Siemens Process Automation End-user Summit- 2011

Experience. Technology. Community

SRAES @ Goa 2011

SIMATIC PCS 7
SIEMENS Answer for global Trends

Dr. Stefan Bamberger

Head Product Management Process Automation
SRAES @ Goa 2011

INEOS Phenol Production Site, Germany

SRAES @ Goa 2011 2011-08-10/11 Industry Sector

Decisive Factors for economical Production

Challenges in Process Industries

Safety Operation with highest availability Maintain safe and secure production condition

SRAES @ Goa 2011 2011-08-10/11 Industry Sector

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

SRAES @ Goa 2011 2011-08-10/11 Industry Sector

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

SRAES @ Goa 2011 2011-08-10/11 Industry Sector

Digital Enterprise Is Our Long-Term Vision

Design & Modernization Engineering

Operation

Commissioning
SRAES @ Goa 2011 2011-08-10/11 Industry Sector

SIMATIC PCS 7 is the Interoperability Platform in the Plant

ERP

PM

QM

TM

OP1 OP2

MP

Process Control System

SRAES @ Goa 2011 2011-08-10/11 Industry Sector

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

SRAES @ Goa 2011 2011-08-10/11 Industry Sector

Fushun Refinery / Ethylene, China High Scalability with strong Process Integration

SRAES @ Goa 2011 2011-08-10/11 Industry Sector

Bohrinsel in der Nordsee

SRAES @ Goa 2011 2011-08-10/11 Industry Sector

Bohrinsel in der Nordsee

SRAES @ Goa 2011 2011-08-10/11 Industry Sector

Protect Investments
Market entry 1979

41 years SIMATIC S5 !! SIMATIC S7 SIMATIC PCS 7 Teleperm M TI505/PCS/OSx APACS / Quadlog

3rd party Systems

Estimated end 2020

1994 1997

Migration paths

1980

1990
2011-08-10/11

2000

2010

2020

2030
SRAES @ Goa 2011 Industry Sector

SIMATIC PCS 7 Continuous DCS Innovation based on Totally Integrated Automation

Digital Plant @ PCS 7 PROFINET incl. Redundancy Alarm Management Plant Asset Management Flexible Redundancy Safety Matrix Batch Route Control Web OS Advanced Process Control PA / FF Redundancy Scalable archiving and reporting Windows 7

PCS 7 V7

PCS 7 V8 2011 f o End

PCS 7 V6

Totally Integrated Automation

SRAES @ Goa 2011 2011-08-10/11 Industry Sector

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

Asset & Change Management

PCS 7

AS

PROFIBUS

PCS 7

SRAES @ Goa 2011 2011-08-10/11 Industry Sector

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 Simatic Hardware Catalogue in Comos available Plausibility & consistency checks

Transfer of PCS 7 libraries to Comos Bi-directional exchange of CFC charts Hardware engineering Plant hierarchy Symbol table

SRAES @ Goa 2011 2011-08-10/11 Industry Sector

Condition-based and predictive Maintenance

through Asset Management and Performance Monitoring
Plant Asset Management
PCS 7 Servers COMOS MRO PumpMon Maintenance Station B.data Powerrate SIPAT Extended services

Performance Monitoring

Customer benefit

Maintenance Station PDM SITRANS F SIPART PS Scalance SIMATIC I/O cards S7-400 AS

Self-diagnostics

Status information Maintenance alarms

KPIs Maintenance alarms Performance alarms

KPIs Performance alarms

Effort and Complexity

Customer Benefits:

Integrated TIA solution to keep complexity down Reduction of maintenance and life-cycle cost Extension to Performance Monitoring
2011-08-10/11

SRAES @ Goa 2011 Industry Sector

Integrated Plant Asset Management

Data flow between Comos and PCS 7
ERP (e.g. SAP)

PCS 7 OS

Real time real time

PCS 7 Plant Asset Management

Cyclic and on event Cyclic and on event

Comos MRO Plant Asset Management

Real time

lt ea

im

Process

PCS 7 Engineering

Comos

SRAES @ Goa 2011 2011-08-10/11 Industry Sector

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

SRAES @ Goa 2011 2011-08-10/11 Industry Sector

PCS 7 Powerrate
Overview
Identify / Measuring with SIMATIC PCS 7 and SIMATIC powerrate PCS 7 Controller
PROFIBUS

SENTRON SIMOCODE pro PAC3200 Motor MultifunctionManagement Meter SENTRON 3WL SINAMICS Circuit Breaker Motor Management

PROFIBUS PA

ET200S Motor Starter

Electrical energies via: Circuit Breakers, Multifunction meters, Motor Management Systems, Motor Starter, ... Non-electrical energies via: Field Devices (o/420mA, HART, Profibus PA, FF)
SRAES @ Goa 2011 2011-08-10/11 Industry Sector

Reducing operating costs by efficient use of resources

Advanced Process Control APC Methods
high Online Optimization

e mb
complexity

dde d

Dynamic Modeling
lean

MPC
external

Soft Sensor Neural Nets Fuzzy Control Control Performance Monitoring Gain Scheduling
Operator Training Simulator

PID Adaptive Tuning Control

ace f r e t in

low low
2011-08-10/11

complexity

high SRAES @ Goa APC Engineering

2011

Industry Sector

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
SRAES @ Goa 2011 2011-08-10/11 Industry Sector

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
SRAES @ Goa 2011 2011-08-10/11 Industry Sector

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
central SINAUT TIM Modem
widely distributed TeleControl remote stations

Modbus
TCP/IP serial Modem 3rd party RTU ET 200S

IEC 870
TCP/IP WAN Router

DNP V3
TCP/IP WAN Router AS 41x FH AS 41x

WAN
3rd party RTU

WAN
3rd party RTU ET 200M PROFIBUS ET 200M

WAN
S7-300

ET 200S ET 200M

ET 200M

S7-300 S7-400 S7-400

S7-300 S7-400

S7-300

S7-400

SIMATIC PCS 7 TeleControl

2011-08-10/11

SIMATIC PCS 7

SRAES @ Goa 2011 Industry Sector

Trends on Field Level

From conventional to distributed Configurations
Conventional Remote I/O
E/A E/A BUS BUS Ex-Coupler RS 485-IS

Remote I/O for Zone 1

E/A

Sub distribution

ET 200M

Minimal wiring and material overhead

ET 200iSP

Zone 1

Zone 0
SRAES @ Goa 2011 2011-08-10/11 Industry Sector

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

SRAES @ Goa 2011 2011-08-10/11 Industry Sector

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 AS 41x HF PA-Link PROFIBUS PA

Seamless integration of complete FF functionality 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) FF-Link Foundation Fieldbus H1

Further improvement of decentralized approach

High speed backbone for fieldbus is PROFIBUS and will be PROFINET in future

SRAES @ Goa 2011 2011-08-10/11 Industry Sector

Homogeneous Integration of Field level

Asset protection via future-proof Technology PROFINET
ERP MES Ethernet backbone

PCS 7
DCS PROFIBUS DP

PROFIBUS DP

PROFIBUS PROFIBUS PA

PA

PROFINET HART
FF H1

PROFINET

HART

FF H1

Customer Customer Benefits: Benefits:

Lower Engineering cost Comprehensive diagnostics and easier commissioning Proxy concept ensures investment protection and backward compatibility
SRAES @ Goa 2011 2011-08-10/11 Industry Sector

PROFINET @ PCS 7
The Future of Fieldbus Infrastructure

IE / WSN-PA LINK

SITRANS TF280

SRAES @ Goa 2011 2011-08-10/11 Industry Sector

Wireless technology for Process Automation

Level Flow
le: ry we Bre
Mashing Lautering

Pressure Positioner

WirelessHART Temperature

mp E xa

WirelessHART Adapter Temperature

Wireless Fermentation HART

WirelessHART Pressure
Yeast Propagation

GSM

Brew Kettles

Heat Exchangers Aging & Storage Filtration

GPRS
Wireless WAN

WirelessHART Gateway

Industrial Wireless LAN

EDGE

IWLAN Machine Vision

3G/4G

Proximity switch Fail safe sensors RFID

Filling Line

SRAES @ Goa 2011 2011-08-10/11 Industry Sector

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

System hardening

access point to a security cell

- 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
2011-08-10/11

SRAES @ Goa 2011 Industry Sector

Siemens Strong Partner for a life time

The 3 P of Excellence
Excellent Products:
Leading technology In-house development

Professional Services:
Dedicated Industry KnowHow Exchange of experience across industries Partners since 150 years

In-house production One-stop supplier

Always RUN a changing System !

Seamless integration Support of Standards Openness, Investment protection

Project Execution:
World-wide presence Standardized processes Power of a major enterprise
SRAES @ Goa 2011 2011-08-10/11 Industry Sector

BASF, China, 3 P of Excellence

SRAES @ Goa 2011 2011-08-10/11 Industry Sector

We wish you a successful meeting!

Dr. Stefan Bamberger PCS 7 Product Management I IA AS PA PRM E-Mail: stefan.bamberger@siemens.com

SRAES @ Goa 2011