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Automation and Drives

SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 1
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Differentiation
SIMATIC PCS 7
versus
SCADA / PLC
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 2
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary

Hardware
PC / OS

Hardware
AS

Hardware
Ethernet
S
o
f
t
w
a
r
e
DCS

Hardware
Highway

Software
HMI

Integration Engineering
/ Services

Software
PLC

Integration Engineering
/ Services

Software
Highway
SCADA/PLC

Hardware
PLC
Overview SCADA + PLC vs. DCS
n x Engineering Environment
n x Integration Overhead
1 x Engineering Environment
0 x Integration Overhead
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 3
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
How to reach the optimum?
HMI
Commissioning
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 4
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Changed cost structures require new
process control solutions
Engineering
Commissioning
Cost development
Hardware
Increased complexity of the automation task
Missing repetition of applications
To much different media
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 5
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Priorities in DCS solutions compared with
SCADA/PLC solutions
DCS SCADA/PLC
Control Capabilities:

Process I/O A A
Multivariable Regulatory Control A C

Complex Interlocking A B

Sequencing B C

Recipe Handling A D
Batch Process Control B D
User Interface:

Ease of Configuration (links & displays) A C

Ease of Operator Use A C

Ease of Creating Custom Displays A C
Cost:

Hardware C A

Installation A C

Application Programming A B
Additional Considerations:

Ease of Expansion (interactive functions) A D

Flexibility A C

Redundancy A C

Reliability A B

Hardware Maintainability A B

Software Maintainability B C
Prio: Prio:
Prio: Prio:
Prio: Prio:
Prio: Prio:
A: highest Prio.
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 6
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Special requirements to DCS solutions
Longer term of use of plants in process industry
longer innovation cycles,
longer availability of spare parts
Safety requirements demand high availability of the control system
redundancy
distribution of technological tasks on different controllers
redundant communication links
continuous self check of the control system
fast diagnostic functions
in case of failure:
DCS keep in RUN
PLC force in STOP
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 7
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Comparison of SIMATIC PCS 7 with a
SCADA / PLC solution
Component engineering
Database for each component
Multiple data entries
Individual programming tools
Individual communication modesl
System engineering
Central database
Data are entered once
Uniform engineering tool
Uniform communication
I/O
Net
PLC
Batch
SCADA
....
Field dev.
Cross-
configuring

Central
engineering
system
AS I/O
Net
OS
Batch
Field devices
BLE
PCS 7
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 8
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary

automical generation

Classical SCADA / PLC solution SIMATIC PCS 7 solution
1 time n times
ES
Comparison of SIMATIC PCS 7 with a
SCADA / PLC solution
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 9
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Low integration effort:
Less errors, increased process reliability
Uniformity not
ensured
Additional effort
on the users side
High integration effort
Uniform functions
System performance
without additional
effort
Alarms/ messages
Redundancy
Documentation
User access rights
Customer Support
Combined system from
various control suppliers
Process Control System
SIMATIC PCS 7
Diagnostics
Low integration effort
Alarms/ messages
Redundancy
Documentation
User access rights
Customer Support
Diagnostics
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 10
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Comparison combined vs. system technique
Integration work necessary Integrated overall system
Individual components with
functional scope that is not
coordinated
Frequently from various
suppliers
Functional extensions in the
components for system
performance
Individual components with
coordinated functional scope
From a single source
System functions are included
in the individual components
Combined system from
various control suppliers
Process Control System
SIMATIC PCS 7
Individual quality assurance for
each component
Individual product documentation
Individual function tests for
components, integration test
in each project
Uniform quality assurance for
the entire system
Uniform documentation
All components qualified by
function & system test
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 11
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Base: ET 200iS
plus
PCS 7 spec. funct.
SIMATIC PCS 7: standard components plus
process control specific add ons
ES
OS-Client
AS AS
Net
OS server
BATCH flexible
Base: Step 7
plus
PCS 7 spec. funct.
Base: S7-400
plus
PCS 7 spec. funct.
Base: WinCC
plus
PCS 7 spec. funct.
Base: standard
Net comp.
Base: standard
Net comp.
Base: WinCC
plus
PCS 7 spec. funct.
Base: PA comp.
plus
PCS 7 spec. funct.
Base: standard
fail safe
Office LAN Ethernet PCS 7 spec.
Batch package
@PCS 7 /
OPC server
Base: standards
plus
PCS 7 spec. funct.
PCS 7
plus
add ons
Base: ET 200M
plus
PCS 7 spec. funct.
PCS 7
plus
diagnostics
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 12
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Certified Add-Ons
Added value of SIMATIC PCS 7 ...
functions as system behavior
Systemwide time synchronisation of all participants
Central plantwide message system and alarm acknowledgement (acknowledge at source)
More Advanced Process Control
Interfaces to SAP, PI etc.
Pre-configured integration of field devices (PDM, CFC, faceplates)
Integrated Batch package for discontinous processes
Pre-configured, tested system components, order of bundles by separate MLFB-No.
Redundancy on all levels
Automatical system diagnostics for OS, AS and I/O modules
Defined startup / restart behavior
Safe and fast commissioning and safe operation of the plant (tested standards)
Life beat monitoring of all participants
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 13
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Selective message groups, process area specific messages
Comprehensive displays for interlockings, limits, times, ...
Detailed user administration and differentiated user access rights
(area specific monitoring / operation and function specific operation)
Advanced State Display (extended state diagram = status +alarms)
Multi-Windows (multiple process windows on one screen)
Safe operation due to preventing windows from overlapping plant area & alarm overview and keyset area
Selection of process displays and TAGs by name
Added value of SIMATIC PCS 7 ...
functions for process control
Operator guidance thru process area display hierarchy and automatically displaying of
summary alarms for plant areas
Safe operator guidance to process failure via Loop-In-Alarm function
Comprehensive process overview due to display split in overview, graphics and keyset area
Multi-Screen technology with 2, 3 or 4 CRTs for better and more comprehensive plant operation
Online display (multi-window) composition by operator
Integration of horns or soundcards for alarming
Visualization of sequential programs via SFC (overview, detail window, transition box, Multi-Chart-Diagramm)
Online trends for operator
Faceplates on OS according EU guidelines
ODBC server/client on board
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 14
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Pre-defined faceplates, overview displays, graphics, keyset,... for cost effective engineering
Textuell programming based on SCL for complexe calculations and formulas.
Differentiated user access rights
Import-/Export-Assistent for efficient bulk engineering, use of Ratio as well
Automatical creation of area specific overview displays
Automatical creation of display hierarchy from plant hierarchy
Safe signal processing, even in stress situations (driver concept)
Libraries with: functions, faceplates, diagnostics and messages, but also
pre-wired chart templates for easy engineering
Added value of SIMATIC PCS 7 ...
functions for engineering
Automatical creation of OS areas and automatical assignment of messages to OS areas
Faceplate Designer: user specific functions and faceplates can be created easily
Technological view and palnt hierarchy (Name scheme): object oriented configuring insted of programming
Pre-configured message, alarm and acknowledgement system (without engineering overhead)
Graphical configuration of sequential function charts (SFC), automatical creation of SFC visualization
Copy of CFC / SFC constructs: all internal connections stay preserved
PLC and control system SW can be engineered on the same system
Object/TAG oriented process data management
User specific libraries for administration of own functions, templates, ...
AMS (Asset Management System) for field bus oriented field devices e.g. transmitter + drives !
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 15
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Added value of SIMATIC PCS 7 ...
functions for installation, commissioning, service
More diagnostics/displays for operators and maintenance staff
(limits, times, interlockings, sequential function charts,...) - automatically
Fast installation due to pre-installed and tested devices
Autotune function
Support of intelligent field devices with 74% less wiring, 93% less space in control room and
80% less overhead for commissioning and AMS functionality. To check a field device maintenance staff
has no longer to go into far away located or dangerous areas to check the devices.
Integrated documentation instead lots of single documents
Automatical system diagnostics for OS, AS and I/O modules
Exchange of modules under power (hot replacement)
Failure strategy for I/O modules (maintain value, alternative value)
Uniform HW diagnostics
Display with life beat monitoring of all participants
In case of problems one system responsibility
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 16
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
0
10
20
30
40
50
60
70
80
90
100
Investment and life cycle costs SCADA/PLC vs. PCS 7
2. Network
7. Service
1. HW
8. System SW
4. Application SW
3. Installation
5. Commissioning
6. Training
SIMATIC PCS 7
SCADA / PLC
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 17
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Solution with S7 + WinCC Solution with SIMATIC PCS 7
System-Hard-/Software: 53%
Appl.-Eng., install., comm.: 47%

total: 100%
Comparison of project costs
(hardware, licenses, appl.eng., installation, commiss, ...)
Example plant with ca. 3.000 Control Loops
Configuration:
3.000 Control Loops
4 operator stations
1 engineering station
6 controllers
7.500 I/O channels
Configuration:
3.000 Control Loops
4 operator stations
1 engineering station
6 controllers
7.500 I/O channels
System-Hard-/Software: 50%
Appl.-Eng., install., comm.: 61%

total: 111%
:11%
Control Loop: Measuring, Motor, Control PID, Valve ...
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 18
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Break even point SIMATIC PCS 7 vs. S7 / WinCC
# Control Loops
Costs
S7 / WinCC
PCS 7
Break even point

Contents & assumptions:
- Conti plant
- system hard- & -software
- application engineering
- installation & commissioning
- training
- ratio AI/AO to DI/DO:
50% zu 50%

100 1.500 7.500 15.000 3.000
11%
:3%
:17%
:11%
ca. 250
Control
Loops
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 19
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Graphical configuration
Pre-defined function block libraries
Pre-defined OS faceplates
Pre-defined overview displays/softkey sets
Uniform AS / OS configuration
Automatical generation of messages
Automatical generation of system diagnostics
Automatical scan of messages after startup
Cost savings in engineering
0
20
40
60
80
100
engineering effort
SCADA PCS 7
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 20
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Graphical configuration
Pre-defined function block libraries
Pre-defined OS faceplates
Pre-defined overview displays/softkey sets
Uniform AS / OS configuration
Automatical generation of messages
Automatical generation of system diagnostics
Automatical scan of messages after startup
Cost savings in engineering
0
20
40
60
80
100
engineering effort
SCADA PCS 7
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 21
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Cost savings in engineering
Graphical configuration
Pre-defined function block libraries
Pre-defined OS faceplates
Pre-defined overview displays/softkey sets
Uniform AS / OS configuration
Automatical generation of messages
Automatical generation of system diagnostics
Automatical scan of messages after startup
0
20
40
60
80
100
engineering effort
SCADA PCS 7
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 22
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Cost savings in engineering
Graphical configuration
Pre-defined function block libraries
Pre-defined OS faceplates
Pre-defined overview displays/softkey sets
Uniform AS / OS configuration
Automatical generation of messages
Automatical generation of system diagnostics
Automatical scan of messages after startup
0
20
40
60
80
100
engineering effort
SCADA PCS 7
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 23
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Cost savings in engineering
Graphical configuration
Pre-defined function block libraries
Pre-defined OS faceplates
Pre-defined overview displays/softkey sets
Uniform AS / OS configuration
Automatical generation of messages
Automatical generation of system diagnostics
Automatical scan of messages after startup
SCADA PCS 7
0
20
40
60
80
100
engineering effort
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 24
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Cost savings in engineering
Graphical configuration
Pre-defined function block libraries
Pre-defined OS faceplates
Pre-defined overview displays/softkey sets
Uniform AS / OS configuration
Automatical generation of messages
Automatical generation of system diagnostics
Automatical scan of messages after startup
SCADA PCS 7
0
20
40
60
80
100
engineering effort
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 25
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Cost savings in engineering
Graphical configuration
Pre-defined function block libraries
Pre-defined OS faceplates
Pre-defined overview displays/softkey sets
Uniform AS / OS configuration
Automatical generation of messages
Automatical generation of system diagnostics
Automatical scan of messages after startup
SCADA PCS 7
0
20
40
60
80
100
engineering effort
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 26
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Cost savings in engineering
Graphical configuration
Pre-defined function block libraries
Pre-defined OS faceplates
Pre-defined overview displays/softkey sets
Uniform AS / OS configuration
Automatical generation of messages
Automatical generation of system diagnostics
Automatical scan of messages after startup
SCADA PCS 7
0
20
40
60
80
100
engineering effort
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 27
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Optimally adapted function scope
Worldwide system competence
System technology from a single source
System approach reduces engineering costs
Low integration effort minimizes risk of errors and
accelerates the engineering process
Unifrom system functions ensure high process reliablity
Highly economical over the entire life cycle
These criteria speak in favour of SIMATIC PCS 7 ...
Automation and Drives
SIMATIC PCS 7
vs.
SCADA / PLC
A&D AS PAS PCS7_vs_SCADA-PLC_E200206 Nr. 28
Copyright Siemens AG 2002
All Rights Reserved
Overview
Technical
Differentiation
Economical
Differentiation
Summary
Totally
Integrated

Automation
SIMATIC PCS 7
with

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