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Title_page_en.fm Seite 1 Mittwoch, 28. September 2011 1:45 13
© Siemens AG 2011
Products and functions for
efficient maintenance in the
process automation
Brochure · October 2011
Maintenance System
Answers for industry.
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Maintenance_PA_04_2010_en.book Seite 2 Dienstag, 6. September 2011 9:45 09 © Siemens AG 2011 Introduction Increase in productivity through intelligent maintenance How can the productivity of a plant with a high level of au- Benefits of intelligent maintenance tomation be increased even further? Plant operators in all sectors consider increased availabili- Continuous plant monitoring ty and shorter downtimes to be the most effective lever to- ward increasing productivity. Investigations have
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Maintenance_PA_04_2010_en.book Seite 3 Dienstag, 6. September 2011 9:45 09 © 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 To
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Maintenance_PA_04_2010_en.book Seite 4 Dienstag, 6. September 2011 9:45 09 © Siemens AG 2011 Plant Asset Management as a maintenance task General information Information on the measured process tags is available for the plant operator. Apart from the measured value itself and its status, this may, for example, be the information on whether Various tasks have to be handled during the operating phase the measured value is still valid. of a plant, for which different groups of persons are r
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Maintenance_PA_04_2010_en.book Seite 5 Dienstag, 6. September 2011 9:45 09 © Siemens AG 2011 Asset management in production Benefits of Plant Asset Management The term asset management comes from the world of finance Plant Asset Management allows the maintenance engineer and economics and refers to the manner in which a company deals with its long-term and current assets. These include the • to unambiguously identify and evaluate the assets, this me- production equipment with its plant com
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Maintenance_PA_04_2010_en.book Seite 6 Dienstag, 6. September 2011 9:45 09 © Siemens AG 2011 Intelligent maintenance in process engineering Despite the different tasks of operators and maintenance In addition, there is a requirement (NE 107) that all field de- staff, it is meaningful and necessary to map the informati- vices must provide standardized status messages about their on of both staff groups within one process control system status as follows: and not to use different systems. • G
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Maintenance_PA_04_2010_en.book Seite 7 Dienstag, 6. September 2011 9:45 09 © Siemens AG 2011 SIMATIC PCS 7 Maintenance Station More productivity with Totally Integrated Automation Integrated plant and cross-system maintenance The integrated functionality of Totally Integrated Automation also makes it possible, using the SIMATIC PCS 7 Maintenance Station, to monitor the packaging or bottling line by means of Plant Asset Management is only truly productive if mainte- a client. Display, logi
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Maintenance_PA_04_2010_en.book Seite 8 Dienstag, 6. September 2011 9:45 09 © Siemens AG 2011 Visualization of information for maintenance In order to recognize the conditions of individual devices The overview display uses the standardized symbols to visua- or components unequivocally, a uniform symbol represen- lize the condition of a component itself and also provides coll- tation has been implemented. ective information on the conditions of all devices in the sub- ordinate hierarchies. Th
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Kap1_Realisierung_en.fm Seite 9 Mittwoch, 28. September 2011 10:10 10 © Siemens AG 2011 Maintenance Station – User interface for maintenance The SIMATIC PCS 7 Maintenance Station software package Exceeding the limits of the pump's rated operating range and is available as an alternative to SIMATIC PCS 7 for imple- deviations from the anticipated characteristic curve are repor- menting Plant Asset Management. You can use this soft- ted to the user as maintenance alarm via the PumpMon block.
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Maintenance_PA_04_2010_en.book Seite 10 Dienstag, 6. September 2011 9:45 09 © Siemens AG 2011 Performance monitoring of turbo compressors with the block CompMon: Depending on the type of medium, the aerodynamic perfor- mance 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 compo- sition or by changes to the flow resi
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Maintenance_PA_04_2010_en.book Seite 11 Dienstag, 6. September 2011 9:45 09 © Siemens AG 2011 This is recorded, and signaled in the symbols. A work instruc- Block icon tion number and a comment can still be entered for each work Device faceplate 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. Faceplate for maintenance view G_ST80_X_00422 Process Device Management Overview
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Maintenance_PA_04_2010_en.book Seite 12 Dienstag, 6. September 2011 9:45 09 © 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 sys- tems to mobile receivers such as cellphones or pagers. The messages are automatically sent to the responsible per- son or group of people. If no response is received within a pro-
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Maintenance_PA_04_2010_en.book Seite 13 Dienstag, 6. September 2011 9:45 09 © Siemens AG 2011 Monitoring and diagnostics for industrial PCs SIMATIC IPCs are rugged industrial PCs for professional au- tomation 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. The SIMATIC IPC DiagMonitor monitoring and signaling soft- ware recognizes poss
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Maintenance_PA_04_2010_en.book Seite 14 Dienstag, 6. September 2011 9:45 09 © Siemens AG 2011 Monitoring and diagnostics of networks SIMATIC PCS 7 communicates with the subordinate com- ponents 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. Monitoring of PROFINET/Industrial
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Maintenance_PA_04_2010_en.book Seite 15 Dienstag, 6. September 2011 9:45 09 © Siemens AG 2011 These can be displayed graphically and if desired also supple- Monitoring of PROFIBUS mented using individual diagnostics screens. In addition, at runtime cyclical data from Ethernet participants is queried and Online diagnostics with diagnostic repeater network alarms are reported. Websites are used to present Particularly in the case of exceptional stress, e.g. trailing and pass on the informatio
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Maintenance_PA_04_2010_en.book Seite 16 Dienstag, 6. September 2011 9:45 09 © Siemens AG 2011 Monitoring and diagnostics for process instrumentation and process analytics Standardized and meaningful diagnostics alarms are a Temperature measurement part of the electrical device description (EDD). SIMATIC PCS 7 utilizes the EDD and forwards the relevant message SITRANS T are the temperature measuring instruments for automatically to the Maintenance Station. The user recei- process engineering
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Maintenance_PA_04_2010_en.book Seite 17 Dienstag, 6. September 2011 9:45 09 © 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 hyd- rostatic level measurement. They have a series of integra
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Kap2_Komponenten_en.fm Seite 18 Mittwoch, 14. September 2011 3:15 15 © Siemens AG 2011 Level measurement Four different technologies are available for level measure- ment: Radar, capacitance, ultrasonic and Guided Wave Radar technology. Level measurement with contactless radar technology: • SITRANS LR400/LR460/LR560 with FMCW radar (Frequency Modulated Continuous Wave) • SITRANS LR200/LR250/LR260, pulse radar • SITRANS Probe LR, pulse radar (radar measuring instruments are available with P
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Maintenance_PA_04_2010_en.book Seite 19 Dienstag, 6. September 2011 9:45 09 © Siemens AG 2011 Gas analyzers 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 para- magnetic principle • OXYMAT 64 SITRANS LG200: Gui
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Maintenance_PA_04_2010_en.book Seite 20 Dienstag, 6. September 2011 9:45 09 © Siemens AG 2011 The gas analyzers have extensive functions for device diag- nostics and thus for corrective maintenance. In addition, they are capable of detecting functional irregularities. These ap- pear 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
