SIMATIC PCS 7 in the edible oil industry - Demo project · Welcome to the world of the edible oil industry. The demo software PCS 7 for the edible oil industry gives answers to the

SIMATIC PCS 7 in the edible oil industry - Demo project

SIMATIC PCS 7 V9.0

https://support.industry.siemens.com/cs/ww/en/view/78649994

Siemens Industry Online Support


Legal information

Edible Oil - Demo project Entry-ID: 78649994, V3.0, 10/2017 2

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Legal information Use of application examples

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Table of contents


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Table of contents Legal information ......................................................................................................... 2

1 PCS 7 Demo Project "Edible Oil" ..................................................................... 4

1.1 Overview .............................................................................................. 4 1.2 Requirements ....................................................................................... 4

2 Installation and Startup of demo project ......................................................... 5

2.1 Preparation ........................................................................................... 5 2.2 Configuration ........................................................................................ 7 2.3 Startup ................................................................................................ 13

3 Operation scenarios of the demo .................................................................. 15

3.1 Hardening ........................................................................................... 17 3.2 Transferring ........................................................................................ 22 3.3 Tracking and tracing ........................................................................... 24 3.4 Asset Management ............................................................................ 26 3.5 Pressing: Start of the Process ............................................................ 28 3.6 Desolventizer Toaster (DT): MPC controller ...................................... 33 3.7 Pump Monitoring ................................................................................ 35 3.8 Condition Monitoring of rotating equipment ....................................... 38 3.9 Simultaneous orders in a Deodorizer ................................................. 41 3.10 Power Control ..................................................................................... 46 3.11 Key Performance Indicator (KPI) ....................................................... 49

4 Appendix .......................................................................................................... 53

4.1 Service and Support ........................................................................... 53 4.2 Related literature ................................................................................ 54 4.3 History ................................................................................................ 54

1 PCS 7 Demo Project "Edible Oil"


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1 PCS 7 Demo Project "Edible Oil"

1.1 Overview

Introduction

Welcome to the world of the edible oil industry. The demo software PCS 7 for the edible oil industry gives answers to the needs of this industry. Self-studying this manual and the demo software will enabled you to present a convincing value proposition to this industry. Many technical concepts in the demo software are applicable for other industries. You are welcome to use the demo wherever it is helpful for you to promote Siemens products and solutions.

The document describes the main steps for the installation and presentation of the PCS 7 demo project for the edible oil industry.

PCS 7 basic knowledge is sufficient for presenting the demo. Installing the PCS 7 project requires advanced knowledge of PCS 7. You also need to have various PCS 7 licenses as described below.

This demo software contains various PCS 7 related software such as APF, POWERRATE, Condition Monitoring and MPC. You may need additional trainings for a deep discussion about each of this software.

1.2 Requirements

Requirements of the automation task

The following software is necessary before starting of the project installation:

Table 1-1

Software Article nr.

SIMATIC PCS 7 V9.0

The following installation packages are necessary:

PCS 7 ES/OS

SIMATIC PDM with CFC-Assetmon Hardware Device

PLCSIM

6ES7651-5AA58-0YA0

SIMATIC PCS 7 Condition Monitoring Library V8.2 Download

SIMATIC PCS 7 APF V2.1 (Advanced Process Functions) 6DL5423-8AX12-0YA0

SIMATIC POWERRATE V4.0 SP3 6AV6372-1DE04-0AX0

SIMATIC PCS 7 POWERCONTROL V8.2 6ES7658-7LX28-0YA5

The used hardware has to be in compliance with the current PCS 7 specification.

NOTE For testing the Edible Oil demo you can use the 14 days PCS 7 Trial-license.

https://mall.industry.siemens.com/mall/en/de/Catalog/Product/6ES7651-5AA58-0YA0

http://support.automation.siemens.com/WW/view/en/109738804

https://mall.industry.siemens.com/mall/en/de/Catalog/Product/6DL5423-8AX12-0YA0

https://mall.industry.siemens.com/mall/en/de/Catalog/Product/6AV6372-1DE04-0AX0

https://mall.industry.siemens.com/mall/en/de/Catalog/Product/6ES7658-7LX28-0YA5

2 Installation and Startup of demo project


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2.1 Preparation

Download

If you haven't done so already, download the "Edible_Oil_Demo_V90.zip " file from the Industry Online Support Site and copy the file to your Engineering System.


De-archiving

1. Open the SIMATIC Manager.

2. Select the menu command "File > Retrieve".

Figure 2-1

3. After retrieving, open the de-archived project.

Load PLC program

NOTE This demo project is configured such that you can use PLCSIM as the automation system. If you would like to load the program in a real automation system, you may need to make adjustments to the hardware configuration and the WinCC connection configuration.

Start PLCSIM by clicking the "Simulation on/off" button in SIMATIC Manager tool bar.

Figure 2-2




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Open the PLCSIM file, which is included in the retrieved project folder "EOIL_MP_V90".

Figure 2-3

PLCSIM will go automatically into the mode "RUN-P" after loading the file.

Register EODataCollectorViewer

To use the "EODataCollectorViewer" tool it is necessary to register the "Vsflex7L.ocx". The needed files are in the retrieved project Folder "EOIL_MP_V90" included. At first extract the ZIP-Archive "EODataCollectViewer".

Figure 2-4



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You have two options to register the needed OCX:

1. Automatically installation:

– Run "EODataCollectViewer.bat" on a 32Bit system.

– Run "EODataCollectViewer64.bat" on a 64Bit system.

NOTE For the installation are administrator rights necessary. Use the option "Run as administrator", if you run the bat-files.

2. Manually installation with following steps:

a. Copy the file "Vsflex7L.ocx" to "c:\Windows\system32".

b. Register the OCX with starting the command in the windows command line: "regsvr32 c:\windows\system32\Vsflex7L.ocx".

c. Move the files "EODataCollectViewer.exe", "EODataCollectViewer.ico" and "EODataCollectViewer.ini" into the folder "c:\Program Files\SIEMENS\WINCC\bin".

2.2 Configuration

PC Station Name

Use the context menu command "Object Properties…" of the PC station-object.

Figure 2-5

Type into the textbox "Computer Name" the name of your PC Station.



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Figure 2-6

SIMATIC PDM Settings

Open the SIMATIC PDM settings with the menu command "Options > SIMATIC PDM > Settings…".

Figure 2-7



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Click on the button "Assign current Project" in the tab "Maintenance".

Figure 2-8

Compile OS project

Use the context menu command "Compile" of the OS project-object.

Figure 2-9



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In the settings of OS compiling use the preconfigured TCP/IP communication, because PLCSIM doesn’t work with named connections. With a right mouse click you get the dialogue "Connection resource". Select the option "Send/receive raw data block"

Figure 2-10

Start the OS compiling with the options shown in the following picture.

Figure 2-11



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WinCC Computer Properties

First open the OS project with the context menu command "Open Object" in SIMATIC Manager.

Figure 2-12

If you’ll get at start the message "The configured server is not available…", then change the computer settings in the OS project as follows:

1. Open the properties of the configured PC-Station with the context menu command "Properties".

Figure 2-13

2. In the tab "General" enter your computer name in the corresponding text field, or use the button "Use Local Computer Name".



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Figure 2-14

3. Closing and re-opening of the WinCC project is necessary to apply the changes.



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2.3 Startup

Start runtime

Start the OS-Runtime with the play button in the WinCC command button line.

Figure 2-15

When the runtime is started, you will invite to authenticate with a valid user. Use the following user for the authentication:

Username: "Operator"

Password: "123456"

Figure 2-16



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Prepare demo project

Before you start with the scenarios as described below, set the demo into an initial state by clicking in the plant area "Demo" the button "INITIALIZE DEMO".

Figure 2-17

3 Operation scenarios of the demo


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Plant overview

The complete supply chain in the edible oil production covers three main steps. Oil seeds such as sunflower seeds, soy or rape seeds are turned into raw oil in the oil mill (1). This raw oil is refined into consumable oil in the refinery (2). Fat for margarine productions and other food industries is produced in the specialty fats factory (3). Each of these three factories can be located on different continents. Typically the various products are shipped as bulk material.

Figure 3-1

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(1) Oil mill

(2) Oil refinery

(3) Special oils and fats

By clicking on the different sections you can zoom into the plants and access various scenarios. These scenarios show the benefits of Siemens solutions. You can find detailed descriptions of each scenario in the following paragraph.



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Scenarios

The needs of the oils and grains industry and Siemens answer to these requirements are described in following scenarios:

Hardening – Chapter 3.1

Transferring – Chapter 3.2

Tracking and tracing – Chapter 3.3

Asset Management – Chapter 3.4

Pressing: Start of the process – Chapter 3.5

MPC Controller - Chapter 3.6

Pump Monitoring – Chapter 3.7

Condition Monitoring of Rotating equipment – Chapter 3.8

Simultaneous orders in a deodorizer - Chapter 3.9

Power Control - Chapter 3.10

Key Performance Indicator (KPI) – Chapter 3.11



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3.1 Hardening

Hardening is a batch process where liquid oil is turned into a solid fat. This scenario uses the hardening process to show a good method to manage data such as material data, process parameters and sequence of orders.

Go to the plant area "Special oils and fats > Hardening".

Figure 3-2

Create a new Order

(1) Open the corresponding faceplate "Job management" of this job symbol.

(2) Open all views with a click on the loop button.

Figure 3-3

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(3) Start with the "new" button.



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(4) Choose the final product.

(5) Specify the quantity.

(6) Type a description.

(7) Create a new job with the button "takeover".

Figure 3-4

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Choose the source and the destination tank

(1) Open the dialog, to define the source and the destination tank, with a right click on the created job.

Figure 3-5



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(2) Select a material

(3) Choose a source- and a destination tank. Which tank you can choose depends on the selected source material.

(4) The selected tanks will be shown here.

(5) Click on the button "save".

(6) Click on the button "release".

Figure 3-6

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Start the production sequence

(1) Run the sequence with a click on the button "activate job".

Figure 3-7

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You can follow the running process in this picture:

(1) Here you can see the status of the production process. It based on standard PCS 7 Sequential function chart (SFC).

(2) With this block icon you have access to the selected raw material tank.

(3) With this block icon you have access to the selected tank of the final product.

Figure 3-8

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3.2 Transferring

Frequently oil is transferred between tanks. Life of an operator can be easier with some helpful functionalities:

Tanks with "wrong" contents and blocked tanks cannot be selected

The operator is encouraged to use the oldest oil first to avoid spoilage.

Almost empty tanks with identical products are avoided.

Go to the plant area "Special oils and fats > tank park".

Figure 3-9

Create transfer job

(1) Open the faceplate to create a new transfer job.

(2) Choose a source tank. Filtering with a material ID is possible.

(3) Choose a destination tank. Filtering with a material ID is possible (1).

(4) Set the transfer quantity.

(5) Start the transferring.

Figure 3-10

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Transferring

If a transfer job is running, the selected route is highlighted (1). For more information you can open the faceplate of each tank with the symbols on the upper side of the picture (2).

Figure 3-11

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3.3 Tracking and tracing

The legislation of literally any country asks food manufacturers to identify the affected lots in case of a contamination in the production process. In this case automated T&T systems are a great help for the food manufacturers. Here you will learn about a simple automated T&T system. This system can be implemented into standard PCS 7. There are much more sophisticated and comfortable systems which require additional hard- and software. The system in this demo requires none of this and should be sufficient if T&T is the exception and not a routine.

Go to the plant area "Special oils and fats > tank park".

Figure 3-12

(1) Open the button "Up-/Downstrean":

Figure 3-13

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(2) Choose a time filter

(3) Select an entry, e.g. a tank, in the upper list.

(4) The list below shows the up- and downstream chosen by the tabulators.

Figure 3-14

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3.4 Asset Management

Preventive maintenance and diagnostics help to keep failures and downtimes to a minimum. Large components such as separators have frequently own automation panels with an own simple automation system and visualization. This example shows how easy the functionalities of a field panel can be integrated in the main DCS and how the condition of equipment could be monitored. Replacing a standalone unit by a function block in the DCS reduces the investment costs and makes the life of the operator easier by using a standardized visualization.

Go to the plant area "Diagnostics > Separator".

Figure 3-15



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Open the special maintenance

(1) For testing the maintenance, activate the simulation "sim on" = yellow.

(2) Switch the motor on or off.

(3) Set the parameter for the switch counter.

(4) Set the parameter for the working duration.

(5) Reset the maintenance.

Figure 3-16

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If a maintenance is required, then a message will be created (6) and the urgency of the maintenance demand is described here (7). In the faceplate you can find the current values for the motor switches and the operating hours (8).



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3.5 Pressing: Start of the Process

Pressing seeds is a continuous process. Here you learn how to start this continuous production. All production data are stored in the user archive.

Go to the plant area "Oil mill > pressing".

Figure 3-17

Create a new pressing job

(1) Open the faceplate "Job management" with the button "Start Order" or a click on the symbol.

(2) Open all views with a click on the loop button.

Figure 3-18

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(3) Start the creation of a new order.



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(4) Choose a parameter set.

(5) Type an optional description here.

(6) Create a new order with the button "takeover".

NOTE The typing of a setpoint quantity isn't possible, because it's a continuous process.

Figure 3-19

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(7) Open the faceplate for the job parameter with a right mouse click.

Figure 3-20



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(8) Insert the process parameter here.

(9) Save the settings into the plc.

Figure 3-21

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(10) Click on the "activate job" button and confirm this command to start the continuous processing.

Figure 3-22

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(11) In this area you can see the process state. For stopping the continuous running process click on the button "stop".

Figure 3-23

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Monitoring the energy consumption

You can see the actual energy consumption of the presses on the analogue display (1). For more detailed information's, you can use the "Energy Trend" button (2) to call up a preconfigured trend display, which shows the archived energy values. The trend image is divided into two areas:

Energy consumption in a defined time range (3)

Energy consumption of the last 15 minutes (4)

The functions of the control allow you to analyze the energy consumption in detail.

Figure 3-24

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3.6 Desolventizer Toaster (DT): MPC controller

Fine tuning the controllers and optimizing the process can make the difference

between profit and loss in an oil plant at the end of the year. Here you see a

method to control the biggest steam consumer of the oil mill. The DT acts as a big

dryer. Meal with hexane is fed to the top of this dryer. The hexane laden meal runs

on heated trays from the top to the bottom. Life steam is injected at the bottom

section of the DT. The dried meal should have below 300 ppm Hexane. Removing

more Hexane means a lower hexane content of the meal at the end of the DT.

Removing more hexane requires more heating steam and higher operational costs.

Optimizing this process means minimizing the amount of heating steam to produce

a product which fulfills the specification but does not exceed it.

This demo shows two methods of controlling a DT. The right DT’s control uses a model based predictive controller (MPC) and the other a PID controller. Both controllers use a temperature in the DT as control variable. This temperature correlates with the hexane content of the dried meal. The modulating valve acts as the control element in the closed loop control. Fluctuations in the feed disturb the process. The MPC controller on the right side has a knowledge advantage compared to PID controller since it gets information about feed fluctuations. You find a line between the controller and the volumetric feeder only at the MPC. This controller is prepared much earlier for disturbances of the process. The PID sees the disturbance when the temperature changes and reacts much later than the MPC.

Go to the plant area "Oil mill > extraction > toaster".

Figure 3-25



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Figure 3-26

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The two diagrams in the bottom section show three curves each. The yellow curve represents the fluctuation in the mass flow of the solvent laden meal at the inlet of the DT. The red curve shows the set point of the control valve and the green curve the temperature in the DT which corresponds to the hexane content of the product. The DT with the MPC has a better performance since the temperature in fluctuates less compared to the other DT.

The MPC controlled DT consumes less steam. You can see it by comparing the values of steam consumption (1). This measuring points (2) shows the hexane concentration of the product

You can reset the steam counter by clicking on the "Reset" button (3).



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3.7 Pump Monitoring

Pump monitoring is a cost-efficient solution for monitoring and analysis of centrifugal pumps.

The function provides:

Warning against potential damage to pumps under unfavorable operating conditions.

Early warning of imminent damage to pump (deterioration, pump-efficiency).

Optimize the pump design over the long term by means of statistical analyses of the operating data. Potentials for energy savings can be shown.

Go to the plant area "Oil refinery > deodorizing > pump".

Figure 3-27



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(1) Open the faceplate of the pump.

(2) Use the failure buttons to simulate a malfunction.

(3) With these sliders you have influence of the material flow and the pressure

Figure 3-28

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The faceplate "PumpMon" have different views, which show various information’s such as:

Height characteristics

Power characteristics

HPSH characteristics

You can switch between these views with the button line in the faceplate.

Figure 3-29

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In the faceplate view "NPSH charact:" can you find following information:

(1) Operating Point

(2) Safety Margin

(3) Cavitation Limit



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3.8 Condition Monitoring of rotating equipment

Monitoring the vibration spectrum of machinery is like heart beat monitoring of a human being. You can find a lot of rotating equipment such as presses, conditioners, separators and centrifugal pumps in an edible oil plant. PCS 7 with SIPLUS CMS condition monitoring system can analyze the vibration spectrum and gives a diagnosis in case of unusual vibrations. There are various SIPLUS CMS systems. The CMS 2000 gives a little more than a digital signal if a vibration level has been exceeded. CMS 4000 visualizes the complete spectrum of a vibration. The demo gives a first impression what these condition monitoring systems can do in an edible oil plant.

Go to the plant area "Oil mill > pressing".

Figure 3-30



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(1) To activate the simulation field, click on the button "SIPLUS".

(2) A click on a dot turns the failure-simulation on and off.

(3) Open the faceplate for the asset management information with a click on this symbol.

(4) A click on this graphic opens the SIPLUS picture.

Figure 3-31

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A right click on a symbol (1) opens an example report (2) of SIPLUS. The configured limits in SIPLUS have been reached. When the measured value cross the limit, the alarm signal will be send to SIPROXY.

A click with the left mouse button on a symbol (1) opens the faceplate of the maintenance status (3).

Figure 3-32

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3.9 Simultaneous orders in a Deodorizer

Some machinery is designed such that various batches are produced at the same time. As an example you can see the automation of a multi batch deodorizer with SIMATIC PCS 7.

Go to the plant area "Oil refinery > deodorizer".

Figure 3-33



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(1) Reset the trays for the demonstration.

(2) Open the "Job Management" faceplate with the button "Start Order".

(3) Open all views of the faceplate with the loop button.

Figure 3-34

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(4) Start the creating of a new order.

(5) Choose a parameter set.

(6) Optional ty a description here.

(7) Create a new order with the button "takeover".

Repeat this procedure for four jobs.

Figure 3-35

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(8) With a right click on a job, you can open the faceplate for the job parameter.

(9) You can change the parameter in this area.

Figure 3-36

9

(10) To start the process of these four jobs, press the button "activate job".

(11) Confirm the starting with the button "OK".

Figure 3-37

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When the process is running, you can see the individual batches passing through the different trays one after another. Active trays are marked in the process picture. With the buttons "Tray 0x" (12) can you open a corresponding faceplate (13) of the trays for detailed information.

Figure 3-38

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3.10 Power Control

Many plants have a process control and a power control system. With PCS 7 Power Control you can integrate medium voltage protection devices into the Process Control system PCS 7. The IEC 68150 describes the requirements of a Power Control system. PCS 7 Power Control requires additional hard- and software to cover the requirements of the IEC 68150. The demo shows an extract of this functionality with a simple example.

Go to the plant area "Power control".

Figure 3-39

Preparation

(1) Start the simulation for the power control plant with the control "Simulation".

(2) Close the necessary feeder for the plant power with the button "Set Feeder".

(3) Set the generator in automatic mode with the control ("GenModeAuto").

(4) Set the feeder in automatic mode with the button "SetAutoMode".

Figure 3-40

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Start drives

(5) Close the motor feeder in substation section 1 and 2.

(6) Start the drives in substation section 1 and 2.

Figure 3-41

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Trigger an external power supply breakdown

(7) Trigger a power breakdown with the "trip" functionality on both overhead lines.

When both external power lines are down, the emergency generator (8) starts to run and the interconnection feeder (9) will be closed.

The drives (10) don’t stops, although no external electricity supply is available.

Figure 3-42

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3.11 Key Performance Indicator (KPI)

KPIs show the health of a plant and the efficiency of the processes. Here you get a first impression what can be achieved with standard PCS 7 means. Advanced systems have long term data storage and can analyze and compare complete sites in different locations simultaneously. This system is an entry solution and all KPI calculations are based on WinCC Global Script and Taglogging.

Go to the plant area "KPI".

Figure 3-43

(1) "Overall Process KPI" is a summary of all other KPIs

(2) "Production Rate" refers to the hardening process.

(3) Overview of the KPI of different process areas.

(4) Detailed view of a selected process area.

(5) Opens a window with web reports.

(6) Go to the picture for KPI configuration. Some of the values for the calculation can be modified.

A click on the bars in the field "KPI per Area" opens the view for more information about the area.

Figure 3-44

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(1) The "Tank Park" detail view shows the steam consumption. If more tanks are filled with product, then more steam will be used. The steam consumption also increases with the oil level in the tank.

(2) "Toaster" is showing the LCQ of PID_CTRL and additional steam consumption located in the toaster area.

(3) "Hardening" shows energy consumption per kg of produced product in hardening part of the demo. These values will be calculated by POWERRATE.

(4) "Pressing": The energy consumption of various equipment is analyzed.

Figure 3-45

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Figure 3-46

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You get an idea of advanced KPI functions by clicking on web report. Additional hard- and software such as the Process Historian (PH) enables the user to create long term reports with additional information and much more layout capabilities.

Figure 3-47

4 Appendix


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4 Appendix

4.1 Service and Support

Industry Online Support

Do you have any questions or need assistance?

Siemens Industry Online Support offers round the clock access to our entire service and support know-how and portfolio.

The Industry Online Support is the central address for information about our products, solutions and services.

Product information, manuals, downloads, FAQs, application examples and videos – all information is accessible with just a few mouse clicks at: https://support.industry.siemens.com

Technical Support

The Technical Support of Siemens Industry provides you fast and competent support regarding all technical queries with numerous tailor-made offers – ranging from basic support to individual support contracts. You send queries to Technical Support via Web form: www.siemens.com/industry/supportrequest

STRAIN – Training for Industry

With our globally available training courses for our products and solutions, we help you achieve with practical experience, innovative learning methods and a concept that’s tailored to the customer’s specific needs.

For more information on our offered trainings and courses, as well as their locations and dates, refer to: www.siemens.com/sitrain

Service offer

Our range of services includes, inter alia, the following:

Product trainings

Plant data services

Spare parts services

Repair services

On-site and maintenance services

Retrofitting and modernization services

Service programs and contracts

You can find detailed information on our range of services in the service catalog: https://support.industry.siemens.com/cs/sc

Industry Online Support app

You will receive optimum support wherever you are with the "Siemens Industry Online Support" app. The app is available for Apple iOS, Android and Windows Phone: https://support.industry.siemens.com/cs/ww/en/sc/2067


http://www.siemens.com/industry/supportrequest

http://www.siemens.com/sitrain

https://support.industry.siemens.com/cs/sc

https://support.industry.siemens.com/cs/ww/en/sc/2067

4 Appendix


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4.2 Related literature

Table 4-1

No. Topic

\1\ Siemens Industry Online Support

https://support.industry.siemens.com

\2\ Link to this entry page of this application example


\3\ PCS 7 Overview


4.3 History

Table 4-2

Version Date Modifications

V1.0 12/2013 First version

V2.0 05/2015 New PumpMon-block, PowerControl area enhanced

V3.0 09/2017 Updated to PCS 7 Version 9.0




Documents

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