Siemens Process Automation End-user Summit- 2011 Experience. Technology. Community
SIMATIC PCS 7 SIEMENS Answer for global Trends Dr. Stefan Bamberger Head Product Management Process Automation
INEOS Phenol Production Site, Germany
Decisive Factors for economical Production Challenges in Process Industries Safety Operation with highest availability Maintain safe and secure production condition
Decisive Factors for economical Production Challenges in Process Industries Safety Operation with highest availability Maintain safe and secure production condition Quality Reproducible quality of products Increasing flexibility and productivity Minimizing life-cycle costs, low maintenance costs
Decisive Factors for economical Production Challenges in Process Industries Quality Reproducible quality of products Increasing flexibility and productivity Minimizing life-cycle costs, low maintenance costs Safety Operation with highest availability Maintain safe and secure production condition Environmental Protect. Efficient use of resources Complying with regulations
Digital Enterprise Is Our Long-Term Vision Design & Modernization Operation Engineering Commissioning
SIMATIC PCS 7 is the Interoperability Platform in the Plant ERP PM QM TM OP 1 OP 2 MP Process Control System
SIMATIC PCS 7 for ALL sizes of Application in more than 21 industry segments BERTRAM Electronics, Germany 648 I/O SIMATIC PCS 7 Box automates space flight simulation system Roche Products AG, Switzerland 5,000 I/O 2 redundant OS Servers 1 redundant Archive-Server 3 Engineering Systems Norsk Hydro ASA, Norway 38,000 I/O 6 redundant OS Servers 4 Engineering Systems
Fushun Refinery / Ethylene, China High Scalability with strong Process Integration
Bohrinsel in der Nordsee
Bohrinsel in der Nordsee
Protect Investments Market entry 1979 41 years SIMATIC S5!! Estimated end 2020 1994 SIMATIC S7 1997 SIMATIC PCS 7 Migration paths Teleperm M TI505/PCS/OSx APACS / Quadlog 3 rd party Systems 1980 1990 2000 2010 2020 2030
SIMATIC PCS 7 Continuous DCS Innovation based on Totally Integrated Automation Flexible Redundancy Safety Matrix Batch Route Control Web OS PCS 7 V6 Alarm Management Plant Asset Management Advanced Process Control PA / FF Redundancy PCS 7 V7 Digital Plant @ PCS 7 PROFINET incl. Redundancy Scalable archiving and reporting Windows 7 PCS 7 V8 End of 2011 Totally Integrated Automation
On the way to the Digital Plant Bridging the gap within the Engineering Workflow! Plant Life Cycle Process Design Basic Engineering Detail Engineering Installation & Commissioning Operation & Maintenance Modernization & Upgrade Digital Engineering Process Control System ES OS PCS 7 Asset & Change Management AS PROFIBUS PCS 7
Comprehensive Integration with Comos for all Industries Complex Features for Batch Industries Enhanced Features Sequential function charts Basic Features for Cont. Industries Messages Control logic Transfer of PCS 7 libraries to Comos Bi-directional exchange of CFC charts Hardware engineering Plant hierarchy Symbol table Simatic Hardware Catalogue in Comos available Plausibility & consistency checks
Condition-based and predictive Maintenance through Asset Management and Performance Monitoring Plant Asset Management Performance Monitoring PCS 7 Servers COMOS MRO Customer benefit PDM SITRANS F SIPART PS Maintenance Station Scalance SIMATIC I/O cards S7-400 AS PumpMon Maintenance Station B.data Powerrate SIPAT Extended services Self-diagnostics Status information Maintenance alarms KPIs Maintenance alarms Performance alarms KPIs Performance alarms Customer Benefits: Integrated TIA solution to keep complexity down Reduction of maintenance and life-cycle cost Extension to Performance Monitoring Effort and Complexity
Integrated Plant Asset Management Data flow between Comos and PCS 7 ERP (e.g. SAP) PCS 7 OS real Real time time PCS 7 Plant Asset Management Cyclic and on event Cyclic and on event Comos MRO Plant Asset Management Real time Real time Process PCS 7 Engineering Comos
SIMATIC PCS 7 goes Energy Efficiency PCS 7 Powerrate Introduced on HMI 2010 Increased energy efficiency with SIMATIC PCS 7 Powerrate integrated into SIMATIC PCS 7 (Option) EM demo model available (for PCS 7 and WinCC) Pumpmon block saves energy by stabilization of working point APC Library to reduce energy consumption by 3-10%, increase yield by 2-10% and flow by 1-5% Perfect fit for automation of green technologies E.g. Solar, Poly-silicon, Bio-gas, Bio-ethanol, Desalination, Waste gas treatment, waste combustion, Sustainability = Energy efficiency and more Reduced emissions and less waste by optimized Processes through SIPAT, PCS 7 APC, PCS 7 Route Control
PCS 7 Powerrate Overview Identify / Measuring with SIMATIC PCS 7 and SIMATIC powerrate PCS 7 Controller PROFIBUS SENTRON 3WL Circuit Breaker SENTRON PAC3200 Multifunction- Meter SIMOCODE pro Motor Management SINAMICS Motor Management ET200S Motor Starter PROFIBUS PA Electrical energies via: Circuit Breakers, Multifunction meters, Motor Management Systems, Motor Starter,... Non-electrical energies via: Field Devices (o/4 20mA, HART, Profibus PA, FF)
Reducing operating costs by efficient use of resources Advanced Process Control APC Methods high Online Optimization complexity low Control Performance Monitoring Adaptive Control Gain Scheduling low embedded PID Tuning Soft Sensor Neural Nets Fuzzy Control Operator Training Simulator lean complexity Dynamic Modeling MPC external interfaced high APC Engineering
SIMATIC PCS 7 TeleControl in typical Oil & Gas Applications Remote Terminal Units in Oil- & Gas Metering stations in pipelines & gas networks Valve stations in pipelines Wellhead monitoring and automation incl. Emergency Shut Down (ESD) - Gas Well - Oil Well - Gas injection wells - Water injection wells These applications require integration of both local automation and distributed automation stations
SIMATIC PCS 7 TeleControl in Water & Wastewater Applications Remote Terminal Units in Water- & Waste Water: Control of pump stations Rain Water Buildings Reservoir Buildings Valve Stations in Pipelines These applications require integration of both local automation and distributed automation stations
PCS 7 TeleControl Merge of DCS and TeleControl Philosophy to serve combined Industries SIMATIC PCS 7 OS Clients Engineering Station TeleControl OS-Server (dedicated or double channel) PCS 7 OS-Server (redundant) SINAUT ST7 Modbus IEC 870 DNP V3 central SINAUT TIM TCP/IP serial TCP/IP WAN Router TCP/IP WAN Router AS 41x FH AS 41x Modem Modem WAN WAN WAN widely distributed TeleControl remote stations S7-300 3rd party RTU ET 200S S7-300 3rd party RTU ET 200S S7-300 3rd party RTU S7-300 ET 200M ET 200M PROFIBUS ET 200M ET 200M S7-400 S7-400 S7-400 S7-400 SIMATIC PCS 7 TeleControl SIMATIC PCS 7
Trends on Field Level From conventional to distributed Configurations Conventional Remote I/O E/A Remote I/O for Zone 1 E/A E/A BUS BUS Sub distribution ET 200M Ex-Coupler RS 485-IS Minimal wiring and material overhead ET 200iSP Zone 1 Zone 0
First in World, Failsafe Periphery for Installation in Ex-Zone 1 / 21 up to SIL3 SIMATIC ET 200iSP-F Failsafe IO-Modules for installation up to Ex-Zone 1 / 21; up to SIL 3 Digital Input Modul 8 F-DI NAMUR Digital Output Modul 4 F DO Analog Input Modul 4 F-AI HART + Line monitoring in Ex area up to the sensor / actuator + Benefit in terms of SIL-Calculation, because of integrated Ex-Barriers + Mixed installation with standard modules (on standard TM ) + Complete portfolio Failsafe modules for direct Zone 1 installation
SIMATIC PCS 7 Fieldbus Technologies Fully support of PROFIBUS & FF Key Benefits: No more market entry barriers PCS 7 customers are free to choose their favorite fieldbus according to preferred instrumentation Seamless integration of complete FF functionality AS 41x HF PA-Link PROFIBUS PA No need of 3rd party components Siemens provides complete fieldbus infrastructure (incl. power conditioning & field distribution) Outstanding scalable FF redundancy options FF-H1 link master redundancy (2x IM) Redundant power conditioning (2x Coupler) Ring redundancy (unique selling point) Further improvement of decentralized approach FF-Link Foundation Fieldbus H1 High speed backbone for fieldbus is PROFIBUS and will be PROFINET in future
Homogeneous Integration of Field level Asset protection via future-proof Technology PROFINET ERP MES Ethernet backbone PCS 7 DCS PROFIBUS DP PROFIBUS DP PROFIBUS PA PROFIBUS PA PROFINET PROFINET HART HART FF H1 FF H1 Customer Benefits: Lower Engineering cost Comprehensive diagnostics and easier commissioning Proxy concept ensures investment protection and backward compatibility
PROFINET @ PCS 7 The Future of Fieldbus Infrastructure IE / WSN-PA LINK SITRANS TF280
Wireless technology for Process Automation Level Flow WirelessHART Temperature Example: Brewery Fermentation Mashing Wireless HART Lautering Brew Kettles Pressure Positioner WirelessHART Adapter Temperature GSM WirelessHART Pressure WirelessHART Gateway Yeast Propagation Aging & Storage Filtration Heat Exchangers Industrial Wireless LAN Wireless WAN GPRS EDGE IWLAN Machine Vision 3G/4G Proximity switch Fail safe sensors RFID Filling Line
Industrial Security via Defense in Depth Strategy Potential Threat Physical Security - Physical access to facilities and equipment Policies & procedures -Security management processes -Operational Guidelines -Business Continuity Management & Disaster Recovery Security cells & DMZ -Secure architecture based on network segmentation DCS Firewalls and VPN - Implementation of Firewalls as the only access point to a security cell System hardening - adapting system from default to secure User Account Management - Administration of operator und user rights (role based access control) Patch Management Malware detection and prevention - Anti Virus and Whitelisting Defense in Depth because you should not rely on just one measure
Siemens Strong Partner for a life time The 3 P of Excellence Professional Services: Dedicated Industry Know- How Exchange of experience across industries Partners since 150 years Always RUN a changing System! Excellent Products: Leading technology In-house development In-house production One-stop supplier Seamless integration Support of Standards Openness, Investment protection Project Execution: World-wide presence Standardized processes Power of a major enterprise
BASF, China, 3 P of Excellence
We wish you a successful meeting! Dr. Stefan Bamberger PCS 7 Product Management I IA AS PA PRM E-Mail: stefan.bamberger@siemens.com