© Siemens AG 2011 SIMATIC PCS 7 TeleControl Process control system with integral telecontrol technology Brochure · January 2011 SIMATIC PCS 7 Answers for industry.
© Siemens AG 2011 Totally Integrated Automation Set new productivity standards for constant competitive advantages The optimization of processes improves quality, shortens the time to market and reduces the total cost of ownership. To survive in increasingly tougher international competition, today it is more important than ever to consistently tap all optimization potentials throughout the entire lifecycle of a plant.
© Siemens AG 2011 Contents Integration of the telecontrol technology in TIA has made it possible to combine the automation of central plants and the monitoring of distributed units in a single process control system.
© Siemens AG 2011 SIMATIC PCS 7 TeleControl Process control system with integral telecontrol center Automation of widely spread process plants In a number of industries, especially the oil & gas, water & wastewater, power and transportation sectors, plants may sometimes be extremely widely spread. Individual distributed units may even be more than a thousand kilometers away from a central unit with a significantly higher degree of automation.
© Siemens AG 2011 Typical application areas Remote control and monitoring of distributed stations, as well as data recording and transmission, with the following focal points: Oil and gas industries • Compressor, pressure reduction, transfer, block valve, and metering stations in gas networks • Pumping and block valve stations in oil pipelines • Automation on the wellhead of gas and oil wells • Stations for the injection of water or CO2 in gas or oil fields Water industry • Well, pumping and valve station
© Siemens AG 2011 SIMATIC PCS 7 TeleControl system architecture System overview PCS 7 OS Clients Engineering Station Serial communication: SINAUT ST7 or DNP3 (dedicated or dual channel) TCP/IP communication: SINAUT ST7 TIM 4R-IE (ST7) or Converter TCP/IP ↔ serial (DNP3) TIM 4R-IE (ST7) or TCP/IP WAN router (DNP3) Widely distributed TeleControl outstations WAN TCP/IP communication: Modbus or IEC 870-5-104 WAN S7-300 + TIM 3V-IE or TIM 3V-IE DNP3 Converter TCP/IP ↔ serial WAN Third-party RTU (DN
© Siemens AG 2011 The serial RTU link is possible at low cost via the following components which can be connected directly to the PCS 7 TeleControl OS (single station or server): • SINAUT TIM communication modules (SINAUT ST7 telecontrol protocol) • TCP/IP converters – serial (DNP3, Modbus, IEC 870-5-101 telecontrol protocols) Devices from MOXA or Lantronix can be used as serial TCP/IP converters.
© Siemens AG 2011 Spectrum of outstations and integration versions SINAUT ST 7 Type of communication Serial Ethernet TCP/IP Serial Interface on the PCS 7 TeleControl OS TIM 4R-IE TCP/IP WAN router or/and TIM 4R-IE TCP/IP converter serial RTU/interface Telecontrol protocol ET 200S with integral CPU (corresponds to S7-314) – Modbus – DNP3 – IM 151-7 CPU or IM 151-8 PN/DP CPU as well as 1 SI module Modbus S7-300/ S7-300F S7-400/ S7-400F TIM 3V-IE TIM 4R-IE TIM 3V-IE TIM 4R-IE CP 341 C
© Siemens AG 2011 Topologies Basic topologies Point-topoint Multi-point Star Ring Star via dedicated line Star via wireless Dial-up network via wireless Star via Internet Star + multi-point Nodes Path redundancy, 1 medium Path redundancy, 2 media Differently structured telecontrol networks can be implemented in the wide area network (WAN) based on the following four basic topologies.
© Siemens AG 2011 SIMATIC PCS 7 TeleControl system components PCS 7 TeleControl Operator System Single-user and multi-user systems Depending on the magnitude of the automation project and the required number of operator stations, the SIMATIC PCS 7 TeleControl Operator System can be configured either as a single-user system (PCS 7 TeleControl OS single station) or as a multi-user system with client/server architecture: • Single-user system - Up to 5 000 process objects - Up to approx.
© Siemens AG 2011 PCS 7 TeleControl blocks for system-conformant operator control and monitoring Long-term archiving and logging The RTUs are integrated into the PCS 7 TeleControl Operator System by means of the PCS 7 TeleControl blocks such that there is no difference for the operator with regard to operating philosophy and alarm behavior for the central or remote automation functions.
© Siemens AG 2011 PCS 7 TeleControl engineering station Engineering station of the SIMATIC PCS 7 process control system SIMATIC PCS 7 TeleControl block library To enable engineering of the PCS 7 TeleControl operator station (single station/server), the functions of the engineering station of the SIMATIC PCS 7 process control system are expanded by DBA technology (Data Base Automation) and the SIMATIC PCS 7 TeleControl block library.
© Siemens AG 2011 Remote terminal units Classification of the remote terminal units RTU Possible telecontrol protocols Information points/ buffer size RTU with up to approx. 30 I/Os • Modbus No buffering For small, cost-sensitive applications • IEC 870-5-101 • IEC 870-5-104 Up to approx. 200 information points Applications RTU Small: controller integrated in SIMATIC ET 200S Buffer size: 800 information points RTU Medium: SIMATIC S7-300/S7-300F controller RTU with up to approx.
© Siemens AG 2011 Telecontrol protocols General/elementary telecontrol functions Telecontrol systems use special protocols to implement data transmission between the control center and the outstations (RTUs) at the process level for the automation functions on site. These telecontrol protocols manage the secure and errorfree data transmission over the WAN even with a low bandwidth and poor transmission quality.
© Siemens AG 2011 SINAUT ST7 telecontrol protocol The telecontrol system based on the SINAUT ST7 telecontrol protocol is used for fully-automatic monitoring and control of widely distributed outstations (RTUs) which exchange data with each other and with one or more control centers over a wide variety of WAN (Wide Area Network) media.
© Siemens AG 2011 Range without repeaters (example) with conductor cross-section 0.8 mm - 1 200 bit/s max. 33 km - 2 400 bit/s max. 27 km - 19 200 bit/s max.
© Siemens AG 2011 Control center SIMATIC PCS 7 TeleControl TIM 4R-IE Ethernet DSL router Firewall SCALANCE S612/613 931 WXQQHO DSL router Internet Firewall Firewall Star via Internet DSL router SCALANCE S612/613 RTU S7-400 TIM 4R-IE RTU S7-300 ··· TIM 3V-IE G_PCS7_XX_00265 RTU S7-300 TIM 3V-IE SINAUT ST7 - example of secure TCP/IP-based connection over Internet via DSL (star topology) Redundant transmission path: classic WAN + classic WAN Redundant transmission path: classic WAN + TCP/IP-ba
© Siemens AG 2011 Special characteristics of SINAUT ST7 communication Up to 10 000 stations can be addressed with SINAUT ST7. Information on the source and target addresses is included in the message frames.
© Siemens AG 2011 Operating modes The communication mode between the control center and outstation (RTU) depends on the support provided by the telecontrol protocol, the configuration of the telecontrol communication, and the type of WAN.
© Siemens AG 2011 DNP3 telecontrol protocol Widely distributed outstations (RTUs) can be controlled and monitored with the DNP3 telecontrol protocol via serial or Ethernet TCP/IP communication links by means of the telecontrol center in SIMATIC PCS 7. The control center integrated with SIMATIC PCS 7 TeleControl into the operator system of the process control system is the master during telecontrol communication.
© Siemens AG 2011 Control center SIMATIC PCS 7 TeleControl DNP3 master SCALANCE S612/613 Ethernet DSL router Firewall SCALANCE S612/613 DSL router 931 WXQQHO Internet Firewall Firewall Star via Internet DSL router RTU S7-400 SCALANCE S612/613 G_PCS7_XX_00268 RTU S7-400H RTU S7-300 ··· TIM 4R-IE DNP3 (Slave) TIM 4R-IE DNP3 (Slave) TIM 3V-IE DNP3 (Slave) DNP3 - example of secure TCP/IP-based connection over Internet via DSL (star topology) Redundant transmission path: classic WAN + TCP/IP-ba
© Siemens AG 2011 Operating modes Special characteristics of DNP3 communication Change-driven data transmission • Change-driven transmission of process data between RTU and control center • Signaling of RTU, control center or connection failure • Automatic data updating for all communication partners involved following troubleshooting and following the startup of the RTU or control center Chronological processing of process data • Time tagging of all data frames at the place of origin allows process data t
© Siemens AG 2011 IEC 870-5-101/IEC 870-5-104 telecontrol protocol Control center SINAUT MD741-1 IEC 60870-5-104 IEC 60870-5-101 DSL router SCALANCE S612, security module Radio network SINAUT MD2 SIPLUS RIC Bundle with SIMATIC S7-300 SIPLUS RIC Bundle with SIMATIC S7-400 IEC 60870-5-101 SIPROTEC 7SJ63 SINAUT MD741-1 SINAUT MD2 SINAUT MD741-1 SINAUT MD2 SIPLUS RIC Bundle with SIMATIC S7-300 SIPLUS RIC Bundle with SIMATIC ET 200S SIPLUS RIC Bundle with SIMATIC ET 200S SIPLUS RIC Bundle with SI
© Siemens AG 2011 The SIPLUS RIC bundles usually comprise: • • • • Classic WAN media (IEC 870-5-101 telecontrol protocol) CPU Interface/communication module (if necessary) Memory card CD with library and registration code. • Dedicated line via modem, e.g. SINAUT MD2 • Dedicated line over fiber-optic cables • Private wireless networks SIPLUS RIC products require additional material to establish telecommunication links, e.g.
© Siemens AG 2011 Control center SIMATIC PCS 7 TeleControl IEC 870-5-104 Ethernet SCALANCE S613 MD741 Internet RTU ET 200S with IM 151-8 PN/DP CPU DSL router IEC 870-5-104 RTU ET 200S with IM 151-8 PN/DP CPU GPRS radio network Complex network structure, combination of different topologies and media MD741 RTU S7-300 with CP 343 Third-Party RTU RTU S7-400 with CP 443 G_PCS7_XX_00271 RTU S7-300 with CP 343 IEC 870-5-104 IEC 870-5-104 IEC 870-5-104 - example of complex TCP/IP-based WAN with cab
© Siemens AG 2011 Modbus telecontrol protocol The Modbus telecommunication protocol is suitable for the integration of existing units with a Modbus infrastructure into the SIMATIC PCS 7 process control system. Telecontrol communication for control and monitoring of widely distributed outstations (RTUs) from a control center in SIMATIC PCS 7 is possible with this protocol via both serial and TCP/IP communication links.
© Siemens AG 2011 Redundancy Increasing the plant availability The example of a SIMATIC PCS 7 process control system with integral telecontrol linking of RTUs on the basis of the IEC 870-5-101/IEC 870-5-104 protocols demonstrates the various possibilities for increasing plant availability: • Redundant SIMATIC PCS 7 TeleControl OS servers for process control of central and widely distributed units and for archiving • Redundant system bus for system communication • Redundant telecontrol communication betwee
© Siemens AG 2011 Migration Migration of existing telecontrol systems Units with Modbus communication SINAUT ST1 stations based on SIMATIC S5 The Modbus is widely used in automation plants due to its straightforwardness and openness. The Modbus telecontrol protocol can be used to implement both serial and TCP/IP communication links between a control center in SIMATIC PCS 7 and RTUs with a corresponding Modbus interface.
© Siemens AG 2011 SINAUT LSX SIMATIC PCS 7 TeleControl SINAUT LSX clients PCS 7 clients PCS 7 Engineering System (DBA) HMI PCS 7 TeleControl OS server SINAUT LSX server (ST7) LAN AS FEP Front End Processor S5 / ST1 (KOMSYS) Master TIM (ST7) S7 (EDC) SIMATIC PCS 7 S7-400 Node station TIM WAN RTU S7-300 S5-115 S7-400 S7-400 S5-135 ST1 RTUs ST7 RTUs G_PCS7_XX_00275 S7-300 Integration of existing SINAUT LSX systems per PCS 7 TeleControl S7 EDC driver Integration of third-party stations wi
© Siemens AG 2011 Application examples Automation of a gas pipeline with block valve and metering stations Uniform automation of all stations in the gas network ■ ■ ■ ■ SIMATIC PCS 7 process control system for compressor and pressure reducing stations SIMATIC PCS 7 TeleControl with SINAUT telecontrol technology on the basis of S7-300/S7-400 controllers for block valve and metering stations Combination of process control at one operator station (SIMATIC PCS 7 OS client) Compliant process control with uni
© Siemens AG 2011 Automation of a sewage treatment plant with pumping station and stormwater overflow tank Municipal sewerage system Mechanical purification Delivery of fecal matter Industry Private Pumping households station Stormwater overflow tank Lifting equipment Preliminary sedimentation Screen Sand and grease trap Digestion tank Dosing of precipitant Biological purification Final clarification Aeration Drainage Sludge treatment Preliminary sedimentation Gasometer Prethickening Diges
© Siemens AG 2011 Additional information SIMATIC controllers: www.siemens.com/simatic-controller SIMATIC automation systems: www.siemens.com/simatic Totally Integrated Automation: www.siemens.com/totally-integrated-automation SIPLUS extreme – ruggedness and refinement: www.siemens.com/siplus-extreme Service and Support: www.siemens.com/automation/service&support SIMATIC contacts: www.siemens.com/automation/partner Information material to download: www.siemens.
