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Predefine engineering tools for optimization plant Automation Systems

Predefine engineering tools for optimization plant Automation Systems. Ami Drori Siemens Israel Industry sector. Ami Drori, Siemens Israel. 11/2012. Energy Management with SIMATIC PCS 7. Automation System for Process Control. How to implement automation system? For example:

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Predefine engineering tools for optimization plant Automation Systems

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

  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 - 11/2012

  3. Full conceptual of a plant withDistil Column Ami Drori, Siemens Israel - 11/2012

  4. P&I Diagram for Distil ColumnPiping and instrumentation diagram Key Performance Indicators AdvancedControl Automation Maintenance Graphics Alarm-Management Ami Drori, Siemens Israel - 11/2012

  5. Control room June 2011 Ami Drori, Siemens Israel

  6. HMI screen Ami Drori, Siemens Israel - 11/2012

  7. 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 - 11/2012

  8. TIA - Totally Integrated Automation Ami Drori, Siemens Israel - 11/2012

  9. Customer Supplier Inbound Logistics Process Outbound Logistics Discrete Productionlife cycle TIA - Horizontal integration Production workflow Hybrid Automation Process Mashing Lautering Fermentation Brew Kettles Discrete Yeast Propagation Heat Exchangers Plant automationfor all industries Aging & Storage Filtration Optimization of all phases your production life cycle Filling Line Modernizationand upgrade Installationandcommissioning Design andengineering Maintenance Operation Modernizationandupgrade Ami Drori, Siemens Israel - 11/2012

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

  12. TIA MES • Production modeller • Historian DB • … • End customer/OEM/SI • Production transparency • Flexible + fasterproduction innovation • Minimize set-up times • Reduce downtime • Investment protection • Reusability • Globalization/International market access • Faster time to market • Reduction in costs (TCO) • … PCS 7 SCADA • Communication • Diagnostics/Maintenance • Engineering • SafetyIntegrated • Security / Traceability • Robustness/Quality • Openness and intl. standards • Scalability and modularity • High availability • Horizontalintegration • Verticalintegration • Faceplates • Archive • Batch • … • Archive • Plant Intellig. • … • Timers • I/Os • … • Resolution • Memory • … • Performance • Torque • … • Meas. ranges • Meas. methods • … Business and economicrequirements Entireproductportfolio System characteristics Automation requirements TIA - Totally Integrated Automation The Solutions for all yourRequirements Ami Drori, Siemens Israel - 11/2012

  13. End-to-end engineering Intuitive Totally IntegratedAutomation Portal Control HMI Networks 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 - 11/2012

  14. Totally Integrated Automation PortalOne 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 - 11/2012

  15. Totally Integrated Automation PortalOne Engineering tool One tool , Configuration , Networks , Logic , HMI ,Drag & Drop Ami Drori, Siemens Israel - 11/2012

  16. PLC with Profinet communication Ami Drori, Siemens Israel - 11/2012

  17. PCS7 Operator System (OS) & Batch Clients Terminal Bus Central Engineering System (ES) for AS / OS / Batch Ethernet TCP/IP Terminal bus PCS7 Operator System (OS) & Batch SERVER Industrial Ethernet System bus PCS7 Engineering System (ES) Control Network Automation System (AS) based on SIMATIC S7-xxx Operating System Server & Batch Server AUTOMATION SYSTEM (AS) PROFIBUS / PROFINETDistributed Peripheral Network Field network ET 200 distributed racks containing the Input / Ouput Modules Operating System Client OS & Batch Client (or Operator Workstation) ET 200 Distributed I/O Basic Architecture Ami Drori, Siemens Israel - 11/2012

  18. Security concept Industrial Ethernet Industrial Ethernet Industrial Ethernet Unknown PC-Station PC-Station Engineering HMI HTTP SNMP DCP S7 CP CP SINAMICS SINAMICS SIMATIC S7-1200with CM 1242-5 S7-300 withCP 343-1 Lean ET200S ET 200S Ami Drori, Siemens Israel - 11/2012

  19. Security concept S7-400 Ami Drori, Siemens Israel - 11/2012

  20. CP 343 Adv. CP 1628 CP443 Adv. Scalance M875 SOFTNET Security Client V4 VPN ■ VPN Client forestablishing a secure VPN channelfrom PCs to SecurityCPsor SCALANCE S NEW: ■ For Windows 7 (64 Bit) ■ VPN-channel also possible to SCALANCE M875 (client-to-client) Security Integrated SIMATIC Net Product family Scalance S V3 Ami Drori, Siemens Israel - 11/2012

  21. HMI screen June 2011 Ami Drori, Siemens Israel

  22. HMI with Build in Faceplate Valve One Feedback Motor Analog Indicator PID controller Totalizing timecounter Ami Drori, Siemens Israel - 11/2012

  23. Engineering Tools June 2011 Ami Drori, Siemens Israel

  24. Function chart Cabinet design 3-D model PCS 7 software configuration PCS 7 hardwareconfiguration Single-pole representation P&ID Circuit diagram Integrated Engineering Today‘s Situation Using a Motor as an Example Ami Drori, Siemens Israel - 11/2012

  25. MPC lean large APC - Advanced Process ControlAvailable tools APC Method Embedded in PCS 7 Soft Sensor Smith Predictor Fuzzy Control Lead-Lag Feed-Forward Control Operator Training Simulator Control Performance Monitoring Override Control PID Tuning Gain Scheduling Integrated / interfaced 3rd party tools low APC Complexity high Ami Drori, Siemens Israel - 11/2012

  26. APC - Advanced Process ControlControl Performance Monitoring Ami Drori, Siemens Israel - 11/2012

  27. APC Tools embedded in PCS 7 embedded • APC Engineering Tool • Modeling & Test • APC OS Faceplates • Operation & Control OS Clients EngineeringStation ES OS-LAN Ethernet OS-Server(redundant) Industrial Ethernet / Fast Ethernet • APC Runtime Function Blocks • Runtime Calculations Ami Drori, Siemens Israel - 11/2012

  28. 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 - 11/2012

  29. 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 - 11/2012

  30. Application impact of online monitoring and support on the performance of control APC - Advanced Process ControlControl Performance Monitoring 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 - 11/2012

  31. Totally Integrated Automation

  32. Predefine engineeringtools for optimization plantAutomation Systems Thank you Name : Ami Drori Company: Siemens Sector: Industry Phone: 054-9151528 E-Mail: amiram.drori@siemens.com Industry Industrial IT TIA_Benefits Ami Drori, Siemens Israel - 11/2012 TIA Portal drag& Drop

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