CEMAT PresentationV71474389

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
Cemat A Success Story

CEMAT has achieved 25% market share and 35% world market share during the past 3 years!
page 5
Januar 2008
Helmut Witt
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
SIMATIC PCS7
Cemat
page 6
Januar 2008
Helmut Witt
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
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
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
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
SIMATIC PCS 7 - Network components Hierarchical network configurations

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
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
SIMATIC PCS 7 - Network components SIMATIC Net SCALANCE W e.g.: Monorail System
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
SIMATIC PCS 7 - Network components SIMATIC Net SCALANCE S (for Security)

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
SIMATIC PCS 7 - connection to the field Flexible and easy integration of field devices
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
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
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
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

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

page 20
Januar 2008
Helmut Witt
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.
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
SIMATIC PCS 7 - Automation system Basic units: AS from the S7- 400 range
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
! Assembly and testing no extra charge

page 23
Januar 2008
Helmut Witt
SIMATIC PCS 7 Operator System Hardware & Software Components

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
Upgrades via PowerPacks

SIMATIC PCS 7 Operator System Hardware & Software Components

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
SIMATIC PCS 7 Operator System GUI Multi-Screen

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
Operator System Overview

Alarm System Process Visualization

Excel
Programming Interfaces
Archive System
Standard Interfaces
Report System
Data Management
page 27
Januar 2008
Helmut Witt
SIMATIC PCS 7 - Operator Station The user interface


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

SIMATIC PCS 7 Operator System Trend Displays

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
SIMATIC PCS 7 Operator System Archive System Performance

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
page 30
Januar 2008
Helmut Witt
SIMATIC PCS 7 Operator System Archive System Performance

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
SIMATIC PCS 7 Operator System Archive System StoragePlus integrated Viewer

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
SIMATIC PCS 7 Operator System Alarm system

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)
SIMATIC PCS 7 Operator System Alarm system

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

SIMATIC PCS 7 Operator System Additional Features


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
SIMATIC PCS 7 - Engineering System
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
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
SIMATIC PCS 7 - Engineering System One Central Engineering


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

SIMATIC PCS 7 - Engineering System Automatic software generator for station plans
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
SIMATIC PCS 7 - Engineering System Generation of overview displays from plant hierarchy
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

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

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
SIMATIC PCS 7 - Engineering System Libraries

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
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
SIMATIC PCS 7 Integrated Fail-Safe

Minimized error sources, because of

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

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

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
SIMATIC PCS 7 - Plant Asset Management Hierarchal Structure

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
SIMATIC PCS 7 Increase Your Profit While Reducing Costs

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
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
SIMATIC PCS 7 - Interfacing SIMATIC IT

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
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
SIMATIC PCS 7 - Interfacing SIMATIC IT Trend Viewer

page 53
Januar 2008
Helmut Witt
SIMATIC PCS 7 - Interfacing SIMATIC IT Excel Add-in

Excel Add-in offers easy data analysis and reporting with standard office tools
page 54
Januar 2008
Helmut Witt
SIMATIC PCS 7 - Interfacing SIMATIC IT Report Manager

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
SIMATIC PCS 7 - Interfacing SIMATIC IT Key Performance Indicators

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
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

MASTERDRIVES SIMODRIVE POSMO A/SI /CA/CD Vector Control Motion Control 611U
SIMATIC PCS 7 - AddOn Advanced Process Control

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)

SIMATIC PCS 7 AddOn Energy Management - SIMATIC powercontrol


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.

SIMATIC PCS 7 - AddOns Examples (1)

Video monitoring
Frequency converter Master drives Fingerprint mouse Motor starter Simocode
Big screen
page 61 Januar 2008
Ex operating units
Helmut Witt
Cabinet engineering
SIMATIC PCS 7 - AddOns Examples (2)

Industry-specific libraries Block library fuel technology CEMAT cement industry package
Bus analysis tool BANY
Adaptive controller ADCO

4-quadrant display
page 63
Januar 2008
Helmut Witt
Cemat is more than a library..

High quality Documentation
Classroom Training & Support
Demo Systems
Engineering Tools
Migration tools
Order Information & Internet links
page 64
Januar 2008
Helmut Witt
Cemat - Control System

Developed in close co-operation with Cement Manufacturers world wide
page 65
Januar 2008
Helmut Witt
Cemat - is a Philosophy
. . . 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
Cemat - Operation of a Cement Plant

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
Cemat - Fault Diagnosis in a Cement Plant

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
Cemat - Software Interlocking in a Cement Plant

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
Cemat - Plausibility/Priority Logic function

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
CEMAT Faceplate - Motor

The heading line contains the plant identification and the associated comment for the AS module. Modul Status Display
Diagnosis Display AS module diagnosis
Help Function
Info Object-related information

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

CEMAT Faceplate - Diagnosis

Process parameter operator control
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
Operating time acquisition

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

CEMAT Message Dialog

The message list window consists of three areas: 1. Toolbar message window
2. Message list
3. Selection input dialog
page 76
Januar 2008
Helmut Witt
Cemat - Sample Configuration

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
Cemat - Key Features


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
Cemat - Cost Savings


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

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
page 80
Januar 2008
Cemat - Engineering

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
page 81
Januar 2008
Cemat - Alarm System, Support for the Maintenance Staff


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
Cemat - Service & Support


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

... fast and reliable

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
Simatic PCS7 Knowledge available Simatic PCS7 Training as precondition 2 weeks
page 84
Januar 2008
Helmut Witt
Cemat - Support ..
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
Cemat - Demo System

page 86
Januar 2008
Helmut Witt
Cemat - Video
page 87
Januar 2008
Helmut Witt
Cemat - Engineering Tools

page 88
Januar 2008
Helmut Witt
Cemat - Incorporated Interfaces for Solution Packages

page 89
Januar 2008
Helmut Witt
Cemat - Migration
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

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

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
Cemat - Migration
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
Cemat - Migrations Tool COROS LSB to CEM V6 OS

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
Cemat - Migration STEP5 to CFC charts

S5 155 U CEMAT V4
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

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

Additional manual work
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
From CEMAT PLC V4 From CEMAT PLC V6
page 97
Januar 2008
Helmut Witt
Cemat - System Integrators give local support (extract from the list)
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
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
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
Cemat - Order Information and Internet links

page 101
Januar 2008
Helmut Witt
Cemat - Order Information

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
Cemat - Product Information

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
Thank you very much for your attention!

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
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
Advanced Process Control
High- and medium voltage
Safety Products
Motor Control Centers
Temperature Transmitters
Level Measurment
Weight Measurement
End
page 106
Januar 2008
Helmut Witt
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
PCS7 V7

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
Cemat - Project Standards

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
page 109
Januar 2008
Cemat - Project Standard 004 - Holcim

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
Cemat - Project Standard 006 Dyckerhoff


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
End
page 112
Januar 2008
Helmut Witt

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Welcome

Protection notice / Copyright notice

Competence Center Cement

More than 30 Years of Cemat

More than 520 CEMAT installations since 1971

CEMAT Philosophy Cemat Cemat V1.6

Our Partners Roadmap

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

PCS7 V7 SP1 SIMATIC S7

Protection notice / Copyright notice A&D CC Cement

CEMAT Version ... throughout the world today

Plants with Cemat based on PCS7

Protection notice / Copyright notice A&D CC Cement

Cemat A Success Story

Protection notice / Copyright notice A&D CC Cement

Cemat is integrated in Simatic PCS7

Protection notice / Copyright notice A&D CC Cement

965 Installations in Asia

360 Installations in America

Algeria Egypt Mauritius Morocco Mozambique Namibia Swaziland Kenia Nigeria

Protection notice / Copyright notice A&D CC Cement

What does SIMATIC PCS 7 comprise ?

PCS7 Operator System (OS) & Batch Clients

PCS7 Operator System (OS) & Batch SERVER

PCS7 Engineering System (ES)

AUTOMATION SYSTEM (AS)

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

SIMATIC PCS 7 System Architecture

Introduction PCS7 CEMAT Philosophy Station Support, Training

Internet/ Intranet OS Single

WEB Server / OPC Server Service

Migration Strategy Our Partners Roadmap Sales, Ordering

AS 417 AS 416 AS 414

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

ET 200M failsafe ET 200M DP/PA Link

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

SIMATIC PCS 7 Large bandwidth of scalability

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

as powerful as you need it to be !

SIMATIC PCS 7 Redundancy At Each Level

Our Partners Roadmap Sales, Ordering

Redundant I/O Sensor/ control element

SIMATIC PCS 7 - Network components Hierarchical network configurations

100 Mbit/s Process bus

Protection notice / Copyright notice A&D CC Cement

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

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

Our Partners Roadmap Sales, Ordering

X208PRO X-200 X208

Protection notice / Copyright notice A&D CC Cement

Protection notice / Copyright notice A&D CC Cement

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

Secure Internal LAN A Security Module A

Secure Internal LAN B

Protection notice / Copyright notice A&D CC Cement

MIS, ERP, Asset Management

SIMATIC PCS 7 Engineering

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

DP/PALink ET 200M ET 200iSP

PROFIBUS-PA field devices

4-20 mA / HART I/O module

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