Siemens - Distributed Control System

Study Title • Executive Overview

Siemens

http://pcs.khe.siemens.com/index_simatic_pcs_7-1075.htm

DCS OfferingsSIMATIC PCS 7, APACS, Teleperm

DCS BusinessSiemens 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

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for the 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 from Profibus International (PI) and Industrial Ethernet. 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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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 application-specific profiles to address a wide variety of specific networking requirements. For HART users, PCS 7 offers integration of HART-compatible field devices.

SIMATIC PCS 7SIMATIC PCS 7 is Siemens’ PAS offering that serves as the fulcrum for all of Siemens’ process industry strategy. SIMATIC PCS 7 currently has over seven thousand reported installations worldwide. 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.



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 derived automatically from control strategies. Users can automatically generate process graphics from the controller configuration. Displays are populated automatically with symbols, which are pre-linked. Configuration management tools within ES include a 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.



OS Provides Common HMIThe 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 PlatformThe 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.



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 InfrastructureThe 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 HART), drives, and provides an interface to other device networks,


Simatic PCS 7 Functional View

SIMATIC I TProduction Management/ MES

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Common I ndustrial Ethernet Network


such as AS-i, Modbus and FF. PROFIBUS PA operates at the process field device level and provides connectivity for fieldbus-compatible 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 DomainsA 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. Batch applications are supported with Siemens’ SIMATIC 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.

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 fault-tolerant 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. The system’s configuration tool automatically creates the simulation environment directly from the control strategy. 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 safety-relevant 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 maintenance costs. 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.

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 CapabilitiesSiemens 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. Siemens’ investment in conversion tools, for example, has been considerable. 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 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, HMI Conversion, an Enhanced Batch Management. 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.

Siemens also has a COE for migration in Cologne, Germany for legacy Contronic systems from ABB/Hartmann & Braun. Another


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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 is responsible for testing and developing all migration products. This is consistent with Siemens’ overall approach to the DCS market.

Partnerships and AcquisitionsIn 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 IndustriesSiemens 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 - Distributed Control System