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PCS 7 Innovations - 2014Sourav Ghosh, Siemens Ltd., Product Management – Process Automation
Siemens Process Automation Conference (SPACe) 2014, Gurgaon, India
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Automation System HighlightsPCS 7 V8.1
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The right product for every requirement
AS RTX AS mEC RTX
For compact solutions
OEMs
Package units
PCS 7 Box Standard AS
For the highest standards in
Performance
Availability
AS 410AS 410 SMART
Automation systems for PCS 7Portfolio
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Hardware NewsAS 410-5H overview
THE controller for process industry
New license concept enables easy plant extension for the whole Life-Cycle
+
+
Improved robustness by removed start-stop-switch, memory card and additional conformal coating+ 70o C with V8.1
+
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SIMATIC PCS 7 AS 410-5HOverview
New controller for process automation with SIMATIC PCS 7
• One hardware for all applications
• One hardware for all application sizes
• Robust design
CPU type:CPU 412-5H PN/DPCPU 414-3CPU 414-3 PN/DPCPU 414-5H PN/DPCPU 416-2CPU 416-3CPU 416-3 PN/DPCPU 416-5H PN/DPCPU 417-4CPU 417-5H PN/DP
CPU type:CPU410-5H
AS 410 System ExpansionPO 100PO 500PO 1000PO 1600PO 2k+. (~ 2600)
SE-Card
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Online Upgrade of the Process Objects of a AS 410-5H
CPU 410-5H + System Expansion Card
System Expansion Card
100 PO
500 PO
1000 PO
1600 PO
2000 PO
1000 PO
System Expansion Packs
100 PO
500 PO
Exchange of the card, stop of the CPU Online Upgrade, no stop of the CPU
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SIMATIC PCS 7 V8.1 Onsite Upgrade of System Expansion Card
Easy bid preparation
Order PO amount independent of CPU size request
PO distribution after engineering
Reduce project risk
Key Benefits:
The CPU capacity is defined in tree point during a project:
Bid: only no. of CPUs and rough PO volume
Order: CPUs with min. PO volume and the rest via upgrade PO
Engineering without CPU limits
Commissioning: The POs are distributed according load requirements
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Customer
System Expansion Card Upgrade
Connect CPU 410-5H(select PCS 7 project) 2
LicenseManager1Receive Upgrade License
(all order options possible)
CPU 410
7 Transfer Upgrade to CPU
get current PO data
SiemensEmail: Send File to SIEMENS 5 File
3 Allocate Licenses:
File4 Request for Activation
(generates Request File)File
6 Email: Receive Upgrade File Internet connectionof ES / ALM is not necessary
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PA Controller CPU 410 V8.1The One and Only for Process Automation
Functional Extensions
• 2nd Ethernet/PROFINET Interface is activated now!
• Online Extension of Capacity possible in 100 PO steps
• Type Change in RUN
• Selective Download
Hardware changed to support 70 o C
70 o C
Ready for Ethernet/PROFINET: Full connectivity with 2 built-in switches
License Extensions online (Only Pay what you need whenever you need)
Upgrade block types and loading of changes without Controller STOP
Maximal Robustness and Premium Functions with no extra costs!
Key Benefits:
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SIMATIC ET 200SP HFPCS 7 V8.1
• 50% smaller footprint
• New AI HART module
• Enhanced product performance
• Power modules to create load groups are now integrated into the system
• Tool-free connection system due to push-in terminals
• Reduced variety of parts due to function compression
Simple to use - smaller in size – stronger in performance
With PROFINET, replacing ET200S
Key Benefits:
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PROFINET in PCS 7 Innovation with V8.1
Industrial Ethernet, plant bus
PCS 7 OS Server
PROFINET, field bus
ET 200M PN
IE/PB-Link
PROFIBUS DP
Zone 2 Zone 1
AFDiS
PROFIBUS PA or FF-H1AFD
PA/FF-Link
PCS 7 CPU410-5H
PAC 3200/4200 PN
SINAMICS PN
FailsafeAS
Weighing systems
Second PROFINET IO Controller on CPU410-5H (Plantbus/PNIO)
ET 200SP: economic Remote I/O with System redundancy for PROFINET
SIMOCODE PRO V with System redundancy Support (SRP)
Innovative IE/PB-Link with media redundancy (MRP, SRP planed)
SIMOCODE PN
ET 200SP PN
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• Built-in analysis, archiving and reporting of information about bus physics on the fieldbus segment• Trunk and spur status• Segment / spur current and voltage• Signal polarity, signal level and quality • Unbalances (Ground short circuit) and disturbances
• How it works• SIMATIC PDM PO License is required• AFD’s provide physical layer diagnostics for each trunk & spurs• PA / FF-Link collects information and provide segment state • PA / FF-Link performs logic analysis (CRC errors, retry statistics)
PROFIBUS PA
Active Field Distributor
PA Link
AFDiS with integrated fieldbus segment diagnostics
Key Benefits:No separate diagnostics module requiredConfiguration / topology is recognized automatically w/o engineeringRemote control for spurs (on/off) from ES/MS USP!
AFDiS with integrated fieldbus segment diagnostics
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• Customer Specific housing possible (Plastic, Stainless steel etc.)
• Plant/enterprise wide standardization.
• More flexibility for plant construction
• Attractive price
• Link and Coupler in a 40mm wide housing (compared to 120mm today)
• Attractive price
• Multiple links within one Rack Save cabinet space and Cost
• Bus powering 500mA
• Ring redundancy possibleCompact Link
DIN-Rail AFDiSAFDiS w/o housing
DP/FF Compact Link
Fieldbus Components
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SIMATIC PDMThe most powerful Process Device Manager
Ethernet
Process-control station
........AS 41x
FF / PA Link
....
Remote I/O
PCS 7 Engineering
Station ES
PDM PDM SA
PDM SA
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SIMATIC PDM V8.2Now with certification HIST61b
HIST61b• Dynamic Block instantiation• Multiple Capability Level• Enhanced Function Blocks • Profiled custom function blocks• DD V5.1 device-level access (enhanced EDDL with Cross-
Block-Referencing)
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Maintenance StationPDM Web Server Functionality
OS Clients
ES with PDM Webserver
SIMATIC PCS 7 Maintenance StationPDM Web Server functionality
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SIMATIC PCS 7 Maintenance StationPDM Web Server Functionality
• Remote access to PDM Files Devices (e.g. from OS-Client)
• Connection count dependent from ES OS
...AS 1 AS 2 AS n
OS Clients
Maintenance ServerOS Server
ES with PDM Webserver
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Engineering and Operator SystemPCS 7 V8.1
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Type Change in RUN
Update block types and loading the changes without AS STOP
Bumpless changeover of instance data
Key Benefits:
• „Update block types“• recognizes type changed blocks (as today)• creates a copy table for changed instances
• Next Download transfers changes to AS
• A dedicated automation system function is being usedfor bumpless transfer from old FB to new FB,(therefore this feature is only available with AS 410)
• The OS has to be recompiled
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CFC Charts: Selective Compile & Download
Reduced risk of download conflicts, if multiple engineers work simultaneously on the same project.
Activation of finalized / approved delta changes for one controller, while other engineering work is still in progress
Key Benefits:
Description of procedure:
• Make the necessary changes in the function charts
• Changes are indicated in a specific colour (red)
• Select one or several charts
• Right mouse click and select on any Engineering Station: „Selective Download“
• The chart(s) will be compiled automatically
• Specific Icons in the Technological Hierarchy indicate the different states of a chart
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SIMATIC PCS 7 V8.1 Flat system architecture (released with V8.0 SP1) - expanded functional range
Improved consistency in serverless configuration
For small and medium size projects
Up to 8 Single Stations possible
High available plant bus
• The operator action messages of any single station are shown at all single stations (synchronization via PH)
• Last delta download can be repeated in case one single station is not available at download time
Process Historian S7-400H
Operator Station 2
Operator Station 3
Operator Station 6
Red. OS SingleStation pair
Operator Station 1
…
Key Benefits:
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PCS 7 Operator Station – increased quantity structure
PCS 7 OS quantity structure
Maximum number of Server/Server-pair (OS, Batch, RC, PH)
18
Process Objects per OS-Server 12.000 PO
Process Objects per PCS 7 project in total 144.000 PO
Number of OS Clients 40
Maximum number of Web-Clients 100 (in addition to OS Clients)
Note: These are system test limits.
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Next generation Industrial PCs (IPC)PCS 7 V8.1
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IPC547E
High PerformanceIntel Core i7 (4. Generation) Fast DDR3-Memoryup to 32 GByte
High System AvailabilityRedundant Power SupplyRAID1-Configuration with Hot Spare HDD Option
SSDNew SSDs with Capacity 160GB – 480GB based oneMLC Technology with Power Loss Protection for all Data, inclusive Write-Cache
High Flexibility4 PCI, 3 PCIe InterfacesOnboard DUAL Multi Screen Solution with identical Interfaces.
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IPC647D / IPC847D
High Performance Industry Server
XEON Processor
Intel Core i (4. Generation)
Fast DDR3-Memory up to 32 GByte
SAS HDD with HW-RAID Controller (2. delivery step)
High FlexibilityUp to 11 expansion slotsNumerous integrated interfacesOnboard DUAL Multi Screen Solution with identical Interfaces.
High System AvailabilityRAID 1-Configuration with Hot Spare HDD OptionHardware RAID 1/5 Configuration (2. delivery step)ECC RAMRedundant Power Supply with diagnostics functions
SSDNew SSDs with Capacity 160GB – 480GB based oneMLC Technology with Power Loss Protection for all Data, inclusive Write-Cache
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PCS 7 BOX System based on IPC627D
Configurator and 2 Main Hardware Versions
BasicXEON ProcessorFast DDR3-Memory 8GB1 x HDD (250GB SATA)
AdvancedXEON ProcessorFast DDR3-Memory 8GB ECCRAID 1 (2x250GB SATA, 2,5“)
High Flexibility1 x PCI, 1 x PCIeOnboard DUAL Multi Screen Solution with identical Interfaces.AC or DC Power Supply
High System Availability and Long LifeCycleRAID 1-ConfigurationECC RAM5 Years Sales Period, 5 Years Spare Part & Repair
22“ Touch Screen (optional)Resolution 1920 x 1080MTBF LED Backlight: up to 80.000h
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Some more news...PCS 7 V8.1
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PCS 7 Condition Monitoring Library
Economic integration of important mechanical assets in PCS 7 to increase efficiency & availability
Advantages:Early detection of wear
Basis for preventive maintenance Reduced maintenance costs
Detection of "unhealthy" operation and energy consumption Basis for reduced maintenance costs / energy costs
Avoid unnecessary plant standstill !!
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Increase Productivity Maintenance of Mechanical Plant Components
Pumpmonitoring
Operator Alarm
PowerPressTemp Press Flow
M
Operating point
Min. flow
Max. flow
Height characteristicMechanical
power characteristic
Pump efficiency characteristic (Eta)
Current operating
pointCavitations
characteristic
Cavitations range
Early warning range
NPSHa-Characteristic
NPSH charact.
Deviation
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IT Security
SIMATIC PCS 7More News …
ConditionMonitoring
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Industrial SecurityCertification
ACHILLES PRACTICES CERTIFICATIONFor Industrial Control System Equipment Vendors & Integrators
The Achilles Practices Certification (APC) Program provides a security best practices benchmark for vendors and integrators of embedded systems, control applications, host devices, and network components found on process control networks.
As the first Automation vendor Siemens achieved the Achilles Level 2 certificate for communication robustness.
SIEMENS has achieved APC bronze level certification for PCS 7 in Nov 2013
Proven concepts & guided methods
Tested & certified components
Key Benefits:
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Simulation ConditionMonitoring
IT Security
SIMIT
SIMATIC PCS 7More News …
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Why Simulation?Real time operator training is possible only with Simulator
know
ledg
e le
vel
time
2 weeks
Trai
ning
co
urse
at
begi
nnin
g
missing knowledgefor high performance and
safe plant operation
2 weeks
Exte
nded
Ref
resh
er
Trai
ning
knowledge level withrefresher training
Knowledge level with typical training
concept
12 - 24 monthsR
efre
sher
Tr
aini
ng
2 days
Ref
resh
er
Trai
ning
Ref
resh
er
Trai
ning
2 days 2 days
Necessary operator knowledge for high
performance and safe plant operation
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What is Simulation-based Automation Engineering?The Principals and a Configuration Scheme
SIMATIC PCS 7/ SIMATIC S7
SIMATIC PCS 7/ WinCC
Real Plant SIMIT Simulation
Testing the original automation project based on a simulated plant +
No changes to the automation project+
Clear separation between simulation and automation +
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SIMIT Simulation Framework – Flexibility Just the Right Level of Detail
Simulationof Signals
Simulation of Drives / Sensors
Simulation of technological behavior
Emulationof controller
Simulationof techno-
logical behavior
Use of real
controller
Import signal list from engineering system +
STANDARD library with drives and sensors ready-to-use+
Connect to real controller via: Profibus, Profinet, Prodave, OPC+Connect to PLCSIM+
SIMIT build in techno-logical simulation: STANDARD, FLOWNET, CONTEC libraries
+Interfaces to 3rd party simulators: Shared Memory, OPC, Remote Control Interface
+
All signals from and to the automation system +
Necessary granularity to test the original automation project +
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Simulation ConditionMonitoring
PowerControl
IT Securityentspr.
EN 16001
SIMIT
SIMATIC PCS 7More News …
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PCS 7 Power Control grows with customer needsfrom simple monitoring & control to tight integration with automation
Process Control – SIMATIC PCS 7
ClientsOperator Station
System bus
Terminal bus
Engineering andMaintenance Station
redundantPowerControlServer
Ethernet FO
StationController
Switchgear plant
TCP/IPIEC 61850
Ethernet FO
TCP/IPIEC 61850
Switchgear plant
StationGatewaysingle /redundant
Fieldbus PA / FF
AutomationSystem S7-4xxFHredundant
Standard +Safety I/O
redundantOperator StationServer
Power Control – SIMATIC PCS 7 PowerControl
SIMATIC PCS 7
Standard +Safety I/O
Ethernet FO
Switchgear plant
TCP/IPIEC 61850
OS-Option
Switchgear plant
S7-4xx
PRO
FIB
US
DP
SIPR
OTE
C IE
Ds
PAC 4200
SENTRON WL
DP-Integration
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PCS 7 Power ControlPower Control Library (PCL)
PCL
PCS 7 Power Control Library (PCL)APL style OS Faceplates- Identical to OS Option- User specific faceplates possibleTechnological function blocks for electrical utilities e.g.:- Feeder- Machine [Motor, Generator]- Synchronization device- Differential line protection- BusbarPCS 7 CFC EngineeringSIEMENS (SIPROTEC) and 3rd Party devices supported
Use CaseTechnological functions using IED data
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Industry Library
Simulation ConditionMonitoring
IT Security
SIMIT
IL
SIMATIC PCS 7More News …
PowerControl
entspr.EN 16001
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PCS 7operatorstation
S7-4xx Touchpanel
(flexible WinCC)
Local HMIfor PCS 7 on a
touch panel
IL PCS 7APL panel
interface blockPCS 7
Central HMI fora package uniton PCS 7 OS
IL S7 Lib
S7-3xx
Package unit a
IL S7faceplates
APLfaceplates
APL
AdvancedLibrary
Concept
Touchpanel
(flexible WinCC)
IL S7 Lib
Local HMIfor package uniton touch panel
S7-3xx
Package unit b
IL S7panel
faceplate block
Plant Wide IntegrationSystem Libraries – Industry Library
Restricted © Siemens Ltd. India, 2014 All rights reserved.June. - 2014 Siemens Ltd. India, Industrial AutomationPage 43
System architecture SIMATIC PCS 7Mobile Client Web Client
- OS- Maintenance
Data Monitor ERP
OS/Batch/Route Control/Maintenance Clients
Ethernet, Office LAN
Industrial Ethernet, terminal bus
Industrial Ethernet, plant bus
EngineeringStations
Web Server/OpenPCS 7
Route Control server
Batchserver
Maintenance server
PCS 7 BOX OS Single Station
IndustrialWireless LAN
Wireless HART
Weighing systems
Integrated power management
AS-Interface
PROFIBUS DP
Modbus, serial connection
PCS 7 AS RTX Standard
automation systems
ET 200pro
PA/FF link
PA link
AFD
PROFIBUS PA
ET 200M,Ex-I/O, HART
AFDiS
PA/FF
ET 200M
Fault-tolerant automation systems
Safety-related automation systems
Zone 2 Zone 1
PROFIBUS
DP-iS
ET 200M
Y-Link
Gas analysis
AFDiS
PA/FF linkAFD
ET 200M, standard andF modules
ET 200M,F modules
PA linkPROFIBUS PA
OSserver
MES/MIS Plant Lifecycle Man.
Archive serverPH / IS
FrontFirewall
BackFirewall
Zone 1ET 200iSP
ET 200iSP
Zone 2 Zone 1
ET 200M
Autom.systemswith PN
Comos
MTA~
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HQ Offices PA Factory
Siemens Process Automation is well geared through an established Vertical Set-up, Globally Certified Partners and anextensive Service Network
SERVICE CENTERChemical
End-to-end solutions in BasicFine & Specialty chemicals
Food & BeveragesE&A packagesDairy, CPG, Sugar, Breweries, etc.
PharmaceuticalExclusive Pharma Suit with solutions forPAT, eBR, Serialization backed up “Life cycle validation” capabilities
Water / Waste WaterAutomation solution for WTP, STP &desalination plant.
Glass & SolarWaste heat recovery solutionPlant wide integrated solutions
Metals and MineralsSIMETAL, SIROLLCEMAT
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Thank you for your attention!
siemens.com/answers
Sourav Ghosh
Product Manager - PCS 7
Kalwa Works, P.O. Box 85Thane-Belapur Road,
Thane- 400 601 (Maharashtra), INDIA
Tel: +91-(022)-3326 5707E-Mail: [email protected]