Siemens Two-Way Radio SIMATIC PCS 7 User Manual
© Siemens AG 2011
Products and functions for
efficient maintenance in the
process automation
Brochure · October 2011
Maintenance System
Answers for industry.
Benefits of intelligent maintenance
Continuous plant monitoring
■ Reduces the risk of failures, and increases the
availability
■ Enables maintenance to be planned
Optimized use of maintenance resources
■ Increases maintenance quality
■ Achieves cost savings
The potential for savings arises
■ During maintenance itself and
■ by avoiding consequential costs
Corrective Preventive
Maintenance
Time-dependent
Load-dependent
Condition-based
G_ST80_XX_00410
© Siemens AG 2011
Introduction
Increase in productivity through intelligent maintenance
How can the productivity of a plant with a high level of automation be increased even further?
Plant operators in all sectors consider increased availability and shorter downtimes to be the most effective lever toward increasing productivity. Investigations have shown
that downtimes are frequently the result of insufficient
maintenance – despite the fact that maintenance is already a significant portion of the lifecycle costs.
Intelligent maintenance strategies can make a significant contribution toward increasing productivity:
• Failures can be prevented by monitoring the current plant
condition.
• Maintenance can then be planned. It does not wait until a
fault has occurred, but implements appropriate measures
in advance for avoiding faults. The timing of maintenance
can be planned such that the existing resources can be
used optimally.
• Innovative maintenance strategies pay for themselves
twice: planning security and the specific application of methods reduces the direct maintenance costs.
• Plant availability is increased at the same time. This means
that consequential costs resulting from failures, such as
quality deficiencies or loss of image, are reduced.
Totally Integrated Automation supports intelligent maintenance strategies. The SIMATIC Maintenance Station is of significant importance, and presents the information relevant to
maintenance from all automation components in a uniform
and clear manner, thus providing the maintenance engineer
with valuable support for making decisions.
Condition Monitoring, that is to say status monitoring, aims
to detect imminent faults at an early stage. It provides information on the remaining duration of use. In the case of condition-based maintenance, the maintenance measures are
only initiated when the period of use has expired.
It has been shown in practice that optimum results can be
achieved through intelligent combination of the different strategies.
Maintenance strategies
There are two maintenance strategies: response to failures or
taking preventive measures. In the case of failure-oriented
corrective maintenance, measures are only initiated when a
fault has occurred, i.e. failures are acceptable in this case and
may be minimized by a redundant plant design.
The objective of preventive strategies is to carry out mainte-
nance measures before faults even occur, in order to avoid
possible downtimes. This strategy can be satisfied using
time-dependent and load-dependent measures. Regular
maintenance work is an example of time-dependent measures. The load state is determined from the number of switching operations, operating hours or load peaks.
Introduction2
Maintenance strategies
© Siemens AG 2011
Contents
Text
Introduction
Increase in productivity through
intelligent maintenance . . . . . . . . . . . . . . . . . . . . . . . 2
Plant-level asset management as a
maintenance task . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Intelligent maintenance
in process engineering . . . . . . . . . . . . . . . . . . . . . . . . 6
SIMATIC PCS 7 Maintenance Station
More productivity with
Totally Integrated Automation . . . . . . . . . . . . . . . . . . . 7
Visualization of information
for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance Station –
User interface for maintenance . . . . . . . . . . . . . . . . . . 9
Add-ons as options for the SIMATIC PCS 7
Maintenance Station . . . . . . . . . . . . . . . . . . . . . . . . . 12
Monitoring and diagnostics
for industrial PCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
of networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
for process instrumentation and analytics . . . . . . . . 16
for positioners and control valves . . . . . . . . . . . . . . . 21
of 24 V load feeders . . . . . . . . . . . . . . . . . . . . . . . . . . 22
of wear in the motor. . . . . . . . . . . . . . . . . . . . . . . . . . 22
of drive components. . . . . . . . . . . . . . . . . . . . . . . . . . 25
Plant-level asset management with
Totally Integrated Automation components . . . . . . . 27
Introduction 3
© Siemens AG 2011
Plant Asset Management as a maintenance task
General information
Various tasks have to be handled during the operating phase
of a plant, for which different groups of persons are responsible.
The production personnel operate and monitor the plant, and
make sure that the desired products are produced with the appropriate quality, in the defined quantity, at a specified time,
and with minimum resources with respect to personnel, raw
materials, energy, costs, etc.
Maintenance staff must
• ensure a high availability of the plant,
• ensure this availability in the long term by implementing
optimization measures, and
• carry out maintenance measures with minimum use of personnel, material, energy, costs, etc.
As a result of their different tasks, these two groups of persons
have different information requirements.
Information on the measured process tags is available for the
plant operator. Apart from the measured value itself and its
status, this may, for example, be the information on whether
the measured value is still valid.
The focus of interest for the maintenance engineer is the status of the production equipment that is reflected in the states
of the devices and components used (i.e. particularly in the
states of the field devices). Typical states in this respect include "Component OK", "Maintenance required", "Failure" or
"Function check".
SIMATIC PCS 7 allows a clear classification of the information
for the user groups Plant Operators and Maintenance Engineers.
Different demand for information at the plant
Plant operator
Information on the process such as:
• Recipe parameters
• Temperature characteristic
• Pressure values
•Raw material stocks
•Output
Maintenance personnel
Information on the state of the production equipment such as:
• Components OK
•Maintenance required
•Failure
• Functional check
Introduction4
© Siemens AG 2011
Asset management in production
The term asset management comes from the world of finance
and economics and refers to the manner in which a company
deals with its long-term and current assets. These include the
production equipment with its plant components such as apparatus, machines, pipelines etc. and the equipment and devices for their automation. All these are referred to as assets.
In association with production, asset management covers all
activities and measures which serve toward retaining or increasing the value of a plant. This is called Plant Asset Management.
Benefits of Plant Asset Management
Plant Asset Management allows the maintenance engineer
• to unambiguously identify and evaluate the assets, this means the production equipment and its components;
• to carry out the appropriate measures in the case of deviations from the desired or expected state.
As a result of monitoring, i.e. the recording and evaluation of
status variables, the condition of a component or device can
be determined.
It can be recognized, for example, that no signal is received
from the sensor, resulting in the diagnosis "Open circuit". This
result triggers a maintenance request, and maintenance must
then be carried out to eliminate the open circuit.
This measure – replacement of a faulty line in this example –
ensures that the component is returned to the desired condition and closes the maintenance cycle. This means that Plant
Asset Management is the basis for increased productivity.
Maintenance
measure
Maintenance
request
Monitoring
Diagnostics
Introduction 5
© Siemens AG 2011
Intelligent maintenance in process engineering
Despite the different tasks of operators and maintenance
staff, it is meaningful and necessary to map the information of both staff groups within one process control system
and not to use different systems.
There are various reasons for this:
• Uniform visualization for all components and devices.
• No limitation to selection of field devices.
• The same information sources (field devices) are relevant
to both automation and maintenance.
• There is a close link between automation and asset management functions because, for example, the current
control strategy of the plant plays an important role for the
assessment of a component status.
• Engineering data for automation can also be used for maintenance.
• Simplified handling of the system, since users need only be
acquainted with the engineering, operator control and monitoring tools of a single system.
The process control special interest group of the pharmaceuticals industry (NAMUR) has formulated essential requirements
(NE 91) from the user's viewpoint. This attaches special significance to the integration of the Plant Asset Management into
the process control system.
• Plant Asset Management is a part of the process control
system
• Recording and assessing the status of the assets
• Inclusion of all assets (process control devices and plant
components)
• Separation of maintenance-relevant information and process data
• Uniform visualization for all assets
• No limitation to selection of field devices
In addition, there is a requirement (NE 107) that all field devices must provide standardized status messages about their
status as follows:
• Good
No known restriction of function
•Uncertain
Operation outside the specified range
• Device failure
Need for maintenance
•Maintenance required
Function check (process value manipulated)
• Function check, local operation
Failure (process value invalid)
Processing plants, whose open and closed loop control is performed with SIMATIC PCS 7 and components of Totally Integrated Automation, satisfy the user requirements formulated
by NAMUR.
The resulting information is divided up to prevent the plant
operators and maintenance staff from being flooded with information. To achieve this, a Maintenance Station (MS) is introduced in addition to the operator station (OS). Maintenance-relevant information is kept away from the operator
station. This information is collected and presented on the
Maintenance Station. The same HMI tools are used for the
operator station and the Maintenance Station and the HMI
philosophy is identical.
Plant Asset Management with SIMATIC PCS 7
■ Process engineering plants with SIMATIC PCS 7 and com-
ponents of Totally Integrated Automation meet the requirements of NAMUR.
■ Automation and Plant Asset Management run on the
same system.
■ The information for plant operators maintenance staff is
divided between the operator station and the Maintenance Station.
■ Shared configuration and uniform user interfaces mini-
mize the expense of an effective Plant Asset Management.
Introduction6
Central control room with plant-wide maintenance overview
Inbound process Productions process Outbound process
G_ST80_XX_00337
Maintenance Station
Server (WinCC)
Maintenance Station
Server SIMATIC PCS 7
,QWHUQHW
Maintenance Station
Server (WinCC)
Maintenance
Station Client
+ Web Server
Maintenance
Station Client
© Siemens AG 2011
SIMATIC PCS 7 Maintenance Station
More productivity with Totally Integrated Automation
Integrated plant and cross-system maintenance
Plant Asset Management is only truly productive if maintenance staff can view diagnostic information relating to the entire process chain. In practice, this means that the same maintenance team that is responsible for the actual process can
support inbound and outbound processes such as logistics,
bottling and packaging plants without having to build up a
great deal of additional expertise. If the process control system and the controllers of the upstream and downstream systems originate from different vendors, different alarm systems can cause considerable additional expense.
If a plant is automated with SIMATIC PCS 7, therefore it is worthwhile for the plant operators to select machines and systems that are automated with SIMATIC and visualized with
SIMATIC WinCC for their inbound and outbound processes, as
then they can exploit all the advantages of Totally Integrated
Automation.
If machines or systems for inbound/outbound processes are
operated and monitored by means of SIMATIC WinCC, then
the SIMATIC Maintenance Station presents itself as an option
to SIMATIC WinCC for maintenance-relevant information.
The integrated functionality of Totally Integrated Automation
also makes it possible, using the SIMATIC PCS 7 Maintenance
Station, to monitor the packaging or bottling line by means of
a client. Display, logic, and message management are identical. The uniform look and feel saves on overhead and generates a high degree of acceptance within the maintenance
team. The SIMATIC Maintenance Station for SIMATIC PCS 7
and SIMATIC WinCC makes a significant contribution to increasing maintenance productivity and thus to increasing the
availability of the overall plant.
Optimizing instead of repairing
The task of maintenance is not only to avoid unscheduled production downtimes, but also to optimize the running of the
plant. Optimization must be based on analysis of traceable
processes. The Maintenance Station offers the basic data set
for integrated analysis of all weak points. This is not unusual
in a process control system. However, in inbound and outbound processes diagnostics are often restricted to signaling
a fault and then forgetting about it as soon as it has been repaired. With Totally Integrated Automation, the Maintenance
Station becomes the basis for Total Productive Maintenance.
SIMATIC Maintenance Station: Collecting diagnostic information from the entire process chain centrally – even via the Web
Suitable protective measures (among others IT-Security, e.g. network segmentation) have to be taken up to ensure a safe operation of the plant.
You find further information about the topic of Industrial Security on the Internet under www.siemens.com/industrialsecurity.
SIMATIC PCS 7 Maintenance Station 7
Overview
Automation
system (AS)
Detailed view
Component/
Device
Plant view
AS rack
1
Subnet
AS rack
2...n
G_ST70_XX_00413
Identification of device
Operate state display
Maintenance state display
Maintenance group display
G_ST80_XX_00421
© Siemens AG 2011
Visualization of information for maintenance
In order to recognize the conditions of individual devices
or components unequivocally, a uniform symbol representation has been implemented.
There are symbols for the device status itself and also for the
importance of a maintenance request. In addition, the status
of a maintenance measure is displayed. The conditions of all
devices and equipment of the automation technology and of
the plant components are indicated by these standardized
symbols.
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Uniform symbols for the conditions of components and devices
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Besides the uniform display of symbols, a significant detail for
the overview is a hierarchical structuring of information in
which the maintenance engineer also has access to all required details of the components and devices, based on an overview display (plant view).
The overview display uses the standardized symbols to visualize the condition of a component itself and also provides collective information on the conditions of all devices in the subordinate hierarchies.
The collective condition message shows the OK condition or
the seriousness of a possible problem in red, yellow, or green,
as per a traffic light. A button can be used to access all subordinate hierarchy levels step-by-step down to the bottom device level.
Further views of the maintenance information are available in
addition so that the maintenance engineer has a complete
overview of all current information of the asset relevant to
maintenance. This permits assessment of the plant status at a
glance.
Extract from the hierarchical visualization of the maintenance
information
SIMATIC PCS 7 Maintenance Station8
Detailed view of a component
The information is consistently structured and hierarchically
organized. The quantity of information displayed on each individual screen always remains manageable for the maintenance engineer, who nevertheless has easy access at any time
to the complete information.
© Siemens AG 2011
Maintenance Station – User interface for maintenance
The SIMATIC PCS 7 Maintenance Station software package
is available as an alternative to SIMATIC PCS 7 for implementing Plant Asset Management. You can use this software package to expand an Operator Station to a
Maintenance Station.
The maintenance engineer can process the diagnostics messages and maintenance requests of the assets on the Maintenance
Station. Via the Maintenance Station the engineer can access:
• Electronic components of the process control system: intelligent field devices and I/O modules, field bus, controller,
network components and plant bus as well as servers and
clients of the operator systems.
• Mechanical components that do not belong directly to the
process control system such as pumps, motors, centrifuges, heat exchangers or control loops (passive or indirect
assets). These are represented by proxy objects in which
the diagnostics rules are stored.
Monitoring and diagnostics of mechanical components
Exceeding the limits of the pump's rated operating range and
deviations from the anticipated characteristic curve are reported to the user as maintenance alarm via the PumpMon block.
The block outputs are simultaneously made available for
further processing. In this way, the user gets the opportunity
to intervene in a preventive way to prevent damage to the
pumps, which helps to reduce plant downtimes and increase
its availability. It also allows the pump layout to be optimized.
PumpMon block: Transport characteristic curve with current operating
point
For mechanical components without self-diagnostics (pumps,
heat exchangers, valves, compressors, etc.), inadmissible operating states can be determined from various measured values
that already exist in a process control system using special diagnostic blocks. Deviations from an established normal status
can be used for this, for example.
Pump monitoring with the block PumpMon
The diagnostic block PumpMon is used for
• Warning of pump damage when there is blocking, dry running, gas in the transported substance, cavitations, overload, or improper running;
• Early detection of initial pump damage, such as wear or decreasing pump efficiency;
• Long-term optimization the pump design by means of statistical analysis of the operating data, for example, recording the load spectrum.
Valve monitoring with the block ValveMon
Abrasion, cavitation, corrosion of the valve plug or seat as well
as caking (fouling, deposits) are the most common signs of
wear for valves. ValveMon monitors the valve status according
to specific process values and enables the detection of malfunctions and impending failures at an early stage.
Heat exchanger monitoring with the block HeatXchMon
The main problem with heat exchangers is fouling. Fouling results when residues of the process medium are deposited on
the transfer surfaces and thus impair efficiency. HeatXchMon
determines deviations of the current heat flow from the reference heat flow in the clean state. The current degree of fouling, the energy loss and daily costs can thus be precisely calculated and displayed.
The HeatXchMon block not only indicates the current performance capability of the heat exchanger, it also calculates the daily energy loss due to
the degree of fouling.
SIMATIC PCS 7 Maintenance Station 9
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