APACS+ process control systemMigration to SIMATIC PCS 7

Brochure · March 2009

© Siemens AG, 2009

SIMATIC PCS 7

Answers for industry.

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© Siemens AG, 2009

IntroductionImprove your competitive position

With its Totally Integrated Automation (TIA), Siemens is the only provider to offer a complete range of harmonized auto-mation products, systems and solutions for all industries, from the field level, through the automation level, and right up to the ERP level. This means that TIA provides the ability to opti-mize production processes across all areas of a plant, leading to reduced complexity and to increased productivity – all while providing a high degree of investment protection.

This leads users to realize a lower Total Cost of Ownership (TCO) – and thereby to improve their competitive position: through improved production throughput, increased availabil-ity, higher product quality, improved operator efficiency, and enhanced maintenance capabilities all with a shorter time to market.

Being flexible to react quickly to new market demands while minimizing production downtime is a basic requirement for any company that wishes to enhance its position in the mar-ket. This is where the SIMATIC PCS 7 process control system from Siemens distinguishes itself. As a cornerstone of Totally Integrated Automation, SIMATIC PCS 7 forms a seamless all-in-one system with capabilities that exceed those of legacy sys-tems and the ability to handle all of your process control re-quirements.

With SIMATIC PCS 7, we are addressing the business issues that are critical to maintaining and building up your competi-tive advantage. You can profit throughout the entire life cycle of your industrial plant. SIMATIC PCS 7 opens up new perspec-tives through

• Integration• Performance• Scalability• Modernization• Safety & Security• Innovation• Global Network of Experts

Siemens has been offering a wide range of innovative migra-tion products and solutions for its globally proven systems for many years already. The maxim of Siemens’ migration strate-gy is to modernize the existing installed basis in steps and without completely changing the system – if possible without a plant shutdown or with minimum production downtimes. Siemens therefore supports customers’ endeavors to achieve long-term safeguarding of investments together with maximi-zation of their return on assets.

SIMATIC PCS 7 at a glance

• Scalable from small to very large plants• Redundancy on all levels (I/O, controller, bus systems,

server)• Online extension/modification during operation• Multi-user HMI (Human Machine Interface) components in

client/server architecture• Smart Alarm Management• Full OPC Support• Remote access via Internet/intranet• Wireless monitoring and operation with MOBIC• Plant security based on virus scanning software• Innovated controllers with scan rates down to 10 msec• I/O modules for hazardous areas• Time stamping on the module level down to 1 msec• Common hardware platform also for process safety• Fast Ethernet and PROFIBUS DP/PA• Interfaces to MODBUS, AS-i and FF• Powerful, centralized, plant-wide engineering system• Comprehensive, efficient engineering with graphic/

PCS tools• Major control languages with user-specific function blocks

(SFC, CFC, SCL)• Central parameterization of field devices with SIMATIC PDM• Software simulation and testing• Change Management (Version Trail, Change Log etc.)• Asset Management with common visualization, diagnos-

tics and maintenance of all process control components• Overview of the entire maintenance workflow• Complete traceability of status and maintenance orders• Condition and Plant Performance Monitoring• Batch with unit- and equipment-independent recipes• Hierarchical recipes according to ISA S 88.01• 21CFR Part11, Audit Trail, access protection, electr. signa-

ture

Introduction

© Siemens AG, 2009

Migration strategy of Siemens

Globalization and permanently increasing competition are forcing companies to continuously increase productivity and shorten product launch times. It is therefore necessary to con-tinuously optimize engineering procedures and production processes, while simultaneously taking into account new in-dustrial requirements, standards and statutory legislation.

Many systems and plants have to be expanded and modern-ized to ensure that companies can also satisfy tomorrow's market requirements. Since the installed basis of hardware, application software and know-how of the operation and maintenance personnel represents an enormous value, in-vestment security for plant owners is always of great impor-tance during modernization plans.

Experience has shown that the success of a migration process greatly depends on a technical solution optimally matched to customer requirements and the respective plant. The objec-tive is to minimize technical and financial risks, and to provide as high a level of security for previously made investments. The different life cycles of the system components must also be considered, which currently vary between 5 years for PC-based workstations, 15 years for controllers, and up to 25 years or more for field instrumentation components and wir-ing.

Therefore Siemens does not simply consider its task to be the complete replacement of an existing system, but to work closely with customers and their system integrators to elabo-rate an individual, future-oriented solution on the basis of the state-of-the-art SIMATIC PCS 7 process control system, always considering the directives:

• StepwiseAllows incorporation of new technology incrementally and at various levels of your existing system in a way that is op-timum for your plant

• AdaptableA procedure for maximizing the return on assets (ROA) matched to the life cycle strategy of the plant (retention and modernization, expansion and improvement, or re-newal and replacement)

• FlexibleConsiders the commercial aspects of production and plant management, i.e. required increases in capacity, expansion of product range, reduction in costs, or shortening of time-to-market

And this as well for their own legacy systems as for those of 3rd party suppliers.

System aspectsHMI/batch- Replaces old HMI- Replaces batch systemController/network- Replaces controller- Gateway to SIMATIC PCS 7 I/O field connection- Further use of I/Os- Field connection elements for SIMATIC PCS 7

Strategy- Plant/product future- Planned modernization (revamping)Cost reduction- Maintenance budget- Investment budgetTime-to-Market- Production time- Available downtime

Innovation pressure- Improved process control- IT integration- Advanced process control & asset managementLife cycle phases- Maintenance & modernization- Expansion & improvement- Renewal/replacement with state-of-the-art technology

Siemens migration strategy

Plant aspects Production aspects

Innovative technologies

FlexibleAdaptableStep-by-step

Introduction 3

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© Siemens AG, 2009

Portfolio of the migration products

Early on Siemens recognized the significance of migration for process automation, and has offered a wide range of innova-tive migration products and solutions for its globally proven systems for many years. Right from the beginning, the maxim of Siemens' migration strategy is to modernize the existing in-stalled base in steps and without completely changing the sys-tem, if possible without a plant shutdown or with minimum production downtimes. Siemens therefore supports custom-

ers' endeavors to achieve long-term safeguarding of invest-ments together with maximization of their return on assets.

Siemens' know-how in the migration sector has continuously grown as time has passed. The experience gained in numer-ous migration projects has been incorporated into new prod-ucts and technologies which are even more efficient.

Step-by-step migration with the right products and services

Migration component Description

OS migration products ■ Interface from SIMATIC PCS 7 OS Server to system bus of legacy system■ OS conversion tool (e.g. DBA)■ Faceplate library

Services for OS migration Tools/services for conversion of process displays

Services for AS migration Tools/services for function-based conversion of AS engineering data to SIMATIC PCS 7

Gateway ■ Gateway between system bus of legacy system and SIMATIC PCS 7 (mainly for AS-AS communication)■ Engineering tool for gateway

Reuse of legacy system I/Os or Field Termination Assembly (FTA)

■ Reuse of I/Os (connection of old I/Os to SIMATIC PCS 7 automation systems, mostly for Siemens systems)■ Field Termination Assemblies (FTAs) for field cabling

ET 200M

PROFIBUS PA

HMI

SIMATIC PCS 7

PROFIBUS DP

S7-400S7-400 HS7-400 HFcontroller

MotorI/OinterfaceI/O

Controller

EngineeringStation

EngineeringSystem

Wiring rack

Server Server

Gateway

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Introduction

© Siemens AG, 2009

Typical migration scenarios

The migration path that a user takes depends on the specific technical and economical factors of each migration project. The migration products offer the modularity and flexibility required to implement different scenarios. The following are typical migration scenarios which can be implemented using these migration products:

Scenario 1: Replacement of existing HMI system by a SIMATIC PCS 7 operator system

If the existing HMI (Human Machine Interface) system no longer complies with current directives and standards for op-erator workstations, or if functional expansion is required (e.g. IT integration), it is possible to simply replace it by a SIMATIC PCS 7 operator system. The controller with applica-tion software and the process I/O are retained.

Scenario 2: Expansion of existing plant

The existing plant is initially retained, and is modernized by expanding with further sections/units with SIMATIC PCS 7.

Scenario 3: Comprehensive modernization

Bottlenecks in the provision of spare parts may force compre-hensive modernization of the old system using the future-ori-ented SIMATIC PCS 7 process control system. Conversion may also be possible during operation. Further use of the existing I/O level is supported, and the investments made for wiring, hardware components or application engineering are safe-guarded.

Advantages• Minimum costs• Reduced and understood risk• Lengthening of service life of complete plant• New application possibilities• Opening of system for IT world• Replacement possible without shutdown

Advantages• Simple, step-by-step increase in production capacity• Reduced and understood risk• Introduction of new technologies

(e.g. PROFIBUS fieldbus, HMI)• Opening of system for IT world• Together with scenario 1, enables process control using

a uniform operator system• Expansion possible without shutdown

Advantages• Increase in performance• Introduction of new technologies

(e.g. PROFIBUS fieldbus, HMI)• Opening of system for IT world• Lengthening of service life of complete plant• Elimination of bottlenecks

Introduction 5

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© Siemens AG, 2009

Migration from APACS+ to SIMATIC PCS 7Migration solutions for APACS+

The APACS+ process control system has been used successful-ly world-wide for over 10 years. Its functionality, reliability and user-friendliness have been demonstrated in more than 10 000 installed systems. Migration of the process control sys-tem based on APACS+/QUADLOG controllers with the innova-tive SIMATIC PCS 7 OS operation and monitoring systems from Siemens provides the opportunity for retaining proven func-tions and for significantly increasing the functionality and per-formance at the same time through specific modernization. With its open system platform, SIMATIC PCS 7 provides an ide-al basis for modern, future-oriented and economical automa-tion solutions in all sectors.

Depending on the plant size, the hardware and user software of an installed APACS+ system represent a considerable invest-ment and, together with the process knowledge of the oper-ating and maintenance personnel, an enormous value. To pre-serve and expand an APACS+ system and to increase its value, Siemens developed a migration strategy which aims to mod-ernize existing operator and engineering systems with SIMATIC PCS 7 while retaining the APACS+/QUADLOG control-lers and the lower-lying I/O level. With this strategy, customers can migrate their existing systems efficiently and economical-ly without having to replace any controllers, I/O devices or

their wiring, and without rendering the associated investment in system configuration useless. In addition, excellent alterna-tives are provided at the controller level by the AS 41x of SIMATIC PCS 7, especially with plant expansions. These are supported by the controller to controller communication via Industrial Ethernet Modules (IEM) and by PCS 7/APACS+ oper-ator systems which can communicate with both APACS+/QUADLOG controllers and AS 41x by dual-channel.

Through the migration to SIMATIC PCS 7, the customers of APACS+ also profit from the numerous advantages provided by Totally Integrated Automation (TIA) and the facilities al-ready provided by the system for integration into the corpo-rate information network. These include integration of the SIMATIC IT Management Execution System as well as monitor-ing via the World Wide Web or OPC data exchange with IT ap-plications.

In addition to the above-mentioned technical aspects, future compatibility is also an important argument in favor of APACS+ migration. This is achieved through Siemens invest-ment in continuous product development and long-term, glo-bal servicing for its range of SIMATIC products.

Configuration example of migration of APACS+ systems

PCS 7/APACS+OS Server

PCS 7 OS /BATCH clients

PCS 7OS server

PCS 7BATCH server

PCS 7 centralarchive server

DP/PA Link

Field devices

Engineeringsystem

(single/redundant)

(dualchannel)

ET 200M

ET 200M

ET 200M

ET 200M

AS 414 /AS 416 /AS 417

AS 414FH/AS 417FH

IEM

IEM

IEM

APACS+/QUADLOG

APACS+/QUADLOG

APACS+/QUADLOG

Industrial Ethernet

PROFIBUS DP

PROFIBUS PA

MBUS

Migration from APACS+ to SIMATIC PCS 7

© Siemens AG, 2009

Possible ways to migration

A large number of APACS+ and QUADLOG systems are in-stalled world-wide. APACS+ is a process control system that had various Human Machine Interfaces (HMIs). The APACS+ controller could be used with a UNIX operator station called APS or a Windows based system called ProcessSuite. Siemens has developed an effective migration strategy for either HMI based on the innovative SIMATIC PCS 7 process control sys-tem. QUADLOG is the safety system that used the same special safety rated software. SIMATIC PCS 7 incorporates some of the best-in-class features of QUADLOG (for example the "Safety Matrix") in the Failsafe (F) version of the AS 400 series control-lers.

Flexibility

Siemens is able to offer a number of advantages in the migra-tion path from APACS+ to PCS 7.

HMI Connectivity

By offering HMI connectivity the system can be migrated over to a standard PCS 7 operator interface, which brings all the lat-est benefits including alarm filtering, supportable operating systems and asset management. As part of the process we have developed our DBA tool (DataBase Automation). The DBA is also the link for the runtime environment providing the bridge between the APACS+ controllers and the standard PCS 7 HMI. As the HMI has been left as standard this allows plant expansions to take place using all SIMATIC PCS 7 compo-nents, right down to field level, using the same operator inter-face (Fig. 1).

HMI Conversion

In some cases a large investment has been made in develop-ing the operator graphics. Siemens has developed a conver-sion service which is able to regenerate the existing ProcessSuite Graphics into standard PCS 7 graphics. These can then be further enhanced using the standard SIMATIC manag-er graphics tools (Fig. 2).

Fig. 1: Database automation from APACS+ to SIMATIC PCS 7

Fig. 2: Conversion Service from APACS+ to SIMATIC PCS 7

Migration from APACS+ to SIMATIC PCS 7 7

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© Siemens AG, 2009

Enhanced Batch Management

For many of our customers using ProcessSuite Batch, it will be important that the new system will be able to take advantage of existing controller batch functionality and integrate it into Siemens SIMATIC Batch. SIMATIC Batch is fully integrated into PCS 7 and able to offer a modern user friendly Batch Manage-ment System. It also has connectivity into our SIMATIC IT suite bringing MES capability to your process.

Engineering Library

To ensure familiar APACS+ libraries are available within PCS 7, Siemens has recreated the APACS+ engineering library of standard APACS+ functions. The PID symbol and faceplate have been recreated into a matching set within PCS 7. Of course, with PCS 7 there is always the ability to create your own templates for symbols and faceplates should your exist-ing APACS+ code have specialized user defined functions.

The PCS7/APACS+ ES library contains the following:

• Single Loop• Single Loop SS• External Setpoint• Ratio Setpoint• Cascade• Primary• Secondary• Analog Alarm• Discrete Alarm• Block Valve 1 Out• Block Valve 2 Out• Valve A• Valve A Alarm• Motor 1 Out• Motor 2 Out• Motor A• Motor A Alarm

Application Conversion

To further enhance migration possibilities for APACS+ we have available products and tools to enable existing controller con-figurations to be converted into standard PCS 7 AS 41x con-trollers. The products and tools are designed to reduce engi-neering costs whilst maintaining investment in existing pro-cess functionality.

Control Network Gateways

Where information is needed across controllers or up to the HMI, a Siemens IEM (Industrial Ethernet Module) can be used. This provides the linkage between the MBUS communica-tions, which are the backbone of the APACS+ system and the Ethernet connectivity to today's modern operator's stations and servers. It will also provide a mechanism to communicate between ACM's over different MBUS segments.

Advantages of the Siemens IEM:

• Allows peer-to-peer communications between APACS+/QUADLOG controllers

• Allows peer-to-peer communications between APACS+/QUADLOG and PCS 7 controllers

• Allow PCS 7 OS Servers to communicate with existing APACS+/QUADLOG controllers

• Provides replacement for earlier APACS+ Ethernet gateways (i.e. NIM, RNI, DOS RIS)

• Eliminates need for MBUS connection on servers/worksta-tions

• Available since: August 2004

Migration from APACS+ to SIMATIC PCS 7

© Siemens AG, 2009

I/O Gateways

Siemens has not only developed products to integrate new op-erator stations with your existing APACS+ ACM controllers; we have also developed the PFM (PROFIBUS Fieldbus Module). The PFM allows connection of PROFIBUS enabled field devices to the controller including PROFIBUS PA using the DP/PA link. It is now possible to integrate smart Motor Control Centers and Intelligent Instrumentation into your existing system. This will simplify expansion of the process and future migration over to Siemens AS41x controllers.

PROFIBUS Fieldbus Module (PFM) - Supports the Integration into APACS+ of:

• Weight Scale• Variable Speed Drives• Smart Motor Control Centers• ASi Devices• PLCs• Smart Xmitters/Valve Positioners• Remote I/O• Remote I/O for Direct Connect to Div 1 Areas

The PFM allows APACS+ users to add fieldbus technology into their existing systems (Fig. 4).

I/O Interfaces

To integrate existing APACS+ I/O cards into a Siemens AS archi-tecture we have developed the DP/IO card. This card will re-place an existing ACM to provide communication with an AS41x and the APACS+ I/O cards. Together with Application Conversion a cost effective solution is available to replace ex-isting ACM controllers whilst retaining field wiring and I/O cards.

The link is the same form factor as an ACM/CCM and can be in-stalled in any slot (Fig. 5).

Fig. 4: Periphery connected to the I/O Gateways through PFM

Fig. 5: I/O Interfaces connected via DP/IO Bus Link

Ethernet

OS Server

PFM

Drives, Motors etc.

Remote I/O

Smart Transmitters,Positioners

PROFIBUS DP

PROFIBUS PA

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2nd DP Master

Migration from APACS+ to SIMATIC PCS 7 9

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© Siemens AG, 2009

ServicesCombined competence for first-class solutionsExpert know-how for migration

A successful and efficient migration is best achieved by work-ing with a team of competent partners. Consequently, Siemens is accustomed to working hand in hand with the cus-tomer and with their system integrator(s), particularly when it involves the migration of third-party systems. In many cases, the system integrator may have specialized knowledge of the customer’s existing application, or an expertise with the third-party control system, or an insight into the needs of the client and the requirements of the plant.

In this way, plant management can be assured that the effec-tive partnership between the system integrator and Siemens will result in a migration solution that is optimum for his busi-ness. There are many reasons why Siemens is in a unique po-sition to be your process automation partner for the future. Combining the innovative SIMATIC PCS 7 process control sys-tem with flexible migration solutions and services, plus indus-try expertise and migration experiences accumulated over years, in addition to global support creates a combination that provides maximum value for our customers.

Since APACS+ and QUADLOG are historically Siemens prod-ucts, there is a large amount of engineering expertise for these systems within Siemens. The Siemens migration spe-cialists are familiar with the systems technology behind APACS+, QUADLOG, and SIMATIC PCS 7 and have many years of experience in engineering, commissioning and service. There are also solution partners that have experience with APACS+ and QUADLOG and can assist you in engineering a modernization plan.

Siemens is able to help you in making an informed decision on the best possible migration strategy to meet your business

needs, by working with you to find the right migration solu-tion.

Furthermore Siemens offers you a fast and safe putting into action of your user software for the operating on the new sys-tem platform. Siemens takes into account trade-specific qual-ities just like operational special solutions. We guarantee con-stant software quality, security and traceability based on the modern tools developed by us.

As part of Siemens’ strategic focus on migration, the company has developed multiple migration centers that provide tech-nology, consulting, support, and educational resources for end users considering a migration project. The core activity of a Migration Support Center (MSC) is to use suitable software tools to intelligently migrate valuable engineering data, which has been optimized over many years, to SIMATIC PCS 7. Intel-ligently – meaning not module-for-module, but rather on a functional level. The result: your system functions just as smoothly after a migration as it did beforehand and the result is practically indistinguishable from a new configuration.

Possible execution steps with support of the MSC

The right approach, working with experts:

• Accumulated knowledge and know-how• Development of efficient migration products and tools• Migration solutions and advice that meets the needs of

your business• Minimizing the costs of life cycle and maintenance

Services

© Siemens AG, 2009

References

Siemens has already completed a number of succesful APACS+ migrations. One such example is the "World Energy Alterna-tives LLC" in Lakeland Massachusetts (US).

Further references are available at:

www.siemens.com/simatic-pcs7/migration

Reference project

Customer: World Energy Alternatives LLC

• Lakeland Massachusetts, US• Subsidiary of Linde Gas

Siemens decision

• APACS+ OS engineering station which will also run APACS+ 4-mation and act as a client

• APACS+ OS single station with a 512 tag SQL historian

SIMATIC PCS 7 quantity size (1st plant section)

• Graphics. 10 process graphics• PCS 7/APACS+ OS

- 1 engineering/operator station- 1 single station with Siemens provided integrated

workstations• Order Value: $ 74 000 as a 3 year TSA option

Further reference projects on request.

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The information provided 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.All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third

© Siemens AG, 2009

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