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trends in distributed control systems

trends in distributed control systems. Dr. G.U. Spohr Siemens A&D ST2. Automation & Drives April 2005. Introduction. Some major technological trends which will influence the design of current and future decentralized control systems : Intelligent Field-Devices and Asset Management

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trends in distributed control systems

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  1. trends in distributed control systems Dr. G.U. Spohr Siemens A&D ST2 Automation & Drives April 2005

  2. Introduction • Some major technological trends which will influence the design of current and future decentralized control systems : • Intelligent Field-Devices and Asset Management • Communication Technology • Redundant Profibus PA Fieldbus • Gigabit Ethernet • Wireless LAN • Web – Technology • Management Execution Systems MES

  3. Intelligent sensor- and actor-systems • intelligent sensor- and actor-systems often provide additional information • acoustic pump monitoring • valve diagnostics • internal self diagnosis • ........ • these informations are transferred to the control system using HART or a fieldbus communication • .... but where do I evaluate these informations ? Asset Management

  4. Integrated Plant Asset Management • Plant Asset Management Systems integrated in SIMATIC PCS 7provides online, real time functions : • Monitoring of the components • Message at status change • Display of diagnostic information • Creation of maintenance request • Tracking of the maintenance activities Asset Management Monitoring Diagnostics MaintenanceRequest Maintenance SIMATIC PCS 7 Plant Asset Management • Main benefits of the implementation : • Homogenous integration into the SIMATIC PCS 7 environment • Maintenance Station integrated into OS or as a dedicated station • Common visualization (symbols, faceplates) of all assets (unified assets) • Automatic generation of all Asset Management diagnostic pictures • Consequent implementation of NAMUR recommendations NA 64 & NE 91

  5. Asset Management – Operating & Monitoring • OS Clients with accessto maintenance area(pictures, messages, faceplates) • Maintenance Station hasadditionally direct onlineaccess to PDM andhardware engineering OS MS OS OS MS ... Asset Management C 1 C n ... AS 1 AS 2 AS n S 1 S n ... AS 1 AS 2 AS n ... AS – Automation System C – Client MS – Maintenance Station OS – Operator Station S – Server • Maintenance Stationintegrated inOperator Station Maintenance Pictures • All SIMATIC PCS 7 components with diagnostic functions included • Common and unified symbols for representing the status of all assets Good Announcement of request for maintenance (low) Request for maintenance unknown/not activated Simulation Request for maintenance(medium) Request for maintenance activated Functioncontrol/ local Maintenance alert (high) Request for maintenancein process

  6. Integrated „Plant Asset Management“Hierarchical Structure Fast and easy-to-use operator guidance through complete hierarchyby unified symbols Asset Management SIMATIC S7-400 and PROFIBUS Network status and selection of underlying hierarchy ET 200M Station diagnosis symbolof the component • Clear hierarchical structure • Plant overview • Overview all controllers • Controller (with sub-hierarchy) • PROFIBUS Assets • DP station (e.g. ET 200M) • Intelligent field device PROFIBUS Assets Faceplatesfor intelligent device

  7. OS OS MS ... C 1 C n ... S 1 S n AS 1 AS 2 AS n ... Integrated „Plant Asset Management“Automatic generation of hierarchical diagnostic pictures Asset Management Plant • Plant view inSIMATIC PCS 7 engineering • Automatic generation of diagnostic area • Operating and monitoring • hierarchical pictures • asset symbols with faceplates • alarm linking • Engineering • CFC charts with diagnostic blocks Unit 1 Unit 2 Boiler 21 Diagnosis Diagnosis AS - Station CP1 - Field bus CP2 - Field bus No engineering overhead !!! All Asset Management related infor-mation is generated automatically !!! Remote I/O DP/PA - Link Link Picture CFC

  8. PROFIBUS PA- Redundancy Possible Failures in a PA- Segment Profibus PA Redundancy

  9. PROFIBUS PA- Redundancy Basic Concept Profibus PA Redundancy

  10. SIMATIC PCS 7 system bus: flexibility in communication • 1 Gbps, ring topology:Double ring topology for Plant bus (double redundant)Fiber optic or twisted pairSwitching technology • High performance variant:Industrial Fast Ethernet (100 Mbit/s, redundant) • Normal requirement:Industrial Ethernet (10Mbits/s, redundant) • Introductory solution:Basic Communication Ethernetvia normal LAN connection 1 GB Ethernet High communication capacity even for "XXL applications“ providing total system stability and high availability ! Gigabit Plant Backbone SCALANCE X208 SCALANCE Serie X400

  11. Wireless LAN –These are the most important requirements Wireless LAN Cyclic data traffic (deterministics) Redundancy Reliable Monitoring of the radio connection Stable radio connection Metal housing with high degree of protection Robust Protection against vibration and shock Extended temperature range Easy configuration Secure Access control (authentication) Encoding of the data WIRELESS – AS RELIABLE AS WIRE!

  12. Reliable Cyclic data traffic Data Data Data rates rates rates 802.11 802.11 802.11 reserv. reserv. reserv. T1 Time T2 T3 T4 T5 Wireless LAN T6 Node 4 is allowed access to the radio channel „only“ in the 3rd cycle Nodes 1, 2 and 3 may access predictably the radio channel, controlled through Robust Access Point • Conform with 802.11, SCALANCE W guaranteed data reservation • Any client devices applicable (non-SIMATIC as well) Cyclic data traffic, well known from fieldbusses

  13. Reliable Redundancy Mode Wireless LAN • Transmission of the data via two different radio channels e.g. by disturbance switching from 2,4 GHz at 5 GHz or vice versa. Redundancy increases the availability and reduces the sensitivity to interference

  14. Secure Security settings Security levels: Wireless LAN When choosing‘none‘ no security level is activated! The required security level is achieved by one software setting

  15. Secure Secure Comparison of SCALANCE W / SCALANCE S Secure • SCALANCE W-700 withWPA, TKIP, MIC and AES • Authentication (Who am I?) • Coding • SCALANCE S-600 with IPsec VPN tunneling and Firewall • Authentication (Who am I?) • Authorisation (What may I?) • Coding SCALANCE W-700 Wireless LAN SCALANCE S-600 Multiple protection against unauthorised access and bugging on automation components or cells.

  16. Secure SCALANCE W or SCALANCE S EITHER ... ... OR SCALANCEW-700 SCALANCEW-700 SCALANCE S Ethernet Ethernet Wireless LAN WPA/AES(Software included in AP) Security mechanism deactivated VPN Tunnel User- defined Firewall setting SCALANCEW-700 SCALANCEW-700 SCALANCE S Ethernet Ethernet Ethernet

  17. IWLAN and mobile diagnosis Access Point SCALANCEW788-2PRO Access Point SCALANCEW788-2PRO Access Point SCALANCEW788-1PRO IE IE IE ClientModule SCALANCEW744-1PRO S7-200 IE ClientModuleSCALANCEW744-1PRO Wireless LAN S7-400 Field PG withCP 7515 PROFIBUS ET 200S ET 200S S7-300 Wireless PLCSeparate radio network Mobile diagnosis and service Automated guidedvehicle systems Components for IWLAN for mobile data access.

  18. Monitoring and Controlvia SIMATIC PCS 7 Web Client • Monitoring and Control via the Internet / Intranet • Web Client as thin client • Complete plant overview • Remote diagnostics and asset management • Advanced security is ensured by • User-specific password • Firewall technology • Individual application concepts • Minimal installation at the Web Client • “OCX” file via net download or CD • Direct conversion of process screens for the web • Superior performance by • Compressed processpictures for the Web • Report by exception basedruntime communication SIMATIC PCS 7 Web-Client Modem LAN Intranet InternetExplorer Web - Technology SIMATIC PCS 7 Web-Client LAN Intranet Web-Server within aSIMATIC PCS 7 Client Terminal Bus Worldwide and safe access to the plant based on state-of-the-art web technology ! Plant Bus

  19. PCS 7 OS Web Client • Monitoring and Control via the Inter- / Intranet • Web Client as Thin Client • Manager node • Remote diagnostics and asset management • Advanced security is ensured by • user-specific password • Firewall technology • Individual applications concepts • Minimal installation at the client (OCX via net) • Direct conversion of process screens for the web • Superior performance by • Compressed PCS 7 screens • Report by exception based runtime communication Web - Technology

  20. Connects the control level with the MIS/MES level Comprehensive basic packages available Integration of vendor-neutral IT products  To the ISA S95 standard; integration of heterogeneous (as well as host) applications  Short response times, more transparency, more reliable decision-making MES -interface to the IT world with SIMATIC IT Information technology (IT), process data management and production planning systems play an increasingly important role in production optimization and cost reduction MES Integration & synchronization of all business processes with the SIMATIC IT technology platform

  21. SIMATIC IT Integration Browsing of MES- relevant Objects MES

  22. SIMATIC PCS 7

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