Welcome
Ruud Welschen
Productmanager Process Control & Safety Systems
Ruud.Welschen@siemens.com
www.siemens.nl/DCS
Definition of an alarm
“A mechanism for informing an operator of an abnormal
process condition for which an operator action is required.”
page 2
11 september 2008
Ruud.Welschen@siemens.com
Simatic PCS 7
Safety Concept of a Plant IEC 61511
Civil
protection
Civil protection
Retention
basin
Passive protection
Pressure-relief
valve,
bursting disk
Safety
system
(automatic)
Active protection
Safety
shutdown
Plant personnel
intervenes
Safety system (SIS)
Process alarm
Process control system
Basis
automation
page 3
Process
data
11 september 2008
Standard behavior
Ruud.Welschen@siemens.com
Simatic PCS 7
Operator reactivity to alarms
100%
Reactivity
80%
60%
40%
20%
Ideal
Critical
Fatal
0%
1
10
100
1.000
10.000
Alarms per 10 minutes
Adapting requirements on the human capabilities
(Recommendation of NAMUR/EEMUA 191)
page 4
11 september 2008
Ruud.Welschen@siemens.com
Simatic PCS 7
Levels of automation according to ISA 99
Level 4
Level 3
Level 2
Level 1
Level 0
page 5
11 september 2008
Ruud.Welschen@siemens.com
Simatic PCS 7
Alarm management procedure
sensor
DCS
Historian
Alarm management
report
Adjust limits or logic
page 6
11 september 2008
Ruud.Welschen@siemens.com
Simatic PCS 7
Difference in DCS or PLC approach
HMI
HMI
DCS
PLC - Scada
Alarm presentation
Alarmstatus
IF “1” text: “Alarm High”
Controller
I/O
2 Sec polling
Alarmstatus
0101010101010101
Alarmtext
I/O
I/O
Eventdriven
IW200 >100 SET M10.1 “1”
I/O Modules
1
2
3
I/O
Field Termination
Field wiring
Field devices
page 7
11 september 2008
Ruud.Welschen@siemens.com
Simatic PCS 7
Basic DCS functionality
sensor
engineer
sim
PID
SP
eng.
4-20mA
lim
de-engineer
0-100%
actuator
4-20mA
lim
alarm
Limit H/L
page 8
11 september 2008
Ruud.Welschen@siemens.com
Simatic PCS 7
Extended DCS functionality
sensor
engineer
sim
PID
SP
eng.
4-20mA
lim
de-engineer
actuator
0-100%
4-20mA
lim
alarm
Urgency
Shift planning
Output
SMS
Limit H/L
Historian
Asset Management
Batch
Route Control
Safety Systems
page 9
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Ruud.Welschen@siemens.com
Simatic PCS 7
Alarm types
Events: Process changes that have to be logged but no operator action is
required and is thus not defined as an alarm.
Process messages: signal process events of the automated process. Such
events include limit value violations of measured values and status information.
Process control messages: are fault messages caused, for example, by the
failure of a component or a wire break affecting a connected I/O signal. This
might be Asset Management messages.
Operating messages are generated each time process variables are
manipulated by an operator, for example, when a controller is switched to a
different mode.
System messages are all messages that are generated by the SIMATIC PCS 7
system and not by the process.
page 10
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Simatic PCS 7
Alarm management techniques
- Include process variable information in alarmline
- Select priorities 0-16 for more important information
- Locking of messages in unused area’s or objects
- Use intelligent sensors for pre-alarming (incrustation level)
- Use build-in statistics for quick analyse
- Time filter for nuisance digital alarms
- Hysteresis filter for nuisance analogue alarms
- Time stamping of alarms in I/O card (1 ms stamping)
- First failure detection
- Manual hiding of specific alarms
- Dynamic state based hiding of alarms
- Integrate Batch alarms in DCS alarm system
- Integrate Safety alarms in DCS alarm system
- Use Plant Asset Management for alarming of non-intelligent devices
page 11
11 september 2008
Ruud.Welschen@siemens.com
Simatic PCS 7
SIMATIC PCS 7 System Functions
Time Synchronization and Time Stamping
Possibilities of time synchronization
OS server is time master with
PC system time
Master Time signal via serial port (GPS / DCF 77 antenna)
Master Time signal via bus from external PC
SICLOCK
Time stamping
Process alarms
Analog block, e.g. "Analog value high"
Motor block, e.g. "Motor fault"
Time stamping cyclic in the AS
Precision: AS scan rate, e.g. 100 msec.
*)
Error messages of the I/O
E.g. "wire break"
Time stamping acyclic in the AS
Precision : approx. 20 msec.
ET200M
Digital signals on the input/output station
Digital signals via IM153-2 / IM151-2
Precision : 1 msec.
ET200iSP
Time master/slave
page 12
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Simatic PCS 7
Operator System
Graphical User Interface
Overview
section
Alarm one line
Navigation
window
Picture
area
Faceplate
Alarm classes
- A Alarm (high / low)
- W Warning (high / low)
- S Control system
- O Operator input prompt
Button
area
page 13
Standard user interface (overview and Picture area, buttons, trends, alarms, faceplates)
is provided by the system - no engineering required !
Easy to operate due to hierarchical structure (top level is each process area) and simple
navigation
11 september 2008
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Simatic PCS 7
SIMATIC PCS 7 Operator System
Alarm Management: Loop in Alarm
Jump: from the overview alarm line directly to the picture / faceplate containing the alarm
A
Loop-in alarm
Alarm with highest priority
in alarm line (overview)
A
A
Jump: from the alarm list directly to the picture / faceplate
A
A
Loop-in alarm
A
Alarm Management by quickly navigating to the source of the fault
page 14
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Simatic PCS 7
PCS 7 Operator Station
Alarm statistics and analysis
call up button
how often
Time between
coming and clearing
Time between coming
and acknowledged
Integrated in PCS 7 standard alarm system
page 15
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Simatic PCS 7
SIMATIC PCS 7 System Functions
OS Alarmlogging of operator actions
Action performed or
Old value / New value
With comment option
Message
Type:
„Operator
Input“
Comment field to
Input reason of change
Date/timeStamp
page 16
Origin
11 september 2008
Operator
Name
Ruud.Welschen@siemens.com
Process
area
Simatic PCS 7
SIMATIC PCS 7 Engineering System
Process Object View: Comprehensive Filter Functions
1
2-level filter
function
2
Selective filtering of relevant parameters allows you to optimize
your configuration activities
page 17
11 september 2008
Ruud.Welschen@siemens.com
Simatic PCS 7
Smart Alarm Hiding
State selector
Filter
Alarms
page 18
11 september 2008
s
Actors
m
ar
Al
Sensors
AS
Logic
Alarms
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Simatic PCS 7
Smart Alarm Hiding
Group 1
Maint
Run
Cip
…31x
Message
Maint
Run
CIP
…31x
Group 2
Maint
Run
Cip
…31x
page 19
11 september 2008
Ruud.Welschen@siemens.com
Simatic PCS 7
SIMATIC PCS 7 Operator System
Alarm Management: Alarm Hiding
Engineering
… than define „hiding rules“
page 20
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Simatic PCS 7
Historian
OS-Clients
• Messages
External
PC
• Batch-Protocols
...
OS-Server
• OS Reports
Packages
• Alternative archive
values
Internet
Explorer
...
Batch-Server
page 21
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Central Archive
Server
Simatic PCS 7
Plant Asset Management Strategies
wear limit
Maintenance alert
wear
failure
wear
reserve
Incrustation
tRest
calibration point
“Not covered”
user adjustable
Good
user adjustable
Maintenance required
Maintenance demanded
Maintenance alarm
operating hours
tact
tfailure
Component Level
Level Switch
Degrees of contamination
page 22
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Simatic PCS 7
Plant Asset Management Strategies
Condition Monitoring of “non-intelligent” components
Monitoring of
- power consumption
- flow
- pressure across the pump
Detection of illegal operation states,
deviation from characteristic curves,
gradual deterioration of performance
Prediction of the remaining life-time
Common and unified symbols for representing the status of all assets
page 23
Good
Announcement of request
for maintenance (low)
Request for maintenance
unknown/not activated
Simulation
Request for maintenance
(medium)
Request for maintenance
activated
Function
control/ local
Maintenance alert
(high)
Request for maintenance
in process
11 september 2008
Ruud.Welschen@siemens.com
Simatic PCS 7
SIMATIC PCS 7 Asset Management
Source for uniform visualization of all field device state
PROFIBUS PA – profile /
FF – status definition
xx Function check / local
override
xx O.K.
xx Update event
xx Function check
xx Maintenance required
x
Uncertain, Process related
On maintenance station
Good device status
PA
HART - status
xx
xx
xx
xx
xx
Malfunction
O.K.
Update event
More status available
e.t.c.
Specific - status
xx
xx
xx
xx
x
Wire break
O.K.
Low range limited
Short current
Channel error
EDD – condition status
xx
xx
xx
xx
x
page 24
-p
ro
file
s
Maintenance alarm
pe
cif
ic
de
fin
itio
n
Maintemance demand
Maintenance request
Siemens specific definition
ition
n
i
f
e
d
cific
e
n
p
rs
tio
i
Use
n
i
ef
d
ific
c
e
sp
ile
of
r
-p
A
P
Simulation
Good.
Maintenance demand
Maintenance request
Configuration change
11 september 2008
Simulation
Out of service
Passivated
Local operation
Update event
Device status unknown
Ruud.Welschen@siemens.com
Simatic PCS 7
SIMATIC PCS 7 Asset Management
Hierarchical Structure
Fast and easy-to-use operation guidance through complete hierarchy
by unified symbols
SIMATIC S7-400
and PROFIBUS
Network
status and selection of
underlaying hierarchy
ET 200M
Station
diagnostic symbol
of the component
Clear hierarchical structure
PROFIBUS
devices
Plant overview
Overview all controllers
Controller (with sub-hierarchy)
PROFIBUS Assets
DP station (e.g. ET 200M)
Intelligent field device
page 25
11 september 2008
Faceplates
for intelligent
devices
Ruud.Welschen@siemens.com
Simatic PCS 7
SIMATIC PCS 7 Asset Management
Uniform View: Identification
Uniform view for all assets according to their information capability
Diagnostic
status
Request status
Direct callup of
SIMATIC PDM
Maintenance status
Direct callup of
HW Config
cyclic information from
application
page 26
11 september 2008
acyclic asset data, e.g.
via PDM
Ruud.Welschen@siemens.com
Simatic PCS 7
SIMATIC PCS 7 Asset Management
Decision Support
The system generates a maintenance proposal (request)
The service staff confirms or changes
Request Status
Maintenance Status
Diagnostic Status
Request status set by
the user
page 27
11 september 2008
Ruud.Welschen@siemens.com
Simatic PCS 7
SIMATIC PCS 7 Asset Management
Asset Report
All important information concentrated
The same structure for all Assets
Asset – Status
Identity
Maintenance Status
Detailed diagnostic
Current massages
page 28
11 september 2008
Ruud.Welschen@siemens.com
Simatic PCS 7
SIMATIC PCS 7 Asset Management
Asset Report as XML
All important information concentrated
The same structure for all Assets
Document Info
Maintenance Status
Current massages
Identity
page 29
11 september 2008
Ruud.Welschen@siemens.com
Simatic PCS 7
Increased Focus on Overall Safety
IEC 61511 / S84-2004
Analyzing the entire Safety Instrumented Function (SIF)
Safety Certified Instruments
Tighter Integration of Safety Instrumentation
DCS
SIS
PS
ESD action
SV
PCV
PT1
PT2
Pressure
Trip Point
Alarm high
Pressure
High Pressure Alarm
Process Control
Normal Pressure
Low level
page 30
11 september 2008
Ruud.Welschen@siemens.com
Simatic PCS 7
SIMATIC PCS 7 Process Safety
Flexible Modular Redundancy (FMR)
DO
DO
DO
DI
AI
AI
DI
AI
Dual
AI
Simplex
Triple
1oo2 Valves
page 31
11 september 2008
Ruud.Welschen@siemens.com
Simatic PCS 7
SIMATIC PCS 7 Process Safety
The “Right” Level of Integration
ENG
ENG
HMI
INTERFACED
DCS
Gateway
ENG
SIS
HMI
INTEGRATED
DCS
SIS
ENG
HMI
COMMON
DCS
page 32
11 september 2008
SIS
Ruud.Welschen@siemens.com
Simatic PCS 7
SIMATIC BATCH
Online Operation, integrated alarming and operator action log
Start
Hold
Complete
Hold after Step Resume
Abort
SIMATIC BATCH
Fulfills 21 CFR Part 11
page 33
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Simatic PCS 7
SIMATIC Route Control
Example of a Material Transport
Source tanks
T1
T2
T3
Destination tanks
T4
T5
T6
T7
Material transport
page 34
11 september 2008
Ruud.Welschen@siemens.com
Simatic PCS 7
RC Block symbol & Faceplate
Block symbol
Route name & state
Pending messages
Route Control faceplate
Source / destination / via
Modes
Open:
SFC, Batch CC, RC Center
page 35
11 september 2008
Ruud.Welschen@siemens.com
Simatic PCS 7
Route Control Center
Monitoring and Controlling your material transfers
Upper frame: List of all transfers
Bottom frame: Elements, modes, setpoint value
(command) and actual value (feedback of the
process)
Green: Ok, Yellow: mode pending, Red: Error /
11 september
2008
page 36
Ruud.Welschen@siemens.com
timeout / mode
error
Simatic PCS 7
Alarm Control Center...
early informing
early informing
by using an alarm management system
controlled
process
alarm
management
service
personnel
process failure
page 37
11 september 2008
Ruud.Welschen@siemens.com
Simatic PCS 7
x
Generating the event > direct from PCS 7
SICALIS PMC
production management
systems
process management systems
visualization
systems
logistic solutions
Alarm Control
Center...
... can be connected to
virtually any system to
send messages from this
system thanks to a lot of
available system specific
and
open interfaces.
building automation
systems
...
Alarm Control Center
any other system
page 38
11 september 2008
Ruud.Welschen@siemens.com
Simatic PCS 7
x
Alarm Control Center...
person and shift management
realization of basic personell / shift definitions with the
integrated shift and person management
MO
... FR
08:00–17:00
day shift
17:01–07:59
Alarm Control Center
SA
&SU
night shift
weekend
standby
possibility to connect to existing personell and shift management
systems
page 39
11 september 2008
Ruud.Welschen@siemens.com
Simatic PCS 7
x
Alarm Control Center...
the output response to the requirements
…forwards error messages from
control and visualization systems
to any recipient (mobile phone SMS,
pager, DECT telephone, fixed network telephone, facsimile, LAN
message to PC‘s and wireless
PDA‘s, printers, e-Mail, etc.).
control- / visualization
system
page 40
Alarm Control Center
11 september 2008
any
further...
Ruud.Welschen@siemens.com
e-M@il
Simatic PCS 7
x
s
SIMATIC PCS 7
Takes you beyond the limits !
Thank you !