Essential tools of the standard engineering software and their functions:

SIMATIC Logon

SIMATIC Logon is a user administration and access control function integrated in the engineering system. Together with the detailed recording facilities provided by the change log, SIMATIC Logon offers plant owners exceptional system support when verifying changes.

Using SIMATIC Logon, the administrator can assign specific access privileges to groups of users, thus controlling the possibilities for data access. Access rights for stations of the process control system and operator privileges for blocks can both be set up. Configurable change logs permit the recording of all access operations to the engineering system as well as all online changes concerning the automation systems, operator systems, SIMATIC BATCH or SIMATIC Route Control.

If the modification reports are linked to the data of SIMATIC Logon during evaluation, it can be clearly proven who has carried out a specific modification and at what time. Such verifications are often the object of special sector-specific requirements, formulated, for example, in FDA 21 CFR Part 11 or GAMP.

SIMATIC Manager

The SIMATIC Manager is the control center of the engineering system. It is the integration platform for the engineering toolset as well as the configuration basis for all engineering tasks of the SIMATIC PCS 7 process control system. All aspects of the SIMATIC PCS 7 project are created, managed, archived and documented here.

The engineering toolset contains tools which are optimally matched to one another for system-wide project-oriented engineering, and which simultaneously provide the basis for asset management of the I&C equipment. These include tools for effective engineering of the following components:

• Control system hardware including distributed I/O and field devices
• Communication networks
• Automation functionality for continuous and batch processes (AS engineering)
• Operation and monitoring functionality (OS engineering)
• Mass data engineering and cooperation with CAD/CAE planning tools
• Diagnostics and asset management functionality
• Batch processes, automated with SIMATIC BATCH
• Material transport, controlled by SIMATIC Route Control
• Safety applications (Safety Integrated for Process Automation)

Technologists as well as process and production engineers can carry out planning and configuration in their familiar environments when using this range of tools as well as predefined blocks and charts.

The hardware required for use in a SIMATIC project, such as automation systems, communications components and process I/O, is stored in an electronic catalog. The hardware can be configured and configured using the HW-Config tool.

Creating hierarchy folders implements a project structure, the plant hierarchy (PH). By storing CFCs and SFCs for automation systems and pictures and reports for operator stations in a hierarchy folder along with additional documentation, the configuring engineer implicitly determines the hierarchical assignment.

Function blocks (FBs) and functions (FCs) can be encrypted and decrypted with the S7-Block Privacy application to protect know-how. Following encryption, the blocks and their attributes can no longer be modified. Only the interfaces of the blocks are then visible.

To implement the automation logic, standardized function blocks must be combined with other blocks in the graphic configuration tool CFC according to technological specifications. You can simply select predefined blocks or charts for this purpose from a catalog and then position, graphically interconnect and configure them in the working area. The process tag data relevant to operation and monitoring, such as messages and variables, are generated at the same time. The SIMATIC PCS 7 Logic Matrix can be used for fast and easy creation of the interlock logic between various Control Modules/Equipment Modules.

Sequential controls permit control and selective processing of the basic automation functions created per CFC by means of changes in operating mode and status. Convenient editing functions for the graphic configuration of sequential controls as well as powerful test and commissioning functions are offered by the SFC editor.

Complete SIMATIC PCS 7 projects or all project modifications can be compiled in one working step and downloaded to the target systems involved, e.g. to automation systems, Operator Systems or SIMATIC BATCH. The engineering system automatically ensures that the sequence is correct. The procedure is displayed and controlled in a central dialog.

A more effective method for less comprehensive changes to the standard automation, e.g. addition or modification of single process tags, is selective compilation and downloading at chart level. This can be started from the technological hierarchy, from the CFC, or from the chart folder.

The project engineer can recognize all changes since the last download by their color, and the current chart states by means of the corresponding symbols. The project engineer can make a specific choice in a dialog form for selective downloading. In association with the Version Trail, each download is automatically followed by archiving.

In the case of blocks being executed on the AS 410 automation system, it is even possible to change types during runtime by means of seamless copying (TCiR).

The SIMATIC Manager can also be used to organize the project data for engineering of the operator systems. All the relevant process tag data relevant to operation and monitoring is generated when the automation function is defined. A powerful Graphics Designer is available for generation of the process displays. The basis for generating process displays is provided by static symbols and dynamic block icons and faceplates that are organized in libraries and linked to the parameters of the function blocks.

Component view: hardware configuration in the SIMATIC Manager with HW-Config

Process tags in the process object view

Project views

The various tasks for creating a plant project are supported by the following project views:

• Component view (HW-Config)
  for configuration of hardware such as automation systems, bus components or process I/O
• Process object view
  as the central development environment for all aspects of process tags/objects

The process object view supports the work carried out by a process engineer by providing a universal view of the process tag. It shows the plant hierarchy represented in tree form in combination with a tabular view of all aspects of the process tag/object (general, charts, blocks, parameters, signals, messages, picture objects, archive variables, hierarchy folders, equipment properties and global declarations). This provides the technologist with fast orientation.

All objects in the marked branch of the hierarchy are displayed in the table so that they can be directly processed with user-friendly edit, filter, replace, import and export functions. A special test mode offers the facility for testing process tags and CFCs online and for starting them up.

The OS areas and the image hierarchy for process control, as well as the SIMATIC PCS 7 asset management, can be derived from the technological hierarchy. Furthermore, it also forms the basis for the plant-oriented identification of process objects.

Common displays can be positioned in pictures by means of the image hierarchy, and automatically linked to lower-level images. The configuration engineer is only responsible for the correct positioning. Since the number of common display fields and their semantics can be configured, it is also possible to implement customized alarm configurations.

I&C and process messages are already pre-configured in the function blocks, and operator input messages are already pre-configured in the faceplates. These are automatically generated when the triggering event occurs. If required, message texts can be modified or message priorities defined.

Using the process object view, "Smart Alarm Hiding" can also be configured. This refers to the dynamic hiding of alarms that are of secondary importance to the safe and interference-free operation of the plant under certain plant conditions. Depending on the operating status of a plant unit (startup, service etc.), messages of the technological blocks grouped in this plant unit are shown or hidden in accordance with the previously set configuration. Alarms can be displayed or hidden separately for each of the maximum 32 operating states through selection of option boxes in the alarm matrix of the process object view. Although hidden alarms are not signaled visually and audibly, they are still logged and archived as before.

Continuous function chart

Continuous function chart (CFC)

The CFC editor permits graphic configuration of the continuous automation functions. In addition to convenient editing functions, its scope of functions also includes powerful test and commissioning functions as well as individually configurable documentation functions.

When creating a new CFC, a new runtime group with the same name as the chart is created. All the blocks that are subsequently entered in the chart are automatically added to this runtime group. Each block is therefore already assigned runtime properties when it is inserted, and configuration engineers can optimize these properties by means of modifications in the runtime editor or by using algorithms.

The algorithm first determines the optimum block sequence separately for each runtime group, and then the optimum sequence of runtime groups.

Instances of function block types can be positioned on CFCs, assigned parameters, and interconnected. Operator privilege levels can already be defined at block level for each block attribute so that finely granular operator privileges can be implemented.

Additional potential for rationalization is offered by special configuration techniques such as chart-in-chart for implementing hierarchical charts, or the multiple use of chart block types (individual control unit types and process tag types) or SFC types (standardized sequence controls) in the form of instances.

The CFC editor supports the following types of standardized software modules:

• Function block type
  The function block types supplied with I&C libraries are used for I&C modeling of engineering equipment such as valves or motors. The smallest standardized software modules for multiple usage have connections for actuating and control signals and for parameter assignment and monitoring functions. Some also contain interlocking functions for automatic transition to defined safety settings.
• Process tag type
  Process tag types implemented with function blocks each represent a standardized CFC for the basic automation of specific I&C functions, e.g. for a level controller. Their instances can be modified centrally by the type-instance concept, and also manually adapted and linked.
• Control module type
  The control module type (CMT) marks a new type of standardized software module that offers even more efficient engineering than classic process tag types. A CMT can contain blocks, charts, control variables (block I/Os such as signals and parameters) and messages.
  Note: As the function "Control module adjustment" is based on a basic functionality of the Version Cross Manager (VXM), you need a VXM license to use this function. In the absence of a license, a message appears telling you to install Version Cross Manager. This is not actually necessary, all you need to install is a valid VXM license that will enable the relevant functionality on the engineering station.

Note:

The CFC is not just a component in the standard engineering software of the SIMATIC PCS 7 process control system. As a separate product, it can also be used together with other SIMATIC products in the context of Totally Integrated Automation (TIA). This SIMATIC CFC is a component from catalog ST 70, "SIMATIC Software" (article number of the current SIMATIC CFC V9.0, goods delivery: 6ES7658-1EX58-0YA5; online delivery: 6ES7658-1EX58-0YH5).

Sequential function chart

Sequential function chart (SFC)

The SFC editor is used for the graphical configuration and commissioning of sequential controls for batch production operations. It possesses convenient editing functions as well as powerful test and commissioning functions. An integrated graphical formula editor for arithmetic operations, Boolean algebra and mathematical functions enables calculations within the SFC.

Using a sequential control, basic automation functions usually created using CFC are controlled and selectively processed by means of changes in operating mode and status. Depending on the subsequent use, the sequential controls can be created either as a SFC plan or SFC type

SFC plan

The SFC can be used to implement sequence controls which can be applied once and which access several partial areas of the production plant. Each SFC plan contains standardized inputs and outputs for status information and for control by the user program or the user. The SFC plan can be positioned and linked as a block in the CFC. The required CFC block connections are selected by simple operations and connected to the steps or transitions of the step chains. A status management conforming to ISA 88 enables the configuration of up to 8 separate sequencers within a single SFC, e.g. for states such as RUNNING, HOLDING or ABORTING, or for different operating modes.

SFC type

SFC types are standardized sequential controls which can be applied repeatedly and which access one partial area of the production plant. They can be organized in libraries, and handled like normal function blocks, i.e. they can be selected from a catalog and positioned, interconnected and configured as an instance in a CFC plan.

Changes to the original automatically result in corresponding changes in all instances. An SFC type may contain up to 32 sequences. Using the function "Create/update block symbols", a block symbol is automatically positioned and interconnected in the associated process display for all SFC instances with HMI features.

I&C libraries

The use of library elements plays a major role in minimizing the amount of engineering required and thus also the project costs.

Two process control libraries are integrated in the standard engineering software of SIMATIC PCS 7:

• Advanced Process Library (current standard, pre-installed)
• PCS 7 Standard Library (former standard, can be installed subsequently if required)

Pre-configured and tested blocks, faceplates and symbols are organized in these libraries and form the basic elements for the graphic configuration of automation solutions.

The comprehensive range of blocks can be categorized as follows:

• Blocks for mathematical operations, analog and digital logic
• Interlocking blocks
• Technological function blocks with integral display, operation and signaling functions, e.g.:
  • Standard Control and Advanced Process Control blocks
  • Motor and valve blocks
  • Counter blocks
  • Dosing block
• Blocks for the integration of field devices
• Operator control and monitoring blocks
• Message and diagnostics blocks

Furthermore, pre-configured process tag types for process equipment such as pumps, valves, dosing units and controllers (cascade, spit-range) etc. extend the scope of library elements.

This is advantageous for adaptation of the user software following a system upgrade so that multiple versions of a library can exist side by side.

Examples of OS standard faceplates from the SIMATIC PCS 7 Advanced Process Library, valves

Advanced Process Library

The Advanced Process Library (APL) based on many years of experience of project engineers and plant owners takes into consideration current NAMUR recommendations and PNO specifications. Proven functions as well as visually attractive GUIs for a high level of operator convenience facilitate and also force interaction of operators with the plant.

Alternative, small versions of function blocks reduced to core functions, whose block icons and faceplates occupy less space in the process display, improve clarity in complex process displays.

Other features worth mentioning are:

• Special operating modes:
  • "Local" for integration and application of local control options
  • "Shutdown" for deactivating a measuring point for maintenance and service
• Several faceplate views:
  • "Preview" with information on the I/O signal status, automatic control, and possible/permissible operator inputs; display of real value for simulation
  • "Memo view" for temporary operator information
• Convenient interlocking blocks with initial signal information, can be directly called from the technological function blocks, e.g. from a motor block
• Flexible adaptation of functions in the library blocks
• Commissioning support through direct simulation on the operator station
• Protection against operator errors as the result of detailed grading of user privileges
• Explicit enabling/disabling of operations for a process tag for individual operator stations of the plant using the function "Local operator enabling"
• Integration of any compact drives and switch/starter objects via standard PROFIBUS profiles
• Coordination of multiple access operations, e.g. of SFC/SIMATIC BATCH, to equipment such as valves, dosing units or pumps
• Tacking of operator input windows facilitates repeated, successive operations
• Browser for the tag selection by status
• Customized online trends for display
• Reduced operator workload and faster operator control with tag groups assembled online for standard situations
  Note:
  SIMATIC PCS 7 Advanced Process Graphics from catalog ST PCS 7 T (SIMATIC PCS 7 technology components) is required.

Technology libraries

The additional technology libraries "Industry Library" and "Condition Monitoring Library" offered in Catalog ST PCS 7 T (SIMATIC PCS 7 technology components) expand the standard functionality of the APL. All display icons, function blocks and faceplates of these libraries are in APL design.

The Industry Library contains blocks for:

• Building automation (heating, ventilation, air conditioning)
• Operator control and monitoring using SIMATIC HMI Comfort Panels
• Integration of SIMATIC S7 Package Units and RTUs based on S7-300
• Interfacing of external Advanced Process Control systems
• Hierarchical multi-control room operation
• Other technological functions, e.g. for expanding measured value monitoring, or specifying a setpoint trend

The Condition Monitoring Library contains blocks for:

• Monitoring of centrifugal pumps (PumpMon)
• Monitoring of control valves (VlvMon)
• Online valve test during operation (PST)
• Monitoring for pressure loss, and early detection of blockages (PressDropMon)
• Detection of steady states of a dynamic process or steady state of a signal.

Advanced Process Control (APC) functions

In addition to numerous basic control functions, e.g. PID control, cascade control, split range control and ratio control, the I&C libraries of SIMATIC PCS 7 also provide function blocks and templates for advanced control functions at no extra cost.

Gain scheduling

The GainSched block allows continuous adjustment of the controller parameters in non-linear processes depending on the operating point. The block, which works in a similar manner to the polygon block, can derive three separate output values from one input value (measured variable X), which serve as regulating parameters for an interconnected controller block. Depending on the characteristic of the measured variable X, the GainSched changes the regulating parameters of the combined closed-loop controller in a sliding manner.

Override control

The outputs of two or more controllers are connected to a common final control element. The decision concerning which controller actually receives access to the final control element is made depending on the evaluation of the current process state.

Lead-lag/feed-forward control

A strong interference which can be measured is compensated in advance by feed-forward control. The control is thus limited to model uncertainties and non-measurable faults.

PID tuning

The integrated PID Tuner is suitable for optimization of the CTRL_PID and CTRL_S software controllers in circuits with PID, PI, or P control. On the basis of an experimentally determined model of the controlled system, favorable controller parameters for an optimum disturbance response or an optimum control response of the controller can be determined according to the procedure of absolute value optimization. Optimization can be carried out in manual or automatic mode. The typical controller values (actual value, setpoint, manipulated variable) are recorded by a trend function. The transient response of the controllers with the determined parameters can be checked by defining jumps. The controller parameters can be saved, and recalled as required.

Monitoring of the control quality

The ConPerMon block determines the control quality of a controller block (e.g. PID controller) on the basis of the online data of the setpoint, actual value and manipulated variable. Depending on deviation of the comparison quality, e.g. the control quality at commissioning, it can trigger a warning or an alarm. The faceplates of all control quality monitoring of a plant or a plant unit can be summarized in OS screens, which enables problems to be detected early on, analyzed, and specifically corrected.

Smith Predictor

The Smith Predictor can significantly improve the control quality of processes with long and relatively constant dead times. By eliminating the dead time component using a process model running parallel to the actual process, the controller can be designed for a process free of dead time, and thus set more effectively.

Model-based predictive multi-variable control

Model-based predictive multi-variable controllers (MPC) separately analyze the behavior of several interdependent variables for complex processes over a longer period. The results are used for optimized control of these variables. They eliminate adverse interactions which occur with separate control of the interdependent variables. Using a mathematical model of the process dynamics, MPCs are able to predict the future process response over a defined period of time (prediction horizon) and optimize a quality criterion on this basis.

The APL provides two multi-variable controllers with different functionalities and performance:

• MPC4x4 (ModPreCon) for up to 4 coupled manipulated variables and controlled variables
• MPC10x10 for up to 10 coupled manipulated variables and controlled variables and up to 4 measurable disturbance variables

Note:
Model-based multi-variable controllers make high demands on memory and processing time of the designated automation system. For that reason, please check the resources of the designated automation system before using them.

Graphics Designer

The project data for the engineering of the operator systems are organized with the SIMATIC Manager. All the data relevant to operation and monitoring of a process tag, such as messages and HMI variables, are generated automatically during definition of the automation function. A powerful graphics designer is available for the generation of process displays.

DOCPRO

DOCPRO is a tool for effective generation and management of plant documentation in accordance with defined standards. DOCPRO permits you to structure your project data in any manner, to process them in the form of standardized circuit manuals, and to print them in a uniform layout. You can incorporate your own cover sheets, layouts, graphics, logos or title block data. It is easy to control printing, i.e. you can specifically output individual parts of the project or all project data on the printer.