Predefine engineering tools for
optimization plant Automation Systems
Ami Drori
Siemens Israel
Industry sector
11/2012
Ami Drori, Siemens Israel
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
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11/2012
Full conceptual of a plant with
Distil Column
Ami Drori, Siemens Israel
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11/2012
P&I Diagram for Distil Column
Piping and instrumentation diagram
cooling
water
Condenser
Reflux
Drum
W1
LIC
1
B1
M
Destillate
Product
(light)
Reflux
P1
TIC
1
FIC
3
Feed
F, xF
FIC
1
K1
Key Performance
Indicators
Automation
TIC
2
condensate
LIC
2
FIC
2
heating
Boil-up
FIC
4
W2
M
heating steam
TIC
3
P-41
Maintenance
Graphics
Reboiler
Advanced
Control
AlarmManagement
Bottom Product
(heavy)
P2
Ami Drori, Siemens Israel
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11/2012
Control room
Ami Drori, Siemens Israel
June 2011
HMI screen
Ami Drori, Siemens Israel
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11/2012
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”)
Ami Drori, Siemens Israel
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11/2012
TIA - Totally Integrated Automation
Ami Drori, Siemens Israel
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11/2012
TIA - Horizontal integration
Production workflow
Inbound
Logistics
Process
Supplier
Customer
Outbound
Logistics
Discrete
Mashing
Lautering
Fermentation
Brew Kettles
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
Design and
engineering
Installation
and
commissioning
Operation
Maintenance
Modernization
and
upgrade
Modernization
and upgrade
Ami Drori, Siemens Israel
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11/2012
TIA - Vertical integration
SAP
ERP
Enterprise Resource Planning
Management level (MES)
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.
TIA - Vertical integration
SAP
ERP
Enterprise Resource Planning
Management level (MES)
Operation level
(SCADA / DCS)
WinCC
PCS 7
Control level
Field level
?‫מה בסה"כ ביקשנו‬
.‫ תכנות קל ואינטואיטיבי‬.1
.‫ תוכנה אמינים‬+ ‫ חומרה‬.2
.‫ אינטגרציה קלה ואמינה של כל מרכיבי מערכת הבקרה‬.3
.‫ השקעה עתידית בטוחה ומשתלמת‬.4
Ami Drori, Siemens Israel
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11/2012
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
Ami Drori, Siemens Israel
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11/2012
End-to-end engineering
Intuitive
Totally Integrated
Automation Portal
Networks
Control
HMI
Drives
Motion
…
Main emphasis on tasks and
users
TIA Portal
Short time-to-market
Smooth integration of
process visualization
and automation
Ami Drori, Siemens Israel
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11/2012
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 base and project consistency.
 Powerful libraries across all
automation objects.
Ami Drori, Siemens Israel
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11/2012
Totally Integrated Automation Portal
One Engineering tool
One tool, Configuration, Networks, Logic, HMI,Drag & Drop
Ami Drori, Siemens Israel
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11/2012
PLC with Profinet communication
Ami Drori, Siemens Israel
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11/2012
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
Ami Drori, Siemens Israel
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11/2012
Security concept
PC-Station
Unknown PCStation
Engineering
HMI
HTTP
Industrial
Ethernet
DCP
SNMP
S7
CP
Industrial
Ethernet
CP
Industrial
Ethernet
SINAMI
CS
SINAMICS
S7-300 with
CP 343-1 Lean
ET 200S
SIMATIC S71200
with CM
1242-5
ET20
0S
Ami Drori, Siemens Israel
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11/2012
Security concept
S7-400
Ami Drori, Siemens Israel
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11/2012
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
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11/2012
HMI screen
Ami Drori, Siemens Israel
June 2011
HMI with Build in Faceplate
Valve One Feedback
Motor
PID controller
Totalizing
Analog Indicator
time counter
Ami Drori, Siemens Israel
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11/2012
Engineering Tools
Ami Drori, Siemens Israel
June 2011
Integrated Engineering
Today‘s 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
Ami Drori, Siemens Israel
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11/2012
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
Ami Drori, Siemens Israel
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11/2012
APC - Advanced Process Control
Control Performance Monitoring
Ami Drori, Siemens Israel
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11/2012
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
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11/2012
APC - Control Performance Monitoring:
Realization in SIMATIC PCS 7 AS-Level
PID function
block
ConPerMon
function block:
„Backpack“ to PID
block
Ami Drori, Siemens Israel
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11/2012
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
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11/2012
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
Ami Drori, Siemens Israel
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11/2012
Totally Integrated Automation
Predefine engineering
tools for optimization
plant
Automation Systems
Thank you
Industrial IT
Industry
TIA Portal drag& Drop
TIA_Benefits
Name :
Company:
Sector:
Phone:
E-Mail:
Ami Drori
Siemens
Industry
054-9151528
amiram.drori@siemens.com
Ami Drori, Siemens Israel
-
11/2012