© Siemens AG 2011 Products and functions for efficient maintenance in the process automation Brochure · October 2011 Maintenance System Answers for industry.
© Siemens AG 2011 Introduction Increase in productivity through intelligent maintenance 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.
© 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 . . . . . . . . . . . . . . . . . . .
© 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.
© Siemens AG 2011 Asset management in production Benefits of Plant Asset Management 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.
© 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.
© 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.
© 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.
© 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.
© Siemens AG 2011 Performance monitoring of turbo compressors with the block CompMon: Depending on the type of medium, the aerodynamic performance of a turbo compressor can be impaired by fouling, caking, or abrasion. The location of the operating point can also be affected by variances in the state of the medium being pumped in depending on temperature, pressure and composition or by changes to the flow resistance on the load side. The block CompMon calculates performance characteristics (e.g.
© Siemens AG 2011 This is recorded, and signaled in the symbols. A work instruction number and a comment can still be entered for each work request. The instruction number has no effect within the Maintenance Station and is only included in the report. This can be used for transfer to maintenance planning.
© Siemens AG 2011 Add-ons as options for the SIMATIC PCS 7 Maintenance Station Alarm Control Center alarm management system The WinCC Alarm Control Center (ACC) alarm management system transmits alarms from visualization and control systems to mobile receivers such as cellphones or pagers. The messages are automatically sent to the responsible person or group of people.
© Siemens AG 2011 Monitoring and diagnostics for industrial PCs SIMATIC IPCs are rugged industrial PCs for professional automation solutions in 24-h operation. Because of their high system availability, in PCS 7 systems they are often used, for example, as operator or Maintenance Station or also as engineering station or OPC server.
© Siemens AG 2011 Monitoring and diagnostics of networks SIMATIC PCS 7 communicates with the subordinate components of Totally Integrated Automation via Industrial Ethernet and PROFIBUS and uses the network components and communications processors (CPs) of SIMATIC NET. In addition to reliable communications, these also offer the facility for network diagnostics during runtime.
© Siemens AG 2011 These can be displayed graphically and if desired also supplemented using individual diagnostics screens. In addition, at runtime cyclical data from Ethernet participants is queried and network alarms are reported. Websites are used to present and pass on the information. Furthermore, the software offers an e-mail client function and OPC server in order to forward network data and alarms to other systems.
© Siemens AG 2011 Monitoring and diagnostics for process instrumentation and process analytics Standardized and meaningful diagnostics alarms are a part of the electrical device description (EDD). SIMATIC PCS 7 utilizes the EDD and forwards the relevant message automatically to the Maintenance Station. The user receives information not only about which problem is involved but also on how to resolve it. The PROFIBUS profile specification 3.
© Siemens AG 2011 Pressure, absolute pressure, differential pressure, flow and hydrostatic level measurement SITRANS P is a family of pressure measuring instruments. The SITRANS P DS III and P300 digital transmitters are suitable as universal transmitters for measuring gauge pressure, absolute pressure, and differential pressure, and also for flow and hydrostatic level measurement.
© Siemens AG 2011 Level measurement Four different technologies are available for level measurement: Radar, capacitance, ultrasonic and Guided Wave Radar technology. SITRANS F M MAGFLO SITRANS FC MASSFLO MASSFLO flow meters are not sensitive to fluctuations in pressure, temperature, density, electrical conductivity or viscosity. An ASIC guarantees improved reaction to discontinuities. The devices are practically unaffected by external noise – an essential requirement for raising the dynamic range.
© Siemens AG 2011 Gas analyzers SITRANS LG200: Guided Wave Radar level measuring instruments SITRANS LR and LU: Radar and ultrasonic level measuring instruments Siemens offers a wide range of gas analyzers: • CALOMAT 6/62 Thermal conductivity gas analyzers for determining the quantity of hydrogen or helium in binary gas mixtures • FIDAMAT 6 Cumulative measurement of hydrocarbons according to the flame ionization principle • OXYMAT 6/61 Gas analyzers for measuring oxygen according to the paramagnetic pri
© Siemens AG 2011 The gas analyzers have extensive functions for device diagnostics and thus for corrective maintenance. In addition, they are capable of detecting functional irregularities. These appear as a maintenance requirement or as a failure alarm in the display of the Maintenance Station, at the signal output, or they are signaled via PROFIBUS PA/DP to higher-level systems. The messages are recorded in a logbook.
© Siemens AG 2011 Monitoring and diagnostics for positioners and valves SITRANS VP300 and SIPART PS2 are intelligent electropneumatic positioners for control valves and two-position valves in the process industry. Both devices can be used very flexibly in various processes. In addition to the standard function of each positioner, i.e.
© Siemens AG 2011 Monitoring and diagnostics of 24 V load feeders Monitoring and diagnostics of wear in the motor and its vicinity In the process industry, automation components are generally powered with 24 V DC. With the SITOP PSE 200U selectivity module, any 24 V load is reliably monitored for overload and short circuit and in the event of faults it is switched off.
© Siemens AG 2011 Number of overload tripping operations Overload tripping operations can have different causes. They can give information about the condition of the machine or plant, or they can signal an incorrect setting or motor selection. If necessary, the motor size should be changed. 0RWRU IHHGHU Current limit/overload Gradual changes in the overall application environment such as pollution or bearing damage can cause increased current consumption.
© Siemens AG 2011 Overview device functions Motor contactor with RLT ■ ■ ■ ■ ■ ■ ■ ■ SIRIUS compact starter and infeed system for 3RA6 ■ ■ ■ ■ ■ ■ SIRIUS motor starter M200D – innovative solution for distributed drive technology ■ ■ ■ ■ ■ ■ 3RW44 soft starter ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ SIMOCODE pro 3UF7 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ 24 Monitoring and diagnostics Tried and tested SIRIUS technology 3 sizes S6, S10, S12 (55 to 250 kW at 400 V) Can be used up to 60 °C without derating Long electrica
© Siemens AG 2011 Monitoring and diagnostics of drive components Diagnostics of drives Status assessment of high-voltage machines Hardly any other group of products influences plant availability as much as drive engineering. Production comes to a standstill when these products fail. Such unscheduled plant downtimes cause expensive production outages, unplanned repairs, and frequently consequential damage.
© Siemens AG 2011 Using the example of a mixer drive, the maintenance with Drive ES PCS 7 is represented: In time, the material to be mixed starts setting in the agitator. Until now, the agitator was cleaned at planned, regular intervals to guarantee its availability. With the aid of new functions in the Maintenance Station, the cleaning can in future be performed as and when required. The frequency converter offers the option of load torque monitoring and the type of reaction when the limit is exceeded.
© Siemens AG 2011 Plant Asset Management – with Totally Integrated Automation components Benefits ■ Plant-wide and uniform display of diagnostics and maintenance states ■ Integrated support of condition-based maintenance ■ Optimization of complete workflow from diagnostics up to termination of maintenance measure ■ Maintenance functionality integrated into the system – no additional engineering overhead For additional information on this subject please visit: www.siemens.
© Siemens AG 2011 Get more information www.siemens.com/automation/maintenance SIMATIC Manuals Guide: www.siemens.com/simatic-docu Information material available for downloading: www.siemens.com/simatic/printmaterial Service & Support: www.siemens.com/automation/support SIMATIC contacts: www.siemens.com/automation/partner Industry Mall for ordering online: www.siemens.com/industrymall Siemens AG Industry Sector Postfach 48 48 90026 NÜRNBERG GERMANY www.siemens.
