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SIMATIC PCS 7 – Performance you trustwww.siemens.com.twOn the way to the digital plant
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PCS 7 Overview
PCS 7 v8.2 New Feature
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OpennessScalability
SIMATIC PCS 7 Overview
PCS 7 in theIndustries
DCS vsHMI / PLC
PCS 7 Upgrades &Migration
ITSecurity
APC Optimization
EnergyManagement
BatchAutomation
MaterialTransports
IntegratedTelecontrolSafety
IntegratedIntegrated
Field devices
IntegratedMCC & Drives
IntegratedSwitchgear
SimulationFAT/OTS
InformationManagement
Life Cycle & Remote Services
IntegratedEngineering
Plant AssetManagement
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-OptimizationAdvanced Process Control (APC)
What is APC and why?broad term of higher level processcontrol methodsTypical APC functions e.g.:- model based predictive control- soft sensors- Neuronal networks- fuzzy controlimprovement / optimization ofprocess control structure / -strategies
Important functions• fully integrated in SIMATIC PCS 7
(same Look & Feel in ES & OS)• APC by default in PCS 7 APL• MPC with static / economic operation
point optimization• high availability for APC (AS 41xH)• interfaced APC solution for:
- existing customer solutions or- using of 3rd Party APC-Tools
Application examplesModel based predictive control (MPC):- two component distillation (2x2)- cement mill (3x4)- liquid petrol gas evaporator (4x4)Smith Prädiktor:- closed-loop control of analysis valuesGain-Scheduling:- pH-control (non-linear titration curve)- Batch process chem. reactions
Benefits• process deviations (... 75%) and
compensate of them faster• yield (typ. 2...10%)• throughput (1...5%) (const. quality)• energy consumption (3 ... 10%)• manual interventions (workload )
• ROI within short time
Inte
grat
edIn
terf
aced
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Energy Management
What is Energy Management?Determine, improve and analyzeEnergy consumption systematicallyand continuouslyConsideration of economic, technical,and legal aspects in optimizationAll kinds of energy: electricaland non-electrical energiesSee also:DIN 4602, VDI 4601-1, EN 16001
Important functions• Integration of electr. consumers
in SIMATIC PCS 7 (Motor-Mngmt, Multifunction meters, Circuit Breakers,...)
• Visualization of the load profile• Configurable reports
(for cost centers, batches, duration curves)• Load Management with powerrate• Managing of the Energy Circle
Identify – Evaluate - Realize
Application examplesAcquisition of consumption behavior(electrical and non-electr. energies)Visualization of consumptions astrends (duration curves)Identification of saving potentials- Load management / shedding- Controlled mode Use of FU- Use of Energy Saving Motors- Energy Recovery
Benefits• Transparency of Energy costs• avoidance of exceeding set power
limits • ensure adherence to contractually
agreed upon conditions• better procurement conditions by
reduction of energy peaks
• Reduction of total energy costs
B.Data
123
Identify
Evaluate
Realize
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Batch AutomationSIMATIC Batch
What is SIMATIC Batch?SIMATIC Batch is the Software-Package for planning, control andreporting of the batch processeswith different complexity Based on and fully integrated intoSIMATIC PCS 7
Important functions• Fully integrated in PCS 7 - AS/OS/ES • Scalable, modular architecture• Easy graphical recipe generation and
charge planning • Hierarchical recipes acc. to ISA-88• Equipment-independent recipes• Validation support• Interaction with Route Control
Application examplesPharmacy prod. active ingredients
Bio plasmaChemicals dyestuffs
pasty materialsFine chem. flavor materialsBio chem. slow bio chem. reactionF&B beer production
food production
Benefits• Engineering data need to be entered
only once• Flexible use in pilot and production
plants, no expensive spare capacities • Minimization of engineering &
validation effort• Safe production, no loss of batch data
due to redundant server
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What is SIMATIC Route Control?Software for PCS 7 for configuration,control, monitoring and diagnosticsof material transportsParticularly recommended if:- frequently conversions, extensions- Transport routes with high flexibility
(regularly changing materials, dynamicselection source/destination o. transport)
-Material transportsSIMATIC Route Control
Important functions• Fully integration into SIMATIC PCS 7• 1:1 map. route network (graphical)• Consideration of material compatibilities
(avoid mixing)• Exclusive assignment of partial routes• Autom. calculation of shifted quant.• Detailed off- & online diagnostics• Combination with SIMATIC BATCH
Application examplesPharma Blood plasma (CIP)Chemical BiodieselF&B Palm-Oil (truck refinery)Chemical Fertilizer plant (solid stuff)Chemical Poly Resins (hardening)F&B Yoghurt (compatibility)Cement Lime transport (solid stuff)O&G Tank terminal, Tank farm
(„on the Fly“ change)
Benefits• Flexible architecture – acc. plant• High availability redundancy• Fast response plant changes (online)• Reduction of operator workload • Constant / high product quality
(avoiding material mixings)• Plant throughput (Debottlenecking)• 25% Engineering savings
20% of normal commissioning time
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SIMATIC PCS 7 Industry Library
What are Package Units?Discrete machines and aggregatesas operational required infrastructurein process engineering plantsDelivered by specialized machinemanufacturer, completely equippedwith controllerHave to be integrated homogenouslyinto a complete automation solution
Important functions• Integration into PCS 7 - AS / OS / ES • Industry Library with technological
functions for S7-300 (motor, valve, ...)• Faceplates for Industry Library to
monitor & operate of Package Units• Faceplates in a PCS 7 Look&Feel for
Touch Panels connected to S7-300• Faceplates for Touch Panels for local
monitor & operate of a PCS 7 ASExamples of typ. Package Units
Compressed air plantWeighing / dosing stationCentrifugeFilter pressDryerAir conditioning plantCooling aggregateWaste air purification
Benefits• Consistent process control also for
Package Units in the plant- same operation philosophy- same alarming- same system message behavior
• Further increase of the integrationlevel of the plant
• Lever to improve the operational efficiency of the plant
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DCS-PCS 7
Function blocks for specific industries
Simulationandoptimization
Industry library
SIWA solutions
Integrate remote communication and RTU into PCS 7
PCS 7 Telecon-trol and
SINAUT
e.g. Model predictive control
User centric design
Operator Training, virtual
commissio-ning
Simulation(SIMIT)
Advanced process control (APC)
U.C.D. and alarm mgmt
For simple recipe structure, material-handling
Migration path for installed base/ emerging country
Common visualization of all assets
Advanced Process Functionality (APF)
Asset
management
Braumatclassic
Plant wide automation
Power supply for for production of Poly-Si
Heat of glass furnaces generates electrical energy
Seamless during integration and commissioning
Poly power unit
Waste heat recovery
Chemical
Food &beverages
Glass &solar
Water &WW
Pharma
Real time quality prediction
Integrated engineering allows
bidirectional data exchange
e.g. Integration of switch gears
(IEC 61850)
SIPAT
COMOS
PCS 7
Power control
in PCS 7
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Efficient plant engineering
Intuitive plant operations
Mobile plant monitoring
PCS 7 v8.2 New Feature
Efficient plant engineering
Intuitive plant operations
Mobile plant monitoring
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SIMATIC PCS 7 V8.2Logic Matrix
Editor in the form of Safety Matrix for creating interlock logic
Improved efficiency compared to interlock engineering on CFC level
Mapping of Logic Matrix configuration on PCS 7 tools & functions (CFC & APL)
Bulk Editing / Engineering (import / export function)
Reduction of engineering effort for interlocks and shutdown logic
Comfortable and intuitive operation
Customer Benefits
Efficient plant
engineering
Intuitive plant
operations
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SIMATIC PCS 7 V8.2SFC Calculations
Reduce Engineering time: no additional blocks required for calculationsEase of use due to graphical formula editorMore flexibility e.g. subsequent adaption of setpoints
Customer Benefits
Graphical Formula Editor
Support of basic arithmetic operations (+,-,*,/)
Support of Boolean logic (AND, OR, NOT, …)
Support of absolut value, absolute term, square root …
Extended SFC Visualization with formula properties
Efficient plant
engineering
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SIMATIC PCS 7 V8.2New Measuring point browser
Operator function to browse the status information of the measuring points1. Single or multiple areas can be selected,
depending on the user right2. “Loop In” function3. Sorting and filter options4. Print or save the results5. Icons with multi language tooltip Text
Possible Filter Criteria's are defined by PCS 7 APL
Customer BenefitsOverview about all active status information in the plant
1. Manual / Automatic / Program / Local / OOS
2. Intern / Extern
3. Signal Status
4. Active Bypass / Forcing / Tracking
5. Lock Information / Active Reset
6. Active Note
R
12
3
4
5
Intuitive plant
operations
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SIMATIC PCS 7 V8.2 APLAPL Curve Control
One click trend configuration - clicking on the value is adding the value to the trend (A)
Save or close without saving the trend (B)
Unit and ranges taken from the tag
Enabling and disabling of values for better overview (C)
Pre defined time ranges for x-axis or user defined time range setting
Display of messages related to the trend (D)
Easy selection of time range (E)
Customer BenefitsEase of use working with trends
Ctrl
>< |
A
B
D
C
E
Intuitive plant
operations
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SIMATIC PCS 7 V8.2 APGGroup View
Online configuration via block icon (A)
Save and restore of groups
All kind of points are supported
Direct control possible (B)
Open Faceplate for detailed view possible (C)
“Loop In Tag” via tag name jumps to the process picture and is highlighting the point (D)
All messages of points in the group are shown in the message view
Customer Benefits
Load removal of operators
Faster operator reaction
Ctrl
>< |
A
B
CD
Intuitive plant
operations
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SIMATIC PCS 7 V8.2Integration of mobile devices via WinCC WebUX
Flexible access to important plant data Clear display of dataEase installation and configurationSecured plant information as a basis for decisions
Customer Benefits
Device independent use of Smartphones, Tablets and other mobile devices
Zero Client installation
Configuration of appropriate pictures at Graphics Designer
Supported functionality
Alarm visualization and alarm acknowledge
Some important tag (key performance indicators) visualization on IO field and Trend Controls
Mobile plant monitoring
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SIMATIC PCS 7 – For all Industries
Basic Chemicals Biofuels Breweries Cement Chemical Fibers
Dairy Glass Industrial Gases Metals & Mining Oil & Gas
Pharma Polysilicons Pulp & Paper Specialty Chemicals Water & Wastewater
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Thank you for your attention!
David Hsu/DCS
Phone: (07) 823-7237
Mobile: 0960-548 523
E-mail:[email protected]