly in the North American market.
Finally, the global migration Center of Excellence in Spring House
1-12 • Copyright " © ARC Advisory Group • ARCweb.com • For Internal Use Only
Study Title • Executive Overview
is responsible for testing and developing all migration products.
This is consistent with Siemens’ overall approach to the DCS
market.
Partnerships and Acquisitions
In 2008, Siemens acquired innotec GmbH.
The company was
assigned to the Industry Automation Division and changed its
name to Comos Industry Solutions GmbH. Comos is a leading
supplier of lifecycle management systems, especially for plant in
the process industry.
The acquisition will allow the Industry
Automation Division to expand its portfolio for customers in the
process industry. Comos enables Siemens to offer an integrated
software solution, all the way from the planning stage of a
production plant, through operation, right up to modernization and
planning of decommissioning work.
This will help Siemens to
extend its global reach in the market for industrial software.
Key Industries
Siemens is a leader in the power generation industry worldwide,
and its presence in the DCS market for power generation is often
underestimated because so many of its projects are captive
business. Siemens IS’ takeover of US Filter in 2004 provided a set
of technology platforms with high-growth potential based on
added value.
Siemens created a new R&D center in Singapore
and continues to invest to remain a leading technology provider.
The new Siemens IS Water Technologies business unit set up sales
organizations in Northeast and Southeast Asia, the Middle East,
Europe, and South America, with the objective of quickly
expanding the previously US-focused US Filter business into other
world regions. Siemens also has large installed base among many
of the world’s large chemical companies, particularly the large
German end users such as BASF and Bayer. The company also
has a strong presence in the life sciences industry and food and
beverage industry.
The company is a leader in brewing
applications worldwide.
Siemens is probably the leading DCS
supplier for the glass industry and is also strong in cement
applications.
Other core industries for Siemens include oil and
gas, pulp and paper, and metals and mining.
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