Vous êtes sur la page 1sur 112

Welcome

Customer Logo

Protection notice / Copyright notice

Competence Center Cement


Your Success with our Know-How

Customer/location - date
Protection notice / Copyright notice

More than 30 Years of Cemat


Introduction PCS7 1976 Support, Training
with Migration Strategy SIMATIC S32 DISIT SIMATIC S5 150A/K

More than 520 CEMAT installations since 1971

New 2007
Cemat V7

1981

1987
Cemat V1.8 - Cemat V2
MIS WIN3.11 LS_C SIMATIC S5

1992
Cemat V3

1996
Cemat V4
MIS WIN3.5

2000
Cemat V5

2003
Cemat V6

2005
Cemat V6.1

CEMAT Philosophy Cemat Cemat V1.6

Our Partners Roadmap

MIS WIN3.11 NT4.0 LS_B SIMATIC S5 SIMATIC S5 SIMATIC S7

PCS7 V5 SIMATIC S7

PCS7 V6 SIMATIC S7

PCS7 V6 SIMATIC S7

PCS7 V7 SP1 SIMATIC S7

Sales, Ordering More than 5500 Simatic PCS7 installations since 1996

Up grade

page 3

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

CEMAT Version ... throughout the world today


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

More than 510 CEMAT Installations worldwide 113 Plant Installations CEMAT based on PCS7
9 in America
Brazil Peru Ecuador USA 1 1 1 6 Italy Spain Switzerland Austria Poland.

60 in Europe
Norway Sweden Ireland Netherlands Belgium Luxembourg
Germany 24

18 in Asia
Bulgaria Croatia Czech Greece Hungary Ukraine Romania Russia Bosnia&H erz Azerbaijan China India Korea Malaysia Pakistan Philippines Sri Lanka Thailand Turkmenistan Vietnam

18 in near east
Iran Lebanon Turkey Saudi Arabia Yemen Qatar

8 in Africa
Algeria Egypt Kenya Morocco South Africa 1 1 1 4 1

Plants with Cemat based on PCS7

page 4

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat A Success Story


CEMAT has achieved 25% market share and 35% world market share during the past 3 years!

Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

page 5

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat is integrated in Simatic PCS7


Can be ordered via Order No. like any other PCS7 Product Available for everybody: System Integrators and Cement Plants Full Customer Support from PCS7 Always updated to the latest Features of PCS7

Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

SIMATIC PCS7

Cemat

page 6

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

PCS7 Installations
2,885 Installations in Europe (incl. Russia)
Belarus Bulgaria Croatia Cyprus Czech Republic Denmark Estonia 2 11 10 3 16 17 1 Greece Hungary Iceland Ireland Latvia Lithuania Macedonia 4 6 3 15 5 4 1 Norway Portugal Romania Slovenia Ukrainia Yugoslavia 8 12 6 7 2 2

Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

965 Installations in Asia


1 2 11 60 1 4 3 2 31 12 2 2 10 6 Japan 40 9 23 1 4 12 5

Kanada 22

USA 192

Mexico 53

360 Installations in America


Argentina Colombia Costa Rica Ecuador Peru Trinidad Venezuela 9 2 2 1 3 3 4

Azerbaijan Bangladesh Indonesia Iran Iraq Israel Libanon Finland 77 Kazachstan Korea Sweden 95 Germany 1202 Malaysia Austria 134 Oman Russia 132 United Kingdom 111 Pakistan Netherlands 126 Philippines Belgium 123 Poland 37 Qatar France Switzerland 130 Singapore 100 Italy 158 Thailand Spain 169 Turkey 113 Slovakia 44 China 630 Turkmenistan Uzbekistan Un. Arab. Emirates India 50 Taiwan 60 Vietnam
South Africa 44

70 Installations in Africa
Brazil 42

Chile 27

Algeria Egypt Mauritius Morocco Mozambique Namibia Swaziland Kenia Nigeria

7 7 1 4 1 2 1 1 2

Australia 43

46 Installations in Australia
New Zealand 3

page 7

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

What does SIMATIC PCS 7 comprise ?


PCS 7 Operating System Client OS & Batch Client (or Operator Workstation) Ethernet TCP/IP Terminal bus PCS 7 Central PCS 7 Operating System Engineering System Server (ES) & Batch Server for AS / OS / Batch Industrial Ethernet System bus PCS 7 Automation System (AS) based on SIMATIC S7-400 PROFIBUS DP istributed P eripheral ET 200MD distributed racks Network containing the Input / Ouput Modules
Protection notice / Copyright notice A&D CC Cement

Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

PCS7 Operator System (OS) & Batch Clients

OS Network

PCS7 Operator System (OS) & Batch SERVER

PCS7 Engineering System (ES)

Control Network

AUTOMATION SYSTEM (AS)

PROFIBUS DP Field network ET 200M Remote I/O racks

page 8

Januar 2008

Helmut Witt

SIMATIC PCS 7 System Architecture


@
Office LAN

SAP R/3
Ethernet

@
Office LAN Ethernet

Introduction PCS7 CEMAT Philosophy Station Support, Training


PCS 7 Slot

Internet/ Intranet OS Single


(multi-VGA) SIMATIC PDM Engineering Toolset OS-LAN OS server (redundant) Industrial Ethernet / Fast Ethernet Fast Ethernet

Plant Information

Engineering Station ES

OS Clients

Plant Maintenance

SIMATIC IT Server

WEB Server / OPC Server Service

Migration Strategy Our Partners Roadmap Sales, Ordering


Box PC
PROFIBUS-DP

DP/AS-I DP/EIB

AS 417 AS 416 AS 414


PROFIBUS-DP

OS
ET 200M Ex-I/O HART PROFIBUS-PA

AS 414 F/FH AS 417 F/FH

AS 414 H AS 417 H ET 200M PROFIBUS-DP DP/PA Link PROFIBUS-PA Y Link

OP

PROFIBUS-DP

ET 200M failsafe ET 200M DP/PA Link


PROFIBUS-PA

MODBUS

DP/PA Link
PROFIBUS-DP

ET 200X

ET 200S

Zone 1 Zone 2

ET 200iS

COx, NOx, etc. Protection notice / Copyright notice A&D CC Cement

page 9

Januar 2008

Helmut Witt

SIMATIC PCS 7 Large bandwidth of scalability


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering Pilot plant Production plants Interconnected plants at a production location

Scalable from the starter package (~100 I/O) ...

... to the distributed system in client/ server architecture (> 100,000 I/O)

as powerful as you need it to be !


page 10 Januar 2008 Helmut Witt Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 Redundancy At Each Level


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy
Redundant PROFIBUS Redundant communication Redundant controller Redundant OS

Our Partners Roadmap Sales, Ordering

PROFIBUS DP

Redundant I/O Sensor/ control element

Redundant IM

Redundant modules can be placed in different racks Automatic analysis of discrepancy between input signals Without additional Engineering Redundancy where needed, i.e. as you require
page 11 Januar 2008 Helmut Witt Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - Network components Hierarchical network configurations


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
redundant servers 1 Gbit/s Terminal bus
SCALANCE X400 managed

MultiClients

100 Mbit/s Process bus


SCALANCE X200 managed

Automation systems

page 12

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - Network components SIMATIC Net SCALANCE X (for Switching)


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy
Performance & Features Modular Gigabit Office-Feat. Redundancy Isochrones Realtime Managed

X-400

X414-3E Isochrones Realtime X204IRT X202-2IRT X204-2 X206-1

Our Partners Roadmap Sales, Ordering

X208PRO X-200 X208

Unmanaged

X-100

X108

X104-2

X106-1

page 13

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - Network components SIMATIC Net SCALANCE W e.g.: Monorail System
Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Travel Direction of Monorail (max. 50 Monorails per RCoax Segment) Stable Communication even during RCoax Segment Change Over through IWLAN RR (Rapid Roaming)

page 14

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - Network components SIMATIC Net SCALANCE S (for Security)


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Secure Internal LAN A Security Module A

VPN-Tunnel
Internet Intranet External Net Security Module B
VPN=Virtual Private Network

Secure Internal LAN B

page 15

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - connection to the field Flexible and easy integration of field devices
Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
PROFIBUS-DP field devices
SIPOS 3, 5 SIPART DR SIMOVERT SIMOCODE
PROFIBUS DP

MIS, ERP, Asset Management

SIMATIC PCS 7 Engineering


Standard Interfaces

Industrial Ethernet

SIMATIC PDM: - PROFIBUS-PA - PROFIBUS-DP - HART

DP/PALink ET 200M ET 200iSP

PROFIBUS-PA field devices


SITRANS P SITRANS F SIPART PS

4-20 mA / HART I/O module

4-20 mA / HART 4-20 mA / HART

page 16

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Process instrumentation in cement plants Siemens technologies in overview


Introduction PCS7 CEMAT Philosophy
Quarry Pre-Homogenization

Quarry

Raw Material Preparation


Vertical Roller Mill or Raw Mill Homogenization Silo

Support, Training Migration Strategy


Level

Primary Crusher

Raw Meal Silo

Our Partners Roadmap


Temperature Sales, Ordering Flow Weighing Process protection Gas analysis
Waste Fuel Tanks Coal Mill Stack ESP Additive Silos Pre-Heater Tower Pre-Calcinator Rotary Kiln Clinker cooler Clinker Silo Finished Cement Silos Packaging

Pressure

Coal Silos

Finishing Mill

Clinker Production
page 17 Januar 2008 Helmut Witt

Finishing Mill

Packing and Shipping

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - connection to the field Process devices from A&D PI


Temperature Flow
SITRANS F US SITRANS T3K SITRANS FM ULTRAMAT23

Analyser

OXYMAT

Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
Positioner
SIPART PS2

Pressure
SITRANS P DSIII

Level
SITRANS LR 400 SITRANS LC

ULTRAMAT

SIPAN32

OXYMAT 61

CALOMAT 6

cyclic/acyclic data safe data Diagnosis


SITRANS LR 300 SITRANS LS 200/300

PA / Profile 3

SIWAREX

:recent development GSE: Basic Device Data File, describes the cyclic communication of the device EDD: Electronic Device Description, describes the acyclic communication of the device (parameters, diagnostics, device configurations) HCF: Hart Communication Foundation page 18 Januar 2008 Helmut Witt Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - connection to the field SIMATIC ET 200M


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Distributed I/O station for Ex Zones 2/21 Modular and space-saving in compact design
Interface module IM 153-1/-2

Up to 8 S7-300 modules
page 19 Januar 2008 Helmut Witt Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - connection to the field SIMATIC ET 200S


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

page 20

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - connection to the field SIMOCODE


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering Multifunctional electronic motor protection

SIMOCODE pro provides all functions for your motor feeder in only one system. All functions can be enabled, disabled and adjusted at any time.

Flexible software for motor control for Start, Stop Detailed operating, service and diagnostics data Communication via PROFIBUS DP

Application: e.g. for pump monitoring (effective power) or energy management with SIMOCODE pro for power-/voltage monitoring.
page 21 Januar 2008 Helmut Witt Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - connection to the field Vendors and products


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering ASICS Bus MonitorCamera CommissioningCertification DCSElectric ActuatorFlow Gas AnalyserGatewayHotline SupportInstallation MaterialLevel Liquid AnalyserLiteratureMotor Starter Operator PanelPC ModulePLC PressureProtocol Tester Remote I/OTemperatureSoftware ToolTrainingValve Positioner ** Variable Speed Drive Valve Manifold Weighing Reference: http://www.profibus.com

* random list ** not a member of PI

more than 1000 companies are member of PROFIBUS International more than 2000 products for PROFIBUS are available
page 22 Januar 2008 Helmut Witt Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - Automation system Basic units: AS from the S7- 400 range
Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

AS bundles: pre-configured, assembled and tested


Central units

- S7 414-3, S7 416-2, S7 416-3, S7 417-4 with integrated PROFIBUS-DP interface - integrated MPI interface - RAM 1,400 to 20,000 kByte Power supply - (options: 24 V~, 120 V~, 230 V~)

CPs for Industrial Ethernet High Performance Event Driven Communication Alarming by Exception
Protection notice / Copyright notice A&D CC Cement

! Assembly and testing no extra charge


page 23

Januar 2008

Helmut Witt

SIMATIC PCS 7 Operator System Hardware & Software Components


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
1

Custom Operator Stations (Bundled hardware + system software)


Single-user system (OS single station)

Clients Single-user system
1 32

Client/server system (OS client / OS server) Basis: Standard PC components Windows 2000/ XP

Server
12

System Software for Operator Systems


System software also available without hardware (for simulation purposes)

Opt. redundant server

Packages for Operator Systems


Variety of quantities available

page 24 Januar 2008 Helmut Witt

Upgrades via PowerPacks


Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 Operator System Hardware & Software Components


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

System Capacity Number of server / server pairs Number of clients for each server/pairs Number of POs for each multiuser system Packages
Number of POs Single-user Server 250 POs ; -2,000 -- " -; ; 3,000 -- " -; ; 5,000 -- " -; ; 8,000 -- " --;

12 32 60.000

page 25

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 Operator System GUI Multi-Screen


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Multi-Screen Technology
One control device (mouse/keyboard) for multiple monitors (1...4)

Provides ease-of-use functions (e.g. store screen composition/layout) No additional configuration required

Configuration of monitor layout


Project Editor

Max. 4 Monitor (each 1600 x 1200)


Multi-Clients can access: All Alarm & Event Archives All Process Data Archives (e.g. in a Trend Window) Process Data from Multiple Servers in a single Display

Comprehensive overview of the process (information at your fingertips) Simple operation using multiscreen technology
page 26 Januar 2008 Helmut Witt Protection notice / Copyright notice A&D CC Cement

Operator System Overview


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Alarm System Process Visualization


Excel

Programming Interfaces

Archive System

Standard Interfaces

Report System

Data Management
Protection notice / Copyright notice A&D CC Cement

page 27

Januar 2008

Helmut Witt

SIMATIC PCS 7 - Operator Station The user interface


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Standard user interface


clear and field proven

sub-navigation window
overview overviewarea area (4x4 (4x4 Matrix) Matrix)

structure

standardized displays for trends, messages multi-window-technique with protected overview and buttons area easy and intuitive handling

Working Workingarea area

Key Key set setarea area

Proven operator interface for a safe operation - even in critical situations


page 28 Januar 2008 Helmut Witt Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 Operator System Trend Displays


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Basic functions of the trend displays


Up to 10 tags (pens) for each trend display

Zoom Ruler (with tabular display of value) Adjustable time scale (duration) Visualization can be stopped (archive continues to run) Scrolling through records (Fwd/Rev) One Y axis for all values (%) or separate Y axis for each value Trend displays merge data from - Online process values - Archived (historical) values

Flexible trend display format maximizes usability Fast online viewing of process data
page 29 Januar 2008 Helmut Witt Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 Operator System Archive System Performance


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Highlights
Can be configured online

Automatic synchronization for redundant systems Process value acquisition / archiving - Cyclic (fastest cycle: 500ms) - Archiving of changes only

Technical data
Microsoft SQL Server 2000

5,000 process values / sec (archive server) 1,000 process values / sec (OS server) Up to 30,000 tags can be archived in the database 10 alarms / sec for each server (steady state) Alarm buffer with 3,000 alarms in 4 sec
Protection notice / Copyright notice A&D CC Cement

page 30

Januar 2008

Helmut Witt

SIMATIC PCS 7 Operator System Archive System Performance


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Process value compression for archiving


(e.g. acquisition: 2 sec. / archiving: 60 sec.)

- Min value - Max value - Average value - Last value - Sum of values (addition) - Custom function (C script)

page 31

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 Operator System Archive System StoragePlus integrated Viewer


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
Alarm Messages Curves

Archived variables in table format

StoragePlus with integrated viewer


Viewing of archived data with standard Internet Explorer

page 32

Batch protocols

easy client - server structures (office) possible


Helmut Witt

Januar 2008

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 Operator System Alarm system


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Alarm system functions - Loop-in alarm


(jump from alarm directly to process screen)

- Acknowledgement
(single, by page, from faceplate, for entire picture)

- Chatter suppression (in AS)


(alarms reannunciated only after acknowledgement)
page 33 Januar 2008 Helmut Witt Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 Operator System Alarm system


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Preconfigured alarm lists - New list (all unacknowledged alarms) - Old list (all Active, acknowledged alarms) - Went out list (all unacknowledged, cleared) - Operator input list (all operator messages) - Log list (all alarms in chronological order)

Alarm priorities

- Priority 0 (lowest) ... Priority 16 (highest)

Quote: "A warning from the main reactor is more important than an alarm - Control system list (all control system alarms) from an auxiliary tank"

- Highest priority alarms in


Alarm classes

alarm line (overview)


Alarm selections

A W S O

Alarm (high / low) Warning (high / low) Control system Operator input prompt Criteria: e.g. date, time, area, class, priority

Comprehensive system support for alarm analysis


page 34 Januar 2008 Helmut Witt Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 Operator System Additional Features


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Smartcard reader for simple and secure user identification Video overlay in process screens User right, each operator/group can be assigned custom authorization using functions, plant sections, etc. Centralized time synchronization with DCF 77 or GPS receiver Signal module (alarm horn for visual and audible signals) Language switching online during runtime operation

page 35

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - Engineering System

Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

One engineering system for all system components from OS via AS to the field level Configuring instead of programming Graphical structuring tools Testing and changes online with graphics tools Data base for the entire project with automatic documentation
Engineering System

page 36

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - Engineering System Central Integrated Engineering System


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy OS configuration with operatorinterface/faceplates User spec. function blocks

SIMATIC SIMATIC Manager Manager


Libraries Libraries STEP STEP 7 7
0000 0000

Our Partners Roadmap Sales, Ordering Technological function blocks

WinCC WinCC
V2 Y2000.0 % V4 P4 0000.0 MBAR F1 R1 0000.0 PC V3 MBAR 0000.0 % A10000.0 Reaktor 01 M1 V5 P5 0000.0 MBAR 0000.0 MBAR V6 P6

Y1000.0 % V1 P10000.0 MBAR INERTGAS

SFC SFC

CFC CFC

SCL SCL

PDM PDM

ABLUFT1 ABLUFT2 ABLUFT3

produkt

Database Database
Network/ communication configuration System configuration Application Engineering Configuration of field devices and components with Process Device Manager

page 37

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - Engineering System One Central Engineering


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Simultaneous display of all process variable aspects Bulk engineering capability Efficient processing of all objects General
Copy/insert block (of attributes) Cooperation with Excel/Access (copy/paste) Find/replace attributes Browser for user-friendly signal routing Import/export texts (for translation) Free columns for customer-specific attributes
OS crossreference Block symbols, I/O fields, status displays Archives Cycles, units

Name, commentary, AS allocation

CFC & SFC parameters/ interconnections Limits, settings, crossmeasuring-point interconnections

Process Messages objects Message texts,


Hardware allocation I/O channels, signal names priorities

Increase your engineering and commissioning efficiency


page 38 Januar 2008 Helmut Witt Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - Engineering System Automatic software generator for station plans
Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Example chart + imported control loop list with parameter values

Automatically generated station plans

+
TH assign. B17/Reac1 B17/Reac2 B17/Reac2 B17/Reac3

Import/ExportAssistent
KP 1.7 1.25 2.0 1.5 TN 2.5 3.5 1.0 10 TV 1.3 1.0 1.0 2.0

Plan name PV_LR PV_LR LIC1710 0 100 TIC2711 0 500 PIC2712 0 10 FIC3210 0 250

page 39

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - Engineering System Generation of overview displays from plant hierarchy
Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
Plant_1 Reactor_1 TIC10 PIC11 V17 Reactor_2 TIC20 Pic: Reactor 2 TIC 20 PIC 21 V 27

building block symbols in the scope of supply of PCS 7 contained, can be changed without programming knowledge
Plant Hierarchy

functions - entire generation - consideration of added/deleted measuring points.

generate building block symbols


Pic: Reactor 1 TIC10 PIC 11 V 17

online

tional i d d a o N ing !!! r e e n i g En


page 40 Januar 2008 Helmut Witt Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - Engineering System Plant Hierarchy Produces all OS Data


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
Plant_1 Reactor_1 TIC10 PIC11 V17 Reactor_2 TIC20

building block symbols in the scope of supply of PCS 7 contained, can be changed without programming knowledge
Plant Hierarchy

functions - entire generation - consideration of added/deleted measuring points.

tional i d d a o N g !! ! n i r e e n i Eng
page 41 Januar 2008 Helmut Witt Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - Engineering System Libraries


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Differentiated application libraries with technology software:


Basic library Field device library Technological library (CEMAT) Driver library for PROFIBUS-PA devices Design guideline for function blocks + faceplates

for ES and AS +

Integrated system features:


Driver library for PROFIBUS-PA devices

Messages Standard faceplates Online assistance

for OS
page 42 Januar 2008 Helmut Witt Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - Engineering System Graphical configuration with CFC acc. IEC 1131
Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering Place blocks by Drag and Drop
nce with a i l p m o In C 1 !!! IEC 113

Easy engineering by means of pre-configured graphics

Automatic connection to other charts and hardware signals

tional No addi ing !!! r e e n i g en


page 43 Januar 2008

Block libraries with search function


Helmut Witt

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 Integrated Fail-Safe


Minimized error sources, because of

Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

reduced system interfaces less system-know-how requirements easy maintenance reduced HW, SW and wiring requirements quick commissioning integrated in the operator station one single engineering tool innovative graphic engineering
PROFIBUS DP

Reduced time and effort, because of


PROFIBUS DP

N) ) I (D EC 6 (I K 3 - A SIL 1 K A L1 SI

S7-400F
ET 200M F-I/O ET 200S F-I/O ET 200M

Reduced engineering

S7-400FH
ET 200M ET 200M ET 200iSP

F-I/O

S-I/O

redundant
F-I/O

page 44

Januar 2008

Helmut Witt

al ion t t To rat e f a eg S t In Protection notice / Copyright notice

x i r at yM

A&D CC Cement

SIMATIC PCS 7 - Engineering System Integrated Plant Asset Management


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
SIMATIC PCS 7 Plant Asset Management Monitoring Diagnostics Maintenance Request Maintenance

Maintenance Personnel

Avoid loss of production Enabling preventive maintenance and diagnosis Perfect integration for plant operators Ideal indication of the status of all system components Consequent implementation of NAMUR recommendations NA 64 & NE 91 Protection notice / Copyright notice
page 45 Januar 2008 Helmut Witt A&D CC Cement

SIMATIC PCS 7 - Plant Asset Management Plant Overview Picture


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
OS Server 1 OS Server n Engineering OS Client 1 OS Client 2 OS Client n

AS 1

AS 2

AS 3

AS n

page 46

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - Plant Asset Management Hierarchal Structure


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
diagnosis symbol of the component status and selection of underlying hierarchy
S7-400 and Profibus Network

ET200M Station

Profibus Assets

Faceplates for intelligent device

page 47

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 Increase Your Profit While Reducing Costs


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
Installation and Commissioning Maintenance Design and Engineering Operation Modernization and Upgrade Advantage 1: Innovative und flexible system architecture Advantage 2: Openness and suitability for integration Advantage 7: Configuration and visualization of sequence control Advantage 8: Use of safety systems in the process industry Advantage 9: Effective a. flexible realiz. of batch processes

Advantage 11: SIMATIC PCS 7 Migration strategy

Advantage 3: Automatic generation of all OS objects Advantage 4: Efficient processing of bulk data

Advantage 5: Simple parametrization, diagnostics, commissioning and service Advantage 6: Parametrization, diagnostics, commiss. and maintenance of intelligent field devices Helmut Witt

Advantage 10: Preemptive plant maintenance, repair and service

page 48

Januar 2008

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 Migration Capabilities Protection Of Investment


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering 3rd party DCS
ABB Emerson Honeywell APACS

Siemens has created what ARC believes is a comprehensive, stepwise approach to migration that effectively addresses the needs of its installed base.
ARC Advisory Group,January 2005

Siemens DCS
OpenPMC

PCS/Tistar

TELEPERM M

... SIMATIC PCS 7 ...


FUJI

From multiple legacy systems to one target system: SIMATIC PCS 7


from Siemens legacy control systems from 3rd party legacy control systems

Migration solutions will be expanded continuously

Take advantage of new technology of SIMATIC PCS 7 while offering a high degree of investment security
page 49 notice / Copyright notice In addition, Siemens is developing a solid strategy forProtection migration from many Januar 2008 Helmut Witt A&D CC Cement competitor systems to SIMATIC PCS 7. ARC Advisory Group,January 2005

SIMATIC PCS 7 - Interfacing Openess on all levels


SAP R/3

@
Office LAN

Introduction
Ethernet


Plant Opti. APC

Integration of ERP Systems Integration of MES Systems Web capability based on interface standards like OPC, OCX, ODBC Interfaces for import / export of data with higher level planning tools (CAD/CAE) Integration of Unit Operations Online Changeability Scaleable System Actuators/Sensors via HART, PROFIBUS DP/PA, ASI, EIB etc.

PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

SIMATIC IT (framework & components) Internet/Intranet Plant Plant Information Maintenance @PCS 7 / OPC-Server Engineering Station SIMATIC PDM SIMATIC BATCH clients

Ethernet

Ethernet S7-400 ET 200M DP/AS-I PROFIBUS-DP

Integration in the existing Infrastructure of


DP/PA-Link

DP/EIB

PROFIBUS-PA

the customer (Sensors to Board Room)

Protection of former Investment

PROFIBUS-DP

COx, NOx, ...

ET 200iS

page 50

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - Interfacing SIMATIC IT


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Data Analysis

Historical Data Display Trending Excel Add-in

Key Performance Indicators (KPI)

Data Collection Data Aggregation Simatic IT Historian


Fuel Consumption Rotation Speed Clinker Feed Temperatures

Overall Equipment Efficiency Kiln Fuel Consumption Total Cement production Total Crusher efficiency Down time management

Long Term Archiving and Compression

Alarm: pump breakdown Mach status: on, off,

Calculation on and storage of raw data

Control
Helmut Witt

Long term archiving of raw data, performance data and alarms

page 51

Januar 2008

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - Interfacing SIMATIC IT Historian Data Display


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering SIMATIC IT Historian allows comparisons between e.g. : Production operations Batches Shifts Equipments

Historian Data Display (HDD) is the native client application for KPI analysis and historical data display

HDD provides four analysis tools


Trend viewer Bargraph viewer Production viewer Message viewer

page 52

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - Interfacing SIMATIC IT Trend Viewer


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

page 53

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - Interfacing SIMATIC IT Excel Add-in


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Excel Add-in offers easy data analysis and reporting with standard office tools

page 54

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - Interfacing SIMATIC IT Report Manager


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Document your plant performance !

The Report Manager combines different data from different sources into standard reports:

Correlation between clinker quality and furnace temperature Report on cement production vs. fuel consumption, cement cost per kg, fuel cost per kg cement, Standard reports making comparison between plants easy

page 55

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - Interfacing SIMATIC IT Key Performance Indicators


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Costs Costs

Quality Quality

Energy Energy
Production Production of of maximum/acceptable maximum/acceptable quality quality with with a a minimum/limited minimum/limited amount amount of of energy energy

Production Production of of acceptable acceptable Production Production of of maximum maximum quality quality quality with with a a minimum minimum quality without without taking taking of detailed of material, material, energy energy and and detailed care care of of other resources other production production resources resources resources

Emissions Emissions
Production Production of of maximum/acceptable maximum/acceptable quality quality with with a a minimum/limited minimum/limited amount amount of of emissions emissions (Kyoto (Kyoto protocol) protocol)

Availability/ Availability/ Long Long life life cycles cycles


Production Production of of maximum/acceptable maximum/acceptable quality quality with with a a minimum minimum of of machine machine load load

Global Global Optimum Optimum Profit Profit


P M 6 Total Efficiency

KPI KPI
Tonnes [t/h]
120 100 80 60 40 20 0

T arget = 100 Production Lo-Limit

CD-Spread [g/m ]

Steam [t/t]

Efficiency Fa ctor : 89

M D-Spread [g/m ]

Electricity [Kwh/t]
Normal Alarm Better

Date : Tim e : Reel : Product :

3/10/97 16:14 P6.987512 Coram edium 120

Improving

Speed [m /m in]

Stable W orsening

page 56

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

ERP
SIMATIC PCS 7 Operator System SIMATIC IT Data Integration Service Archive System Performance 3rd Party
Components
Process value compression for archiving IntroductionSIMATIC IT Product (e.g. acquisition: 2 sec. / archiving: 60 sec.) PCS7 Definition - Min value CEMAT Philosophy Manager

SIMATIC IT Framework

SIMATIC IT Production Order Manager

Support, Training

- Max value

SIMATIC IT Migration Strategy Messaging - Last value Our Partners Manager Roadmap Sales, Ordering SIMATIC IT Unilab

- Average value - Sum of values (addition) - Custom function (C script)

SIMATIC IT Material Manager

SIMATIC IT Personnel Manager SIMATIC IT Historian PPA


RTDS

SIMATIC IT Interspec

SIMATIC BATCH
page 57

SIMATIC Januar 2008

PCS 7

3rd Party Devices Protection notice / Copyright notice


Helmut Witt A&D CC Cement

SIMATIC IT Client Application Builder

3rd Party Components

SIMATIC IT Report Manager

SIMATIC PCS 7 - AddOn All SIEMENS variable speed drives are integrated by Drive ES
Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering Drive ES PCS7 Drive ES SIMATIC Drive ES Basic Drive ES Graphic Motion Control mit
PROCESS FIELD BUS

Drive ES

SIMATIC S7-300 ( +FM357-2 )

SIMATIC S7-400 (+ FM458 )


1

SIMATIC WinAC

SIMOTION

DC-MASTER Standard Drives MICROMASTER COMBIMASTER


page 58 Januar 2008 Helmut Witt

MASTERDRIVES SIMODRIVE POSMO A/SI /CA/CD Vector Control Motion Control 611U
Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - AddOn Advanced Process Control


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Advanced Process Control


PID Enhancements
Structure

Rapid Prototyping
Rapid

Fuzzy / Neural
Fuzzy

Predictive Control
Model

decomposition with SIMATIC PCS 7 standard controller PCS 7 PID Tuner1 Optimization with RaPID2 adaptive control with ADCO2

Prototyping with Matlab/ Simulink (DDE-Client2)

Control++2 Soft

Presto2

Sensor

predictive multi variable controller INCA2

SIMATIC PID

Permanent

Process Control with SIMATIC PCS 7 (with PID Control)


page 59 Januar 2008 Helmut Witt Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 AddOn Energy Management - SIMATIC powercontrol


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Optimized operating costs thanks to increased transparency of the power flows from the infeed to the consumer More precise and more efficient power import thanks to accurate knowledge of the demand profile Optimized application of resources thanks to targeted diagnostics and maintenance Flexible integration options thanks to open and modular design and expansion variants For all Energies of a plant (Power, Steam, Water, ...)

SIMATIC powercontrol the First Software Facilitating Comprehensive Power Management.


page 60 Januar 2008 Helmut Witt Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - AddOns Examples (1)


Video monitoring

Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
Frequency converter Master drives Fingerprint mouse Motor starter Simocode

Big screen
page 61 Januar 2008

Ex operating units
Helmut Witt

Cabinet engineering
Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - AddOns Examples (2)


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
Industry-specific libraries Block library fuel technology CEMAT cement industry package

Bus analysis tool BANY

Adaptive controller ADCO


page 62 Januar 2008 Helmut Witt

4-quadrant display
Protection notice / Copyright notice A&D CC Cement

Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

page 63

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat is more than a library..


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

High quality Documentation

Classroom Training & Support

Demo Systems

Engineering Tools

Migration tools

Order Information & Internet links

page 64

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Control System


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Developed in close co-operation with Cement Manufacturers world wide

page 65

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - is a Philosophy
Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

. . . how to operate a Cement Plant . . . how to make Fault Diagnosis in a Cement Plant . . . how to interlock drives, valves, process signals etc.

page 66

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Operation of a Cement Plant


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Self explainable Standard Interfaces with Windows Look an Feel Detailed Curve Display and Analogue Value Indication Starting/Stopping of complete Drive Groups with one Mouse Click only High sophisticated and easy Route selection

page 67

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Fault Diagnosis in a Cement Plant


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Generates one message only per alarm condition because of high sophisticated Plausibility Logic Detailed Information about the location of hardware faults Messages are concise and clear because of detailed separation between types of faults and detailed and clear message text

page 68

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Software Interlocking in a Cement Plant


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Library of Software Modules for all kind of functions in a Cement Plant Strict guidance of the engineer during programming avoids patchwork of software Very low possibility of programming errors because of standard interfaces between software modules.

page 69

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Plausibility/Priority Logic function


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
Start Feedback ON Feedback OFF

Group #1
Start Stop

Route #1
Start Stop

Stop

Start

Route #2
Start Stop

Stop

D1
Position 1

Damper #1
Position 2

D2

Start

1 1
Start Operation Interlocking

Stop of this motor also, without fault message


Stop

Motor #1
Running Signal Operation Interlocking

Start

Valve #1
Open Protection notice / Copyright notice A&D CC Cement

page 70

Januar 2008

Helmut Witt

CEMAT Modules

Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering Announcing Damper Valve Motor Drive

Group

Route

Selection

Controlle r

Measuring Value

Silopilo t

page 71

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

CEMAT Faceplate - Motor


The heading line contains the plant identification and the associated comment for the AS module. Modul Status Display

Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Diagnosis Display AS module diagnosis

Help Function

Info Object-related information


page 72 Januar 2008 Helmut Witt Protection notice / Copyright notice A&D CC Cement

CEMAT Faceplate - Motor Info Dialog


The header lines display the general location designations and the installation location of the object with the plant structure.
Registers: contain standard information about - Input/output descriptions with overview plan key - MCC descriptions with overview plan key - AS hardware and software modules with overview plan key - Service inputs for Loop in Alarm, etc.

Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

The object-related messages are output in a message window.


page 73 Januar 2008 Helmut Witt Protection notice / Copyright notice A&D CC Cement

CEMAT Faceplate - Diagnosis


Process parameter operator control

Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
Input signal states

Module outputs The output signals important for diagnostic evaluation are displayed together with their status.

Fault Signal Status

Parameter field This displays the hardware signal states of the object
page 74 Januar 2008 Helmut Witt

Operating time acquisition


Protection notice / Copyright notice A&D CC Cement

Extended Diagnosis with the Interlock Module


The interlock dialog displays the input parameter name of its logical state and the subsequent interconnection. A single click on the corresponding interface designation opens the Interlock dialog.

Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

In an error situation, the input signal is displayed with a red background.


page 75 Januar 2008 Helmut Witt Protection notice / Copyright notice A&D CC Cement

CEMAT Message Dialog


The message list window consists of three areas: 1. Toolbar message window

Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

2. Message list

3. Selection input dialog

page 76

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Sample Configuration


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
ET-200
Scalance 400 Scalance 200 Scalance 200

Each sreen with access to every plant section Raw Material Handling Kiln & Cooler Coal Mill and Utilities Silos & Dispatch

@PCS7/ OPC- Server

MIS-Client

TCP/IP

TCP/IP

TCP/IP

TCP/IP

TCP/IP
Scalance 200

TCP/IP

Crusher
Local Operator Panel Scalance 200

Scalance 200

Scalance 200 Scalance 400

Terminal-Bus Industrial Ehternet


Scalance 200

OfficeBus Industrial Ethernet


Scalance 400

S7-4163

Fast Ethernet TCP/IP

TCP/IP

TCP/IP
Engineering Station with CP1613 and 3Com
SIMATIC IT Data Server

Server with CP1613 and 3Com

Monitor switch

H1-Bus Process Bus Industrial Ethernet H1-Bus


S7-416-3 Kiln Feed & Kiln S7-416-3 Kiln&Coole r
Scalance 200 Scalance 200

Scalance 200

S7-416-3 Raw Material Handling

S7-416-3 Raw Mills

S7-416-3 Silos & Dispatch

S7-416-3 Coal Mill & Utilities

Profibus DP

Profibus DP

Profibus DP

ET-200

ET-200

Profibus DP

ET-200

ET-200

Profibus DP

ET-200

Profibus DP

ET-200

page 77

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Key Features


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Integrated interfaces to further Subsystems and integrated Kiln Optimisation System Modular Design Concept Distributed Configuration Easily Configurable Openness to Technological Innovations Easier Working Conditions for Operators and Electricians Less Downtime

page 78

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Cost Savings


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

No unreasonable start of drives or groups because of detailled status report prior to any start No unreasonable selection of routes because of plausibility logic behind Easy handling for the operator because of self-explainable face plates with Windows Look-and Feel Object lists provide detailed information about asignment for all objects to a route or group. Fast fault finding because of detailled fault indication with high performance plausibility logic 4 limits for alarms and 4 limit for interlockings for each analog value from the field.
Helmut Witt Protection notice / Copyright notice A&D CC Cement

page 79

Januar 2008

Cemat - Infosystem
Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Individual sound settings, video sequences, drawings, manuals can be assigned for each object Notes to each individual event can be keyed in from a operator and read out from any operator. Detailed object information via integrated data

base provides location of each object (drive, valve etc.), i.e. the MCC the I/O slot the central rack including building-, floor-, room-, cubicle-information reduces Down Times

Detailed Curve display of analog values from the field and free selectable group of curves
Helmut Witt Protection notice / Copyright notice A&D CC Cement

page 80

Januar 2008

Cemat - Engineering
Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Easy and fast Engineering with pre-defined CEMAT-modules Very low possibility of programming errors because of standard interfaces between CEMAT modules. Simple engineering because of low number of basic CEMAT modules Proven software typicals for specific requirements in the cement industry Because the CEMAT modules are specificaly tailored to the demands of the cement industry, the number of I/O-parameters is low compared to modules of general libraries. This makes enginereing easy and reduces programming errors significantly. Strict guidance of the engineer during programming avoids patchwork of software
Helmut Witt Protection notice / Copyright notice A&D CC Cement

page 81

Januar 2008

Cemat - Alarm System, Support for the Maintenance Staff


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Not more than one alarm message will be generated per plant/process fault Every alarm is shown as detailed as possible Each alarm must be acknowledged individually Logging of all Downtimes and of Faults Clear overview display of alarm summaries Automatic display of alarm mimics and operator notes Selection and sorting of Fault Messages, e.g. Electrical Faults, Mechanical Faults etc. Detailed Information about the Location of Hardware Faults Plausibility/Priority Logic Eliminates guesswork by the operator

page 82

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Service & Support


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Helpline for Service & Support

... looks for the appropriate contact Technical Support

... personal consultation by experts on the phone Online Support

... Internet support around the clock

Field Service

... on-site help anywhere in the world

Spare Parts and Repairs


Protection notice / Copyright notice A&D CC Cement

... fast and reliable


page 83 Januar 2008 Helmut Witt

Cemat - Training
Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering CEMAT Classroom Training in Germany 1 week CEMAT Classroom Training in Germany 1 week CEMAT Training No Knowledge available Either in Germany or at your site as per your requirements
Protection notice / Copyright notice A&D CC Cement

Simatic PCS7 Knowledge available Simatic PCS7 Training as precondition 2 weeks

page 84

Januar 2008

Helmut Witt

Cemat - Support ..
Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

High quality Documentation

Language reference & Project Support

Demo Systems offline/online/vide o

Engineering Tools/ sample PCS7 Projects

Migration tools

Order Information & Internet links

page 85

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Demo System


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

page 86

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Video
Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

page 87

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Engineering Tools


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

page 88

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Incorporated Interfaces for Solution Packages


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

page 89

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Migration
Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
l l u F C o m b i i t p a C t y C

CE M AT

CE M AT

EM AT

EM AT

CE MA T

Ve rs io n

Ve rs io n

Ve rs io n

Ve rs io n

Ve rs io n

6
2003

2000
i b

1996
e P o

y i t l i

3
1994
p g d r a

s s

2
1987
F u l l

Precondition: Cemat is engineered as per the manuals

CEMAT based on PCS 7 is an investment in the future


page 90 Januar 2008 Helmut Witt Protection notice / Copyright notice A&D CC Cement

Cemat - Migrations V1.x , V3.x to V6


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
PMC V2 V3
OS - AG S5 155U

COROS LS-C
Color Graphic Color Graphic

COROS LS-B Host

Multi- Clients
Color Graphic Color Graphic

Single Station Engineering-Station

OS-Server Ethernet H1

SIMATIC-Preconditions

SIMATIC S5 155U SIMATIC S5 155U


R I/O R I/O R I/O R I/O

CPU 948 CP143 or CP1430 30 kWords available

SIMATIC S7-416 Profibus DP

Extension

page 91

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Migration
Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
V1.8 / V1.9 / V2.0 / V3.0 / V3.1 / V4.12 S5 V1.8 / V1.9 / V2.0 / V3.0 / V3.1 / V4.12 S5 S5 remaining PCS7-OS with PMCchanell Has to created new Will be generated with Excel-Tools from LSC-, LSB-, V4.12-Data CEMAT Version AS AS-User-program OS Process pictures OS-Variable / Annunciations

Replaced with S7-AS

Has to created new 50-60 % will be generated automatical with Excel-Tool an Information from the old S5-Program

PCS7 V6 OS

Has to created new

Will be generated with SIMATIC-Manager

V4.12 S7

S7 with new Systemsoftware

Has to created new 50-60 % will be generated automatical with Excel-Tool an Information from the old S5-Program

PCS7 V6 OS

Has to created new

Will be generated with SIMATIC-Manager

page 92

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Migrations Tool COROS LSB to CEM V6 OS


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
AG_WINCC S5L.TXT S5_VAR_WINCC = _VEX (Variable) trennen in CTyp > 1000 und CTyp < 1000 = _CEX (Verbindungen) Mit VAR_EXIM.EXE in das Tag Management Und Structure Tag importieren NNN.S5L NNN.MLD MELDUNGEN TAG TEXTE COROS LSB EXCEL TAG Export Import mit VAR_EXIM.EXE WinCC zu Textlexikon hinzufgen in Alarm Logging importieren

MELD.TXT

MIG_V3_V6_dex.csv

= _DEX (Strukturen)

page 93

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Migration STEP5 to CFC charts


S5 155 U CEMAT V4

Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Example program language STEP5 PCS7 CFC

STEP 5

MOTOR 5H02M1 ROTARY BLOWER SPA FB 1 ( KF 1 ESB I 30.2 H5H02M1.C41 ERM I 30.0 H5H02M1.C61 EVO F 1.1 LOG 1 EBM I 30.3 H5H02M1.C71 ESP M 1.1 LOG1 ESR E 30.1 H5H02M1.C51 EBE Q 36.0 H5H02M1.C31 ELS F 0.0 LOG0 )

data block for 5H02M1 DW14 = 4 ;Feedback time DW15 = 0 ;Start Delay DW16 = 0 ;Speed Monitor time DW17= 10 ;Hooting time for Single Start DW18 = 0 ;Stop Delay

drive list group 5 = DX 105 DW 2: 1,1 ;H5H02M1 DW 3: 1,2 ;H5H02M2 DW 4: 1,3 ;H5H03M1 DW 5: 1,4 ;H5H03M2 DW 6: 1,5 ;H5H04M1 DW 7: 1,6 ;H5H04M2 DW 8: 1,7 ;H5H29M1 DW 9: 'BE'

Chart name = TAG Inputs like feedback local switches electrical ready

block comment

output to contactor

S7 416/ 417 CEMAT V6 based on PCS7 V6


group commands

CFC

group link

page 94

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Migration STEP5 to CFC charts


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
group commands Inputs like feedback local switches electrical ready output to contactor

Generated CFC - motor


Chart name = TAG

group link

page 95

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Migration STEP5 to CFC charts


Additional manual work
Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
logic for start, operating and protection interlock

logic for start and stop command

annunciation release

After generation of the charts, some additional manual programming has to be done:
logic for logic for start, operating and protection interlock logic for start and stop command feedback to group module join objects (which belong together) in one chart, e. g. motor and current Protection notice / Copyright notice Januar 2008 Helmut Witt A&D CC Cement

page 96

Cemat Continuous design for faceplates Example: motor diagnosis in CEMAT V6


From CEMAT PLC V2 From CEMAT PLC V3

Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
From CEMAT PLC V4 From CEMAT PLC V6

page 97

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - System Integrators give local support (extract from the list)
Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

System Integrators
I&S worldwide KMI Germany PSA Germany Hauser Switzerland TRIPS Germany Profi Vision Germany FLS Automation Denmark C.A.C. Vietnam Narime Vietnam Lilama Vietnam SIAS China TJRDI China ICER/Catii France Elin EBG Austria Pricision Control Malaysia
Januar 2008 Helmut Witt

US Status
Source: CC CCG

page 98

Protection notice / Copyright notice A&D CC Cement

Cemat Roadmap
2005 2006 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 2007 Q3 Q4 Q1 Q2

Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering V6.1

9 9 9 9 9 9

V6.1 SP 1 V6.1 SP 2 CEMAT V7 PCS7 V7 PCS7 V7 Sp1

page 99

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Roadmap Migration


Introduction PCS7 CEMAT Philosophy Support, Training
9/10 11/12 1/2 3/4 5/6 7/8 9/10 11/12 1/2 3/4 5/6

Migration from V2, V3, V4 to V6.1


2003 2004 2005

Migration Strategy Our Partners Roadmap Sales, Ordering


V3 to V6.0 V4 to V6.0 V4-S5 to V6.1CFC V4-S7 to V6.1 CFC V2 to V6.0 V2,V3,V4 to V6.1

page 100

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Order Information and Internet links


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

page 101

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Order Information


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering
Licenses for CEMAT 6DL5436-8AX16-0XA0 ENG 6DL5435-8AX16-0XA0 Client 6DL5434-8AA16-0XA0 OS with 3 AS 6DL5433-8AA16-0XA0 Server with 3 AS 6DL5433-8AB16-0XA0 Server with 6 AS 6DL5433-8AC16-0XA0 Server with 9 AS 6DL5433-8AD16-0XA0 Server with unlimited PLC 6DL5433-8AB16-0XD0 Upgrade from AS3 to AS6 6DL5433-8AC16-0XD0 Upgrade from AS6 to AS9 6DL5433-8AD16-0XD0 Upgrade from AS9 to ASU

Microsoft Excel-Arbeitsblatt

page 102

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Product Information


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Internet/Intranet: www4.ad.siemens.de Product Support Process Automation Process Control Systems Add-ons for SIMATIC PCS 7 CEMAT application software or via Search Entry ID: 15219757

page 103

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Thank you very much for your attention!


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Helmut Witt Technical Management Development CEMAT Competence Center Cement

Phone +49 9131 18 3464 Fax +49 9131 18 3444 helmut.witt@siemens.com

page 104

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Siemens and the Cement Industry Products, Services and Solutions


Controller & IOs Operator Stations Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering Motors and Drives Pressure Transmitters Flow Metering Low voltage switch gears, motor starters Gas Analyzers
page 105 Januar 2008 Helmut Witt

Advanced Process Control

High- and medium voltage

Safety Products

Motor Control Centers

Temperature Transmitters

Level Measurment

Weight Measurement
Protection notice / Copyright notice A&D CC Cement

End

Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

page 106

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

SIMATIC PCS 7 - Life cycle


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering References Long term availability

Market introduction

1979

Market introduction

Projected ending

1994 1996

2009

2014 2015

SPS PLS

36 years SIMATIC S5 SIMATIC S7 Migration TELEPERM M SIMATIC PCS7 Migration

page 107

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

PCS7 V7

Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Alarm Management Optimized Engineering Turnaround, Usability Advanced Process Control- Library incl. APC CAE- Integration Improved Integration SIMATIC Batch, SFC, Route Control PROFIBUS PA- Redundancy Improved SIMATIC IT Integration Full Language Support Chinese Version and MICREX NX Open PCS7

page 108

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Project Standards


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Project Standards for Cemat V6.1


Code 000 004 006 007 023 024 025 026 027 028 Standard normal Holcim Dyckerhoff Heidelberger Zement Vigier Bushehr Caima Alsen Lafarge Rossi
Helmut Witt Protection notice / Copyright notice A&D CC Cement

page 109

Januar 2008

Cemat - Project Standard 004 - Holcim


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Main Characteristics Process Picture:


Beside the tagname indication for local or single mode. Tagname indicates no fault, not ready, fault or warning Machine indicates running or not running Annunciation blocks are only visible in case of a fault or simulation

page 110

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

Cemat - Project Standard 006 Dyckerhoff


Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

Main Characteristics

Operating modes: Each drive/damper/valve can individually be switched to single or non-interlocked single-start-mode (= local mode). In local mode Start-Button must remain pressed to run the drive Speed monitor must be acknowledged from local

page 111

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement

End

Introduction PCS7 CEMAT Philosophy Support, Training Migration Strategy Our Partners Roadmap Sales, Ordering

page 112

Januar 2008

Helmut Witt

Protection notice / Copyright notice A&D CC Cement