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Restricted / © Siemens AG 2014. All Rights Reserved. siemens.com/answers

PCS 7 Innovations - 2014Sourav Ghosh, Siemens Ltd., Product Management – Process Automation

Siemens Process Automation Conference (SPACe) 2014, Gurgaon, India


Automation System HighlightsPCS 7 V8.1

Restricted / © Siemens AG 2014. All Rights Reserved.

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


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

+


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


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


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


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


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:


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:


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


• 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


• 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


Field ManagementPCS 7 V8.1


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


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)


Maintenance StationPDM Web Server Functionality

OS Clients

ES with PDM Webserver

SIMATIC PCS 7 Maintenance StationPDM Web Server functionality


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


Engineering and Operator SystemPCS 7 V8.1


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


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


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:


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.


Next generation Industrial PCs (IPC)PCS 7 V8.1


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.


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


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


Some more news...PCS 7 V8.1


SIMATIC PCS 7More News …

ConditionMonitoring


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 !!


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


IT Security


ConditionMonitoring


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:


Simulation ConditionMonitoring

IT Security

SIMIT



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


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 +


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 +



PowerControl

IT Securityentspr.

EN 16001

SIMIT



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


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


Industry Library


IT Security

SIMIT

IL


PowerControl

entspr.EN 16001


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 Automation

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~


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


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]

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