siemens - distributed control system

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

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


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

1-2 • Copyright © ARC Advisory Group • ARCweb.com • For Internal Use Only


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 7

SIMATIC 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 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.



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

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


Simatic PCS 7 Functional View

SI MATI C I TProduction Management/ MES

Simatic PCS 7

Continuous

Batch

Safety

Logic

Common Controllers and I / O

Common Profibus PA Field Network

Common HMI and Engineering

ISA

-88

Stru

ctu

res

I SA-95 Definitions

Common Profibus DP/ PROFIsafe/ Industrial Ethernet Control Network

Common I ndustrial Ethernet Network

SI MATI C I TProduction Management/ MES

Simatic PCS 7

Continuous

Batch

Safety

Logic

Continuous

Batch

Safety

Logic

Common Controllers and I / O

Common Profibus PA Field Network

Common HMI and Engineering

ISA

-88

Stru

ctu

res

I SA-95 Definitions

Common Profibus DP/ PROFIsafe/ Industrial Ethernet Control Network

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 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. 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 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. 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.


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Complete Scope of Migration Services

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Complete Scope of Migration Services

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

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.


siemens - distributed control system

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