AUTOMATIZACIN DE SISTEMAS ELCTRICOS INDUSTRIALES

Predefine engineering tools for

optimization plant Automation Systems

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

E
n
e
r
g
y

M
a
n
a
g

Full conceptual of a plant with

Distil Column

P&I Diagram for Distil Column

Piping and instrumentation diagram

Key
Performance
Indicators

Automati
on
Graphic
s

Advance
dControl
Maintenanc
e

AlarmManageme
nt

Control room

Ami Drori, Siemens Israel

June 2011

HMI screen

The distillation column consists of the following main components:

1. Distillation column
4. Condenser with reflux (Reflux)
2. Feed
5. Extraction of the head product (Light end)
3. Vaporizer-Temperature control cascade
6. Extraction of the bottom product (Heavy end)

TIA - Totally Integrated Automation

TIA - Horizontal integration

Production workflow

Inbound
Logistics

Process

Customer

Hy
bri

d AOutbound
uto
Discrete Pr
Logistics
oce
ma
ti o
s
s
Mashing
n
Lautering

Supplier

Dis
cre
te
Heat Exchangers

Fermentation

Brew Kettles

Yeast Propagation

Plant automation
for all industries

Aging &
Storage

Filtration

Optimization of all phases

your production life cycle
Filling Line

Production
life cycle

Design and
engineering

Installation
and
commissioning

Operation

Maintenance

Modernization
Modernization
and upgrade

and upgrade

Ami Drori, Siemens Israel

11/2012

TIA - Vertical integration

SAP

ERP
Enterprise Resource Planning

Management level (MES)

Operation level
(SCADA / DCS)

WinCC

PCS 7

IC
AT er
SIManag
M

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.

TIA - Vertical integration

SAP
Management level (MES)
Operation level
(SCADA / DCS)
Control level
Field level

WinCC

PCS 7

IC
AT er
SIManag
M

ERP

Enterprise Resource Planning

TIA - Totally Integrated Automation

The Solutions for all your Requirements

TIA

MES

Production modeller
Historian DB

PCS 7

SCADA

Faceplates
Archive
Batch

Archive
Plant Intellig.

Timers
I/Os

Resolution
Memory

Performance
Torque

Meas. ranges
Meas. methods

Entire product
portfolio

Communication Openness and

intl. standards
Diagnostics/
Scalability and
Maintenance
modularity
Engineering
High availability
Safety
Horizontal
Integrated
integration
Security /
Vertical
Traceability
integration
Robustness/
Quality

System
characteristics

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

End-to-end engineering

Intuitive

Totally Integrated
Automation Portal

Networks

Control

HMI

Drives

Motion

TIA Portal
Short time-to-market
Smooth integration of
process visualization
and automation

Main emphasis on tasks

and users

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

Totally Integrated Automation Portal

One Engineering tool
One tool, Configuration, Networks, Logic, HMI,Drag & Drop

PLC with Profinet communication

Basic Architecture
PCS7 Operator
System (OS) & Batch
Clients

PCS7 Operator
System (OS) & Batch
SERVER

AUTOMATION
SYSTEM (AS)

Field network

ET 200
Distributed I/O

Operating System Client

OS & Batch Client
(or OperatorEthernet
Workstation)
TCP/IP
Terminal bus
Terminal Bus
Central Engineering
Operating System Server &
System (ES) for
Batch Server
AS / OS / Batch
Control Network
Industrial Ethernet
System bus
Automation System (AS)
based on SIMATIC S7-xxx
PCS7
Engineering
System (ES)

PROFIBUS / PROFINET
Distributed Peripheral Network
ET 200 distributed racks
containing the Input / Ouput
Modules

Security concept
PC-Station

Unknown PCStation

Engineering
HMI

HTTP

Industrial
Ethernet

DCP

SNMP

CP

Industrial
Ethernet

S7
CP

Industrial
Ethernet

SINAMI
CS
SINAMICS
S7-300 with
CP 343-1 Lean
ET 200S

SIMATIC S71200
with CM
1242-5

ET20
0S

Security concept

S7-400

Security Integrated
SIMATIC Net Product family
Scalance S V3

Scalance M875

CP 343 Adv.

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)

CP443 Adv.

CP 1628

HMI screen

Ami Drori, Siemens Israel

June 2011

HMI with Build in Faceplate

Valve One Feedback

Motor

PID controller

Totalizing

Analog Indicator

time counter

Engineering Tools

Ami Drori, Siemens Israel

June 2011

Integrated Engineering
Todays Situation Using a Motor as an Example

Function chart

3-D model

Cabinet
design
PCS 7 software
configuration

P&ID

Circuit Single-pole representation

diagram

PCS 7 hardware
configuration

APC - Advanced Process Control

Available tools
APC Method
Embedded
in PCS 7

MPC
lean

large

Soft Sensor
Smith
Predictor
Lead-Lag
Control
Feed-Forward
Performance
Control
Monitoring
Override
Control
PID
Tuning
Gain
Scheduling

low

Fuzzy
Control
Operator
Training
Simulator

Integrated / interfaced
3rd party tools
APC Complexity

high

APC - Advanced Process Control

Control Performance Monitoring

APC Tools embedded in PCS 7

e
b
em

APC Engineering Tool

Modeling & Test

APC OS Faceplates
Operation & Control

OS Clients

Engineering
Station ES

ed
d
d

OS-LAN

Ethernet
OS-Server
(redundant)

Industrial Ethernet / Fast Ethernet

APC Runtime Function Blocks

Runtime Calculations

APC - Control Performance Monitoring:

Realization in SIMATIC PCS 7 AS-Level
PID function
block

ConPerMon
function block:
Backpack to PID
block

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

APC - Advanced Process Control

Control Performance Monitoring
Application
impact of online monitoring and support on the performance of
control
Benefits
commissioning

2-3 years

Online Monitoring (+10%)

Good Support

No Monitoring (-25%)
Support
No Monitoring (-40%)
Poor Support
No Monitoring (-40%)
No Support

Time

Totally Integrated Automation

Predefine engineering
tools for optimization
plant
Automation Systems

Thank you
Industrial IT

Industry

TIA Portal drag& Drop

TIA_Benefits