1. Predefine engineering tools for optimization plant Automation Systems
Ami Drori
Siemens Israel
Industry sector
11/2012
Ami Drori, Siemens Israel

2. Energy Management with SIMATIC PCS 7
Automation System for Process Control
How to implement automation system?
For example:
How to implement distil column?
The challenge
Standard Automation System
Advance automation system (APC)
Predefine solutions
Ami Drori, Siemens Israel /2012

3. Full conceptual of a plant with Distil Column
Ami Drori, Siemens Israel /2012

4. P&I Diagram for Distil Column Piping and instrumentation diagram
Key Performance Indicators
AdvancedControl
Automation
Maintenance
Graphics
Alarm-Management
Ami Drori, Siemens Israel /2012

5. Control room
Ami Drori, Siemens Israel
June 2011

6. HMI screen
Ami Drori, Siemens Israel /2012

7. The distillation column consists of the following main components: 1
The distillation column consists of the following main components: 1. Distillation column Condenser with reflux (“Reflux”) 2. Feed Extraction of the head product (“Light end”) 3. Vaporizer-Temperature control cascade 6. Extraction of the bottom product (“Heavy end”)
Ami Drori, Siemens Israel /2012

8. TIA - Totally Integrated Automation
Ami Drori, Siemens Israel /2012

9. TIA - Horizontal integration
Production workflow
Inbound Logistics
Process
Discrete
Outbound Logistics
Supplier
Customer
Hybrid Automation
Process
Mashing
Lautering
Fermentation
Brew Kettles
Discrete
Yeast Propagation
Heat Exchangers
Plant automation for all industries
Aging &
Storage
Filtration
Optimization of all phases your production life cycle
Filling Line
Production life cycle
Installation and commissioning
Modernization and upgrade
Design and engineering
Modernization and upgrade
Operation
Maintenance
Ami Drori, Siemens Israel /2012

10. TIA - Vertical integration
SAP
ERP
Enterprise Resource Planning
Management level (MES)
SIMATIC
Manager
WinCC
PCS 7
Operation level (SCADA / DCS)
Control level
Field level
TIA integrates all the components that you need in a plant or Machine,
from the field level (Process Instruments, Motors, Valves…) through the Control level (PLC), Operation level (SCADA / HMI / DCS)
to the Management level (MES) and the ERP.

11. TIA - Vertical integration
Field level
Operation level (SCADA / DCS)
Management level (MES)
Control level
PCS 7
WinCC
SIMATIC
Manager
SAP
ERP
Enterprise Resource Planning
מה בסה"כ ביקשנו?
1. תכנות קל ואינטואיטיבי.
2. חומרה + תוכנה אמינים.
3. אינטגרציה קלה ואמינה של כל מרכיבי מערכת הבקרה.
4. השקעה עתידית בטוחה ומשתלמת.
Ami Drori, Siemens Israel /2012

12. TIA TIA - Totally Integrated Automation
The Solutions for all your Requirements
Resolution
Memory …
Archive
Plant Intellig.
MES
PCS 7
SCADA
Production modeller
Historian DB
Faceplates
Batch
Timers
I/Os
Meas. ranges
Meas. methods
Entire product portfolio
Performance
Torque
System characteristics
Communication
Diagnostics/ Maintenance
Engineering
Safety Integrated
Security / Traceability
Robustness/ Quality
TIA
Openness and intl. standards
Scalability and modularity
High availability
Horizontal integration
Vertical integration
Automation requirements
End customer/OEM/SI
Production transparency
Flexible + faster production innovation
Minimize set-up times
Reduce downtime
Investment protection
Reusability
Globalization/ International market access
Faster time to market
Reduction in costs (TCO) …
Business and economic requirements
Ami Drori, Siemens Israel /2012

13. End-to-end engineering Totally Integrated Automation Portal
Intuitive
Totally Integrated Automation Portal
Networks
Control
HMI
Main emphasis on tasks and users
Drives
Motion …
TIA Portal
Short time-to-market
Smooth integration of process visualization and automation
Ami Drori, Siemens Israel /2012

14. Individual engineering systems
Totally Integrated Automation Portal One Engineering tool for: Intuitive – efficient – future proof
Individual engineering systems
Separate software packages are limited
because they lack consistency and integration.
We need One Engineering Framework – to achieve full integration and consistency of individual products.
A common user interface concept for all automation
tasks with common services like: configuration, communication, PLC programming,
Visualization and online diagnostics.
Automatic data and project consistency
Powerful libraries across all automation objects
Ami Drori, Siemens Israel /2012

15. Totally Integrated Automation Portal One Engineering tool
One tool
, Configuration
, Networks
, Logic
, HMI
,Drag & Drop
Ami Drori, Siemens Israel /2012

17. PLC with Profinet communication
Ami Drori, Siemens Israel /2012

18. Basic Architecture Operating System Client OS & Batch Client
(or Operator Workstation)
PCS7 Operator System (OS) & Batch Clients
Ethernet TCP/IP
Terminal bus
Central Engineering System (ES) for
AS / OS / Batch
Terminal Bus
Operating System Server & Batch Server
PCS7 Operator System (OS) & Batch SERVER
PCS7 Engineering System (ES)
Control Network
Industrial Ethernet System bus
Automation System (AS) based on SIMATIC S7-xxx
AUTOMATION SYSTEM (AS)
Field network
PROFIBUS / PROFINET Distributed Peripheral Network
ET 200 distributed racks containing the Input / Ouput Modules
ET 200
Distributed I/O
Ami Drori, Siemens Israel /2012

19. Security concept Unknown PC-Station PC-Station Engineering HMI HTTP
SNMP
DCP
Industrial Ethernet S7 CP
Industrial Ethernet CP
Industrial Ethernet
SINAMICS
SINAMICS
S7-300 with CP Lean
SIMATIC S with CM
ET200S
ET 200S
Ami Drori, Siemens Israel /2012

20. Security concept
S7-400
Ami Drori, Siemens Israel /2012

21. Security Integrated SIMATIC Net Product family
Scalance S V3
Scalance M875
CP 343 Adv.
CP443 Adv.
CP 1628
SOFTNET Security Client V4
VPN
■ VPN Client for establishing a secure VPN channel from PCs to Security CPs or SCALANCE S
NEW:
■ For Windows 7 (64 Bit)
■ VPN-channel also possible to SCALANCE M875 (client-to-client)
Ami Drori, Siemens Israel /2012

22. HMI screen
Ami Drori, Siemens Israel
June 2011

23. HMI with Build in Faceplate
Valve One Feedback
Motor
Analog Indicator
PID controller
Totalizing
time counter
Ami Drori, Siemens Israel /2012

24. Engineering Tools
Ami Drori, Siemens Israel
June 2011

25. Integrated Engineering Today‘s Situation Using a Motor as an Example
3-D model
Function chart
PCS 7 software configuration
Realisierung der Integration von Anlagenplanung und Automatisierungs-Engineering in drei Stufen:
Die Integration von Anlagenplanung und Automatisierungs-Engineering erfolgt in mehreren Stufen bis zur vollständigen Verknüpfung der klassischen EMSR Technik als Teil der Anlagenplanung mit der Automatisierung.
Dabei werden für den Endkunden die für den Anlagenbetrieb und die Wartung und Instandhaltung wichtigen Funktionalitäten der Integration von COMOS und PCS 7 nach und nach vollumfänglich nutzbar.
Stufe 1 - Stand heute, am Beispiel eines Motors:
Hardware- und Messstellendaten, Ein-/Ausgänge und CFCs werden in COMOS geplant bzw. erstellt.
Der objektorientierte, bidirektionale Datenaustausch zu SIMATIC PCS 7 erfolgt ab Oktober 2011 mit den Funktionalitäten:
Übertragung der Hardwarekonfiguration
Übertragung der Anlagenstruktur
Typbasierte Generierung der Einzelsteuerebene
Cabinet design
P&ID
Circuit diagram
Single-pole representation
PCS 7 hardware configuration
Ami Drori, Siemens Israel /2012 25

26. APC - Advanced Process Control Available tools
APC Method
Embedded
in PCS 7
lean
large
MPC
Soft Sensor
Smith
Predictor
Fuzzy
Control
Lead-Lag
Feed-Forward
Control
Control
Performance
Monitoring
Operator
Training
Simulator
Override
Control
PID
Tuning
Gain
Scheduling
Integrated / interfaced
3rd party tools
low
APC Complexity
high
Ami Drori, Siemens Israel /2012

27. APC - Advanced Process Control Control Performance Monitoring
Ami Drori, Siemens Israel /2012

28. APC Tools embedded in PCS 7
APC Engineering Tool
Modeling & Test
APC OS Faceplates
Operation & Control
OS Clients
Engineering Station ES
OS-LAN
Ethernet
OS-Server (redundant)
Industrial Ethernet / Fast Ethernet
APC Runtime Function Blocks
Runtime Calculations
Ami Drori, Siemens Israel /2012

29. ConPerMon function block: „Backpack“ to PID block
APC - Control Performance Monitoring: Realization in SIMATIC PCS 7 AS-Level
ConPerMon function block: „Backpack“ to PID block
PID function block
Ami Drori, Siemens Israel /2012

30. APC - Control Performance Monitoring: Realization in SIMATIC PCS 7 OS-Level
Control Performance Status
Control Performance Index
Standard Deviation of Process Variable
Mean value of Control Error
Mean value of Manipulated Variable
Estimated Steady State Process Gain
OS faceplate
of PID controller
Ami Drori, Siemens Israel /2012

31. APC - Advanced Process Control Control Performance Monitoring
Application
impact of online monitoring and support on the performance of control
Benefits
Online Monitoring (+10%)
Good Support
commissioning
2-3 years
No Monitoring (-25%)
Support
No Monitoring (-40%)
Poor Support
Time
No Monitoring (-40%)
No Support
Ami Drori, Siemens Israel /2012

32. Totally Integrated Automation

33. Predefine engineering tools for optimization plant Automation Systems
Thank you
Name : Ami Drori
Company: Siemens
Sector: Industry
Phone:
Industrial IT
Industry
TIA Portal drag& Drop
TIA_Benefits
Ami Drori, Siemens Israel /2012