Siemens pa module p03-01 User Manual

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SCE Training Curriculum for Integrated Automation Solutions Totally Integrated Automation (TIA)

Siemens Automation Cooperates with Education

PA Module P03-01

SIMATIC PCS 7 – Advanced Layout of UIs

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Matching SCE Trainer Packages for these curriculums

 SIMATIC PCS 7 Software block of 3 packages

Order No. 6ES7650-0XX08-0YS5

 SIMATIC PCS 7 Software block of 6 packages

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 SIMATIC PCS 7 Software Upgrade block of 3 packages

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 SIMATIC PCS 7 Hardware Set including RTX Box

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Note on Usage

The training curriculum for the integrated automation solution Totally Integrated Automation (TIA) was

prepared for the program "Siemens Automation Cooperates with Education (SCE)“ specifically for

training purposes at public educational and R&D facilities. Siemens AG is not liable regarding the contents.

This document may only be used for initial training on Siemens products/systems. This means: it may be copied entirely or partially and handed to trainees for use within the scope of their training. Passing on or copying this document and communicating its contents is permitted within public training and continued education facilities for training purposes.

Exceptions require written permission by Siemens AG. Contact person: Roland Scheuerer

roland.scheuerer@siemens.com.

Violators are subject to damages. All rights including translation rights are reserved, particularly in the event a patent is granted or a utility model or design is registered.

Usage for industrial customer courses is explicitly not allowed. We do not agree to the commercial utilization of these documents.

We would like to thank the Technical University Dresden, particularly Prof. Dr. Leon Urbas and Annett Krause MS, as well as the Michael Dziallas Engineering Corporation and those who provided support in preparing this training curriculum.

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ADVANCED LAYOUT OF UIS

TRAINING OBJECTIVE

After working through this module, the students have additional knowledge regarding the design of the user interface of an operator station. They are able to make additional information available on the detail level. To this end, they use adapted message lists and trend curves. The students are able to combine created composites into a user defined object and redesign existing objects as user defined objects. These objects can then be made available for reuse.

THEORY IN BRIEF

In this chapter, some aspects of OS engineering are considered in greater depth. While in chapter P02-01 automatic generation of process images was primarily discussed, now supplementary techniques for designing process control are described.

The flow diagrams (refer to P02-01) are usually arranged in the following hierarchical levels:

– Plant display – Area display – Plant section/group display – Detail display

This classification can result from the plant hierarchy. While the upper levels aim for a good overview of the entire plant or corresponding areas, the plant section display and the detail display are to provide considerably more information about the area under consideration to make situation-conforming settings of parameters or fault diagnosis possible.

In addition to detailed information about the current state of the areas under consideration, the representation of process values in curves is particularly helpful to analyzing deviations. In curves, the time characteristics of a process value are represented. With one glance, the operator can immediately read off the following information:

– The time when striking changes occurred in the course – Process values at the time mentioned above – Gradients for certain points in time – Dependencies between process values at simultaneous display – Extreme values (when and how large) – Fluctuation range – Set point deviations – Frequencies

Curve displays provide the operator with an expanded basis for decisions regarding control action. If a process value is outside the permissible range, based on the curve the user is informed of process value development in the most recent past and can detect whether the value continues to change for the worse or is improving.

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Multi purpose plant

Educt tanks Reaction Product tanks

Tank 1

Rinsing

Tank 2 Tank 3

Reactor 1Reactor

Tank 1 Tank 2 Tank 1

Plant and area

display

Plant section

display

Detail display

THEORY

HIERARCHY OF FLOW DIAGRAMS

In chapter P02-01 the objectives of process control as well as of basic design concepts and techniques for OCM interfaces (operator control and monitoring interfaces) were described.

Chapter P01-03 introduced the physical model of a system consisting of a plant, a plant section, equipment module and an individual control unit. Analogously, a hierarchy of flow diagrams exists in process visualization that is arranged as follows, according to [1]:

– Plant diagram – Area diagram – Plant section/group diagram – Detail diagram

The hierarchy of the flow diagram facilitates orientation and specific display selection. The uppermost levels Plant display and Area display provide an overview and are usually represented schematically. In small plants, the plant display corresponds to the area display (refer to Figure 1). In the plant display, it has to be possible to select each area directly. In the area display, the plant sections are displayed in a manner that their state can be recognized and the plant section can be selected and operated. The plant section and group display reflect functional relationships; typical units, final control units and control systems can be operated. Detail displays are of great importance to parameter assignment, commissioning and error search if there are plant faults. In detail displays, individual devices and units are represented and by means of effective lines, the functional relationships can be visualized. For example, the signal flow of a control loop can be tracked. [1].

CURVES

Curves are used for process control during intended operation, or for diagnosing faults [2]. They supplement the display with flow diagrams, particularly because they indicate the dependence of process values on time.

Related displays are: the display of a process value depending on the path, on other process variables, and even of several reference variables that are not described here, however.

Figure 1: Hierarchy of mimics

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The Purpose of Curves

Curves are displayed to show courses. By selecting different time horizons, different tasks can be implemented. Three variants exist in reference to the time the operator has the curve displayed.

1. The curve shows the past without the present. Such a curve is called history and is used for analysis. This can refer to a fault analysis but also to an analysis to optimize process control.

2. The curve shows the present with the recent past. This type is called pre-history. It can be used to display a trend. It is the most frequently used type of display regarding process control. From the course, the operator is able to read off qualitative values such as rising, falling, or steady and quantitative values such as the process value at a certain time, or the difference regarding a setpoint.

3. The curve shows the most recent past, the present and the future, and is called prediction display (refer to Figure 2). It is used to predict a process value and allows the user to intervene before the event occurs. To represent the future, the possible value course has to be calculated in advance.

Figure 2: Prediction display according to [2]

In general, the following values can be determined quite well through curves:

– Points in time where striking changes occurred in the course – Process values at the points in time indicated before – Gradients at certain points in time – Dependencies between process values at simultaneous displays – Extreme values (when and how large) – Fluctuation ranges – Deviations from the setpoint – Frequencies

This variety of characteristics that can be read off shows the importance of curve displays. While the current process values and extreme values that occurred can be represented otherwise -for example, with analog or digital displays- the display of the other characteristics in such a compressed and immediately understandable form is difficult to conceive [3].

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Prehistory

History

Position of the time span shown in the curve field

Always relative to the present

Through an absolute point in time and a selected time span or through two absolute points in time

Labeling of the time axis

Relative time indications; if needed, can be switched to absolute time indication

Absolute time indications can be switched to time indications relative to a defined point in time of an event

Updates

Curve is updated during the display whereby all curve points are shifted

Curve does not change

Value axis

The value axis is usually located at the point in time of the present (at the right margin of the display)

The value axis is located on the left margin of the display

Acquisition and Storage of Curve Values

For the displayed course to reflect the actual course, the sampling rate of the process value has to correspond at least to twice the change frequency of the process value. In most cases, this requirement can be met with cyclical acquisition every 1s [2].

In PCS 7, the sampling rate corresponds to the acquisition cycle of a process value. As long as a process value is not archive, only the pre-history of the process value can be displayed. By archiving a process value (refer to chapter P02-03) the history can be displayed also, since archive variables are resorted to.

When curves are displayed, the pre-history differs from the history as shown in Table 1.

Table 1: Visible Differences between Prehistory and History [2]

Designing Curve Displays

In [2], guidelines for designing curve displays are provided. PCS 7 implements the basic design details by default; for that reason, they are described here only briefly. There are design rules, however, that you can implement yourself by means of the settings at OS engineering. To do this in a specific way, a few details are introduced here.

The curve display is displayed in the working area of the display area (refer to P02-01). It consists of the title field, the curve labeling field, and the curve field. The title field should contain the information for the unambiguous assignment to the process environment. In the curve labeling field, it should be possible to read off the relationship of displayed the curve and the process value. The curve display field is used to display the curve and should be as large as possible. To implement the curve display field, the following information is provided.

To facilitate reading off the values, grid lines have to be available. The value axis in this case should display several lines as an extension of the scale marks, and the time axis several lines according to the current time grid. The number of grid lines should be low and optically remain in the background. To this end, they should not be shown in color or blue. Reading rulers can provide additional support.

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Primary Task

Preassigned Display

Time Spans

Updating Cycle (only for prehistory)

Scale Mark

Commissioning

5 min

1 s

1 min

Process Control or Analysis

15 min

1 s

5 min

30 min

2 s

5 min

2 h

8 s

30 min

8 h

32 s

1 h

24 h

96 s

4 h

4 days

384 s

12 h

Analysis

7 days

1 day

30 days

7 days

90 days

15 days

360 days

90 days

The curves should be displayed colored as continuous lines or as a series of dots. Color coding can be selected as required. The number of curves for each curve display field should be limited to six. The colors of the curves should be easily distinguishable from each other.

To implement the curve course, the following directions are recommended:

– From right to left: more recent values to the right, older values to the left – From top to bottom: more recent values on top, older values on the bottom

The deciding factor in this case is whether a display time span that is as large as possible (from left to right) or a value resolution that is as high as possible (from top to bottom) is needed.

When curves with a prehistory are displayed, the curve course is updated; the entire curve shifts in the direction of the past (refer to Figure 2). If there is a shift with each new entry, the entire curve display field can be used to display the prehistory, and the operator can follow the display well since the curve is shifted only a little. If needed, it should be possible to stop the update.

For labeling the value axis, 1, 2 and 5 should be used for scale marks as well as their decade multiple. The value axis can be scaled in units or in percent. Table 1 shows where the value axis should be located. Also, a display with two value axes can be useful; in this case, the percent axis for all curves is displayed to the left, and the display of the values of a curve in units to the right. The time axis should always be labeled as shown in Table 1.

To display time spans [2] offers the time spans and scale marks recommended in Table 2. It was taken into account here that if there is a change to another display time span, the same point in time can be located again.

Table 2: Recommended Display Time Spans [2]

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ACTIVEX CONTROLS

Working area

Message list filtered by Reactor R001

Curve display with process values for Reactor R001

- temperature

- level

- manipulated value of the controller

- ...

PID-Regler

Detail display of Reactor R001

Curves are configured in OS engineering of PCS 7 either by setting up curve groups (Chapter P02-03) or by using configurable ActiveX Controls. PCS 7 provides ActiveX Controls for alarms, curves, and tables. Curves can be used to display time characteristics (Online Trend Control) and also to display dependencies between process values (Function Trend Control).

In the Online Trend Control, two different sources exist for displaying a curve. The first source is the process value that is buffered while the ActiveX Control is active. With this source, the trend can be displayed during monitoring. Here it is important that when ActiveX Control is closed, the values can no longer be called. If the second source is used, the data is taken from the archive (refer to P02-03). The process values taken from there can be displayed again and again. Depending on the time span selected, past data (history) can be called as well as the most recent data (prehistory). These values can be called again as long as they are in the short term archive. The size of the short term archive depends on the configuration as described in chapter P02-03.

Additional ActiveX Controls are the display of process values in tables (Online Table Control) or of the alarms in alarm lists (Alarm Control). Alarm Control receives its data always from the archive while the table, analogous to the Online Trend Control, has different sources.

ActiveX Controls are quite suitable for designing detail displays, since they provide additional information specifically for a detail area. To this end, specific process values for the corresponding detail display or filters for alarm lists can be selected and preconfigured; for example, by means of the attribute Origin. Figure 3 sketches a possibility for designing the detail display.

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Figure 3: Layout for a detail display

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USER DEFINED OBJECTS

A user defined object (UDO for short) is an object that can be dynamical and consists of individual objects. At OS Engineering, we identify the properties that can be changed and select them for the user defined object. Thus, only the most important properties of all individual objects are visible and provide a good overview of the properties. In addition, it is possible to specify some properties as unalterable for all instances, and combining each individual object for each instance is dispensed with also.

On the other hand, there is the increased effort for the careful selection of the properties; however, it amortizes quickly through multiple use. User defined objects that are to be used multiple times are stored in the library.

Also, alterability is facilitated since, for example, a block name or a CFC name has to be changed only at the user defined object and not at all individual objects.

The individual instances can be changed or supplemented with additional objects any time. If C-Actions are used for dynamical actions, this is done in the case of user defined objects in a script, and not in many individual objects. This increases the performance of visualization.

LITERATURE

[1] VDI/VDE 3699 Blatt 3: Prozessführung mit Bildschirmen – Fließbilder, Nov 1999. (Process Control with Screens – Flow Diagrams) [2] VDI/VDE 3699 Blatt 4: Prozessführung mit Bildschirmen – Kurven, Aug 1997. [3] Kindsmüller, M. C.: Trend-Literacy, Shaker Verlag 2006. [4] Siemens AG: Projektierungshandbuch Operator Station (V7.1), März 2009. (Configuration Manual Operator Station)

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STEP BY STEP INSTRUCTIONS

TASK

In this task, the display structure will be expanded by another level in order to show more detail for the individual tanks and reactors.

In the example, create in the display for reactor R001 a detail view with a bar display for the reactor level, an online trend display and a message window for displaying the alarms associated with Reactor R001.

Then, for better reusability (for example, for Reactor 002) change the bar display into a user defined object.

TRAINING OBJECTIVE

In this chapter, the student learns the following:

– To set up an ActiveX Control for displaying alarms – To filter the display of alarms matching the hierarchy – To insert and parameterize an ActiveX Control of the type ‘Online Trend’ to display

archive variables

– To create from a group of objects a user defined object – Parameterizing and using user defined objects These instructions are based on the project ‘PCS7_SCE_0203_Ueb_R1305_en.zip‘.

PROGRAMMING

1. First, insert a picture in the folder ‘Reactor R001’ and name it ‘Reactor R001‘. ( Reactor R001  Insert New Object  Picture  Reactor_R001)

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2. Then, adapt the settings of the plant hierarchy to the expansion. ( Tools  Plant Hierarchy  Settings)

3. The number of hierarchy levels is retained. However, at the third level a checkmark has to be placed at 'Included in HID‘; otherwise, there may be problems during simulation. ( Included in HID  OK  Yes)

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4. Then, the block icons have to be generated in the new picture. ( Reactor R001  Plant Hierarchy  Create/Update Block Icons)

5. Have the object name created from the chart names and include, as previously, a lower level hierarchy level. ( Object name: Chart Lower hierarchy levels included: 1  OK)

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6. Read the note regarding the compilation of the OS due now. The log can also be displayed. Confirm the dialog with ‘Yes’. ( Yes  )

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