‫ﺑﺨﺶ اول – ﻣﻌﺮﻓﻲ ﺳﻴﺴﺘﻢ‬

‫ﻣﺤﻤﺪرﺿﺎ ﻣﺎﻫﺮ‬

‫ﻣﻬﺮ ﻣﺎه ‪94‬‬

 1- Introduction

2- DCS Siemens (PCS7)

3- ESD Siemens

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 3

 ESD ‫ و‬DCS ‫ﻣﻘﺎﻳﺴﻪ ﻋﻤﻠﻜﺮد‬

Boom?
Mechanical safety level

Unsafe Condition ESD action Trip level

Safety

Alarm Condition
Operator takes action High alarm level

Normal Condition High level

Control

11/07/1394 Process value

DCS ESD Seminar – Part1 ‐ Maher 4
Low level
 Basic DCS Functionality

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 5

 ‫ ﻫﺎي زﻳﻤﻨﺲ‬DCS ‫اﻧﻮاع‬
SPPA T2000 ‫ ﻳﺎ‬Teleperm XP
( SPPA T3000 ‫)ﻧﻮع ﺟﺪﻳﺪﺗﺮ‬

APACS Moore

PCS7

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 6

 T3000 ‫ و‬TXP
‫ ﻧﻴﺮوﮔﺎﻫﻲ‬DCS

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 7

 APACS
Moore ‫ ﺳﺎﺧﺖ‬DCS

PCS7 ‫ﻗﺎﺑﻞ اﺗﺼﺎل ﺑﻪ‬

PCS7 ‫ﻗﺎﺑﻞ ارﺗﻘﺎ ﺑﻪ‬

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 8

 ‫ﺑﺮرﺳﻲ ﺳﻴﺴﺘﻢ ‪PCS7‬‬

‫ﻣﻌﻤﺎري ﺳﻴﺴﺘﻢ‬ ‫•‬

‫ﺳﻴﺴﺘﻢ ﻛﻨﺘﺮل‬ ‫•‬
‫ﺷﺒﻜﻪ در ﺳﻄﺢ ﻛﻨﺘﺮل و ﻣﺎﻧﻴﺘﻮرﻳﻨﮓ‬ ‫•‬
‫اﻣﻨﻴﺖ ﺷﺒﻜﻪ‬ ‫•‬
‫ﺷﺒﻜﻪ در ﺳﻄﺢ ﻓﻴﻠﺪ‬ ‫•‬
‫ﺳﻴﺴﺘﻢ اﭘﺮاﺗﻮري‬ ‫•‬
‫ﺳﻴﺴﺘﻢ آرﺷﻴﻮ ﻣﺮﻛﺰي‬ ‫•‬
‫ﺳﻴﺴﺘﻢ ﺗﻌﻤﻴﺮاﺗﻲ‬ ‫•‬
‫ﺳﻴﺴﺘﻢ ﻣﻬﻨﺪﺳﻲ‬ ‫•‬

‫‪11/07/1394‬‬ ‫‪DCS ESD Seminar – Part1 ‐ Maher‬‬ ‫‪9‬‬

 ‫ﻣﻌﻤﺎري ﺳﻴﺴﺘﻢ‬
System Architecture
11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 10
 PCS7‐ Main Objects

Automation AS
technology
• Measurement
• Closed‐Loop Con.
• Open‐Loop Con.
etc.
HMI
•Displaying
•Operating OS
•Logging
+ etc.

Communication
technology Bus
11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 11
 PCS7 ‫ﻣﻌﻤﺎري ﺳﻴﺴﺘﻢ‬
@ SAP R/3
@

ERP / MES
Office Ethern Office Ethern
LAN et LAN et
Plant Plant
Internet/Intran InformatioMaintenanc
Engineerin SIMATIC @PCS 7 et / n e
OS Clients
g BATCH OPC-
OS Single Station ES Clients Server
Station
(Multi-VGA)
Servic
OS OS‐LAN Ethern
et
e Terminal Bus
ES
OS‐Server Batch‐Server
(redundant) (redundant) Workstations

AS AS 417 OS AS 414 AS 414 H Plant Bus

414 AS 416 F/FH AS 417 H

DP/AS‐
AS 414 ET
200M
AS 417
F/FH ET ET Controllers
I O 200M 200M
Ex‐I/O

PROFIBUS‐DP
PROFIBUS‐DP

Fail‐
PROFIBUS‐DP

HART P DP/PA‐Link
ET
Safe
PROFIBUS‐
200M PROFIBUS‐PA
DP/EI PA
B DP/PA‐
Link
DP/PA‐Link Y‐Link Fieldbus
PROFIBUS‐ PROFIBUS‐PA
ET ET DP ET
200 200 200iS COx,
Zone 1
X S NOx,
Zone 2
...
11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 12
 Basic Architecture
Operating System Client
PCS7 Operator System
(OS) & Batch Clients

(or Operator Workstation)

Ethernet TCP/IP
Terminal Bus
Terminal bus
Central Engineering System
PCS7 Operator
Operating System Server & Batch
PCS7 Engineering
System (OS) & Batch
SERVER System (ES) (ES) for
Server
AS / OS / Batch
Control Network Industrial Ethernet System
bus
AUTOMATION SYSTEM
Automation System (AS) based on
(AS) SIMATIC S7‐4xx

PROFIBUS / PROFINET Distributed

Field network
Peripheral Network
ET 200 distributed racks containing the
ET 200
Distributed I/O
Input / Ouput Modules
 Scalability
‫اﻣﻜﺎن ﺗﻮﺳﻌﻪ ﺳﻴﺴﺘﻢ‬
‫آزﻣﺎﻳﺸﮕﺎﻫﻲ‬ ‫ﻛﻮﭼﻚ‬ ‫ﻣﺘﻮﺳﻂ‬ ‫ﺑﺰرگ‬

From 100 to 120,000 Process Objects

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 14

 ‫اﺗﺼﺎل ﺑﻪ ﺳﻴﺴﺘﻢ ﻫﺎي ﻛﻨﺘﺮل ﺳﺎﻳﺮ ﺳﺎزﻧﺪﮔﺎن‬
‫‪PLC / DCS / ESD‬‬

‫‪11/07/1394‬‬ ‫‪DCS ESD Seminar – Part1 ‐ Maher‬‬ ‫‪15‬‬

‫اﻣﻜﺎن ارﺗﻘﺎ ﺳﻴﺴﺘﻢ ﻫﺎي ﻗﺪﻳﻤﻲ‬
‫‪MIGRATION‬‬
 ‫اﺗﺼﺎل ﺑﻪ ﺳﻄﻮح ﻣﺪﻳﺮﻳﺘﻲ‬
SAP ERP
Enterprise Resource Planning

Management level (MES)

PCS 7
Operation level

Control level

Field level

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 17

 PCS7 MODEL – Functional View

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 18

 ‫ﺳﻴﺴﺘﻢ ﻛﻨﺘﺮل‬
Automation System (AS)
11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 19
 Automation System
‫اﻧﻮاع ﻛﻨﺘﺮﻟﺮ‬

PCS7 Box

Standard : AS400

Redundant : AS400H
Fail Safe : AS400FH

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 20

 ‫وﻳﮋﮔﻲ ﻫﺎي ﻋﻤﻠﻜﺮدي‬
Memory
AS‐400H CPU 417-5H
[ MB ]

32
CPU 417-4H
CPU 416-5H
30
New
16 CPU 414-5H

4
CPU 414-4H

2,8 CPU 412-5H ƒ New AS 416H close cap between

CPU 414H und CPU 417H
1 ƒ 19% more I/O with innovated CPU
CPU 412-3H
414-5H
ƒ CPU 416-5H nearly same level as
0,75 CPU 417-4H

75 45 31,25 18,75 18 12,5 7,5

MPI/DP
DP Performance in ns [bit-operation, word operation, fixed-word operation]
PROFINET
(2 port switch)

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 21

 ‫اداﻣﻪ وﻳﮋﮔﻲ ﻫﺎي ﻋﻤﻠﻜﺮدي‬
AS‐400H

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 22

 AS ‫ﻣﺤﺪودﻳﺖ ﻫﺎي‬
Server ‫ ﺑﺮاي ﻫﺮ‬AS ‫ﻣﺤﺪودﻳﺖ ﺗﻌﺪاد‬
‫ ﺑﺎ ﻛﺎرت ﺷﺒﻜﻪ اﺗﺮﻧﺖ ﻣﻌﻤﻮﻟﻲ‬Server ‫ ﻛﻨﺘﺮﻟﺮ اﺳﺘﺎﻧﺪارد ﺑﺮاي ﻫﺮ‬8 •
CP1623 ‫ ﻳﺎ‬CP1613 ‫ ﺑﺎ ﻛﺎرت ﺷﺒﻜﻪ ﺻﻨﻌﺘﻲ‬Server ‫ ﻛﻨﺘﺮﻟﺮ اﺳﺘﺎﻧﺪارد ﻳﺎ اﻓﺰوﻧﻪ ﺑﺮاي ﻫﺮ‬64 •
‫ﻣﺤﺪودﻳﺖ ﻫﺎي ﭘﺮدازﺷﻲ ﻛﻨﺘﺮﻟﺮ ﻫﺎ‬
AS414-3
AS 412 - AS414- AS417-4
H/F/FH H/F/FH AS416-2 AS416-3 AS417-4 H/F/FH
Analog value measurement 10 35 125 200 150 700
Digital value measurements 15 110 350 450 400 1 200
PID controls 6 35 110 150 130 300
Motors 10 50 125 250 150 450
Valves 10 50 125 250 150 450
SFC 0 15 40 100 50 200
Digital inputs 50 220 800 1 200 850 2 000
Digital outputs 25 110 300 500 315 1 000
Analog inputs 20 80 250 400 275 800
Analog outputs 10 40 110 180 130 400

11/07/1394Process objects (PO) 50DCS ESD Seminar

283 – Part1 ‐ Maher
890 1 400 995 3 145 23
 ‫‪AS 410‐5H‬‬
‫)ﺟﺪﻳﺪ(‬
‫• ﺗﻮاﻧﺎﻳﻲ در ﺣﺪ ‪AS 417‐4‬‬
‫• ﻗﺎﺑﻞ اﺳﺘﻔﺎده در ﻫﺮ ﭼﻬﺎر ﻧﻮع ﺳﻴﺴﺘﻢ ‪ Standard‬و ‪ H‬و ‪ F‬و ‪FH‬‬
‫• داراي داﻧﮕﻞ ﺳﺨﺖ اﻓﺰاري از ‪ 100 PO‬ﺗﺎ ‪2500 PO‬‬

‫‪11/07/1394‬‬ ‫‪DCS ESD Seminar – Part1 ‐ Maher‬‬ ‫‪24‬‬

 I/O ‫ ﺑﺎ‬AS ‫ارﺗﺒﺎط‬
Central

With Remote I/O :

• Profibus
• Profinet

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 25

 AS‐400H
System‐redundante I/O
I/O ‫ارﺗﺒﺎط ﺑﺎ‬ Switched I/O

PROFINET

ET 200M

Y-Link
ET 200S

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 26

 Control Availability
ET
200M

Sync wiring
Data synchronization

CPU 41x-5H CPU 41x-5H

Switch Switc Switch

PROFINET
h

ET 200M ET 200M ET 200M E 200M

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 27

 I/O Availability

availability
Redundant
Profibus

Scalable
11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 28
 OS OS ES

MPI / PROFIBUS / Industrial Ethernet

‫ﺷﺒﻜﻪ ﻛﻨﺘﺮل و ﻣﺎﻧﻴﺘﻮرﻳﻨﮓ‬

Control and Monitoring Networks
11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 29
 Control and Monitoring Networks
Terminal Bus - ۲ Plant Bus - ۱
: ‫ﺷﺒﻜﻪ در ﺳﻄﺢ ﻣﺎﻧﻴﺘﻮرﻳﻨﮓ ﺑﺮاي اﺗﺼﺎل ﺳﻴﺴﺘﻢ ﻫﺎي‬ : ‫ﺷﺒﻜﻪ در ﺳﻄﺢ ﻛﻨﺘﺮﻟﺮ ﺑﺮاي اﺗﺼﺎل ﺳﻴﺴﺘﻢ ﻫﺎي‬

OS Client• AS •
OS Server• OS Single •
OS Server •

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 30

 Bus / Star ‫ﺗﻮﭘﻮﻟﻮژي‬

Bus / Star ‫ﺗﻮﭘﻮﻟﻮژي‬ Redundant Bus / Star ‫ﺗﻮﭘﻮﻟﻮژي‬

Industrial Industrial
Ethernet ISO-on-TCP Ethernet ISO-on-TCP

Sync wiring Sync wiring

+

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 31

 Ring ‫ﺗﻮﭘﻮﻟﻮژي‬

Ring ‫ﺗﻮﭘﻮﻟﻮژي‬ Redundant Ring ‫ﺗﻮﭘﻮﻟﻮژي‬

Industrial Industrial
Ethernet ISO-on-TCP Ethernet ISO-on-TCP

Sync wiring Sync wiring

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 32

 ‫‪Network Availability‬‬
‫ﻣﻴﺰان آﻣﺎدﮔﻲ ﺷﺒﻜﻪ‬

‫‪ Availability‬ﺩﺭ ‪Terminal / Plant Bus‬‬

‫• اﺳﺘﻔﺎده از ﺗﻮﭘﻮﻟﻮژي ﺣﻠﻘﻮي ﺑﺼﻮرت اﻓﺰوﻧﻪ‬

‫• ﻧﻴﺎز ﺑﻪ ﺳﻮﺋﻴﭻ ﻫﺎي ﺧﺎص‬

‫• ﻧﻴﺎز ﺑﻪ ﻛﺎرت ﺷﺒﻜﻪ ﺧﺎص روي ﺳﺮور ﻣﺎﻧﻨﺪ ‪CP1623‬‬

‫‪11/07/1394‬‬ ‫‪DCS ESD Seminar – Part1 ‐ Maher‬‬ ‫‪33‬‬

 Total Availability
‫ﻣﻴﺰان آﻣﺎدﮔﻲ ﻛﻠﻲ ﺳﻴﺴﺘﻢ‬

Control I/O
Monitoring Availability Availability
Availability

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 34

 Network – Main component

CP1623 Scalnce X500

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 35

Scalance X400
Network Security ‫اﻣﻨﻴﺖ ﺷﺒﻜﻪ‬
 ‫ﺟﻠﻮﮔﻴﺮي از ارﺗﺒﺎط ﻫﺎي ﻧﺎﺷﻨﺎﺧﺘﻪ‬
Unknown PC-
OS-Station Engineering
Station
HMI

Industrial
Ethernet

SINAMI
CS

SINAMICS
S7-300 w ith SIMATIC S7-
CP 343-1 Lean 1200 ET20
ET 200S w ith CM 1242- 0S
5
 ‫ارﺗﻘﺎ اﻣﻨﻴﺖ ﺷﺒﻜﻪ‬
‫اﺳﺘﻔﺎده از وﻳﻨﺪوز ﻣﻨﺎﺳﺐ‬ ‫•‬
‫ﻋﺪم اﺗﺼﺎل ﻣﺴﺘﻘﻴﻢ ﺑﻪ ﺷﺒﻜﻪ ﻫﺎ ﻳﺎ ﺳﻴﺴﺘﻢ ﻫﺎي ﺑﻴﺮوﻧﻲ‬ ‫•‬
‫اﺳﺘﻔﺎده از ﻓﺎﻳﺮوال ﺳﺨﺖ اﻓﺰاري و ﻧﺮم اﻓﺰاري‬ ‫•‬

‫‪11/07/1394‬‬ ‫‪DCS ESD Seminar – Part1 ‐ Maher‬‬ ‫‪38‬‬

‫ﻓﺎﻳﺮوال ﻫﺎي ﺳﺨﺖ اﻓﺰاري‬
SOFTNET Security
Client V4 (VPN)

CP443 Adv.
CP 1628

Scalance S V3

CP443 Adv
 Field communication

‫ﺷﺒﻜﻪ در ﺳﻄﺢ ﻓﻴﻠﺪ‬

Fieldbus Protocols
11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 40
‫ﻓﻴﻠﺪﺑﺎس ﻫﺎي ﭘﺮﻛﺎرﺑﺮد‬

• Profibus‐ DP
• Profinet
• Profibus – PA
• Foundation Fieldbus
• Modbus
• AS‐I
• others
 ‫‪Profibus ‐ DP‬‬
‫ﻣﺮﺳﻮم ﺗﺮﻳﻦ ﺷﺒﻜﻪ ﻓﻴﻠﺪ ﺑﺎس در اﻳﺮان‬ ‫•‬

‫ﻗﺎﺑﻞ اﺟﺮا ﺑﺎ ﻛﺎﺑﻞ ﻣﺴﻲ ‪ ،‬ﻓﻴﺒﺮ ﻧﻮري و واﻳﺮﻟﺲ‬ ‫•‬

‫ﻣﺎﻛﺰﻳﻤﻢ ﺳﺮﻋﺖ ‪12Mbps‬‬ ‫•‬

‫ﻃﻮل ﻛﺎﺑﻞ ﻣﺴﻲ در ﺳﺮﻋﺖ ‪ 1.5‬ﺣﺪاﻛﺜﺮ ‪ 2‬ﻛﻴﻠﻮﻣﺘﺮ‬ ‫•‬

‫ﺑﻴﺸﺘﺮ ﻛﺎرﺑﺮدﻫﺎ ﺑﺼﻮرت ‪Central‬‬ ‫•‬

‫اﺳﺘﺎﻧﺪارد ﻻﻳﻪ ﻓﻴﺰﻳﻜﻲ ‪RS485‬‬ ‫•‬

‫‪11/07/1394‬‬ ‫‪DCS ESD Seminar – Part1 ‐ Maher‬‬ ‫‪42‬‬

 PROFIBUS DP ‐ Topologies
Single‐sided connection Single‐channel connection Switched connection

+ Tree

ET 200S ET 200S

PROFIBUS
ET 200M
ET 200iSP ET 200iSP
PROFIBUS

PROFIBUS

ET 200M ET 200M
PROFIBUS PA
ET 200pro ET 200pro

ET 200eco ET 200eco ET 200iSP

PROFIBUS Normslave PROFIBUS Normslave

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 43

 ‫‪Profibus DP with ET200‬‬
‫ﺗﻔﺎوت ﻫﺎ ‪:‬‬
‫ﻣﺮﺳﻮم ﺗﺮﻳﻦ ﻫﺎ‪:‬‬ ‫درﺟﻪ ‪IP‬‬ ‫•‬
‫• ‪ET200M‬‬
‫اﻣﻜﺎن اﺳﺘﻔﺎده در ﻣﺤﻴﻂ ‪ex‬‬ ‫•‬
‫• ‪ET200S‬‬
‫اﻣﻜﺎن ‪Redundancy‬‬ ‫•‬
‫اﻣﻜﺎن ﻧﺼﺐ اﺳﺘﺎرﺗﺮ ﻫﺎي ﻣﻮﺗﻮر‬ ‫•‬
‫و‪...‬‬ ‫•‬

‫‪11/07/1394‬‬ ‫‪DCS ESD Seminar – Part1 ‐ Maher‬‬ ‫‪44‬‬

‫‪Profinet‬‬

‫ﺳﺮﻋﺖ در ﺣﺪ اﺗﺮﻧﺖ‬ ‫•‬

‫اﻃﻤﻴﻨﺎن در ﺣﺪ ﭘﺮوﻓﻲ ﺑﺎس‬ ‫•‬
 PROFINET and PROFIBUS in one system
One solution for PROFINET and PROFIBUS

ƒ PROFINET and profibus can be operated at

the same time at the controller
ƒ Reduced Hardware need

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 46

 PROFINET Bus Topology

Single‐sided connection

Sync wiring

ET 200S 2x CPU 41x-5H

PROFINET

ET 200M PROFINET

ET 200pro

PROFINET Device ET 200M ET 200M ET 200M

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 47

 PROFINET Star / Ring Topology

PROFINET

PROFINET

With use of IE With Ring Topology With System

Switches Redundancy

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 48

 ‫‪Profibus‐PA‬‬

‫ﺷﺒﻜﻪ ﻛﺮدن ‪Transmitter , Actuators‬‬ ‫•‬

‫ﺳﺮﻋﺖ ‪31.25 kbps‬‬ ‫•‬
‫ﺗﻐﺬﻳﻪ از ﺑﺎس‬ ‫•‬
‫‪ 31‬وﺳﻴﻠﻪ‬ ‫•‬
‫ﻛﺎﺑﻞ ﺣﺪود ‪ 1000‬ﻣﺘﺮ‬ ‫•‬
‫اﻣﻜﺎن اﺳﺘﻔﺎده در ﻣﺤﻴﻂ ‪ex‬‬ ‫•‬
‫اﻣﻜﺎن ﻛﺎﻧﻔﻴﮓ وﺳﺎﻳﻞ از را دور‬ ‫•‬

‫‪11/07/1394‬‬ ‫‪DCS ESD Seminar – Part1 ‐ Maher‬‬ ‫‪49‬‬

 Profibus PA – Bus Topology
Possible Failures in a PA- Segment
 Profibus PA ‐Ring Topology

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 51

 Use in Hazard Area – Zone2 / Zone1

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 52

 Fieldbus Availability
‫ﻣﻴﺰان آﻣﺎدﮔﻲ ﻓﻴﻠﺪﺑﺎس‬

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 53

 Foundation Fieldbus (H1)

: PCS7 ‫در‬ Profibus – PA ‫وﻳﮋﮔﻲ ﻫﺎ ﻣﺸﺎﺑﻪ‬ •

Profibus PA ‫• اوﻟﻮﻳﺖ اول‬ ‫اﻣﻜﺎن ﻛﻨﺘﺮل در ﻓﻴﻠﺪ‬ •
Foundation Fieldbus (H1) ‫• اوﻟﻮﻳﺖ دوم‬ DP/FF ‫ از ﻃﺮﻳﻖ ﻛﻮﭘﻠﺮ‬AS ‫ارﺗﺒﺎط ﺑﺎ‬ •

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 54

 AS‐I
Actuator Sensor Interface
Discrete I/O ‫• ﺷﺒﻜﻪ ﻛﺮدن‬
170 Kbps ‫• ﺳﺮﻋﺖ‬
Factory Automation ‫• ﻛﺎرﺑﺮد ﺑﻴﺸﺘﺮ در‬

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 55

‫‪Modbus‬‬
‫ﺑﻴﺸﺘﺮﻳﻦ ﻛﺎرﺑﺮد ‪:‬‬
‫• اﺗﺼﺎل ﺳﻴﺴﺘﻢ ﻫﺎي ﻛﻨﺘﺮل ﺳﺎزﻧﺪﮔﺎن ﻣﺨﺘﻠﻒ‬

‫ﻛﺎرﺑﺮدﻫﺎي ﻣﻬﻢ دﻳﮕﺮ ‪:‬‬

‫• ارﺗﺒﺎط ﺑﺎ ﺗﺠﻬﻴﺰات ﻗﺪرت ﺑﻮﻳﮋه در ﺳﻴﺴﺘﻢ ‪SCADA‬‬

‫اﻧﻮاع ‪:‬‬
‫• ‪ : Modbus RTU‬ﻛﻨﺪ ‪ ،‬ﺑﺎ ﺑﺴﺘﺮ ‪RS485 , RS422 , RS232‬‬
‫• ‪ : Modbus TCP‬ﺳﺮﻳﻊ ﺑﺎ ﺑﺴﺘﺮ اﺗﺮﻧﺖ‬
‫ﺳﻴﺴﺘﻢ ﻫﺎي اﭘﺮاﺗﻮري‬
Operator Stations
 ‫‪Operator Stations‬‬
‫ﺳﻴﺴﺘﻢ ﻫﺎي اﭘﺮاﺗﻮري‬
‫‪Single Stations‬‬
‫ﺳﻴﺴﺘﻢ ﻫﺎي اﭘﺮاﺗﻮري ﻛﻪ ﻣﺴﺘﻘﻴﻤﺎٌ ﺑﻪ ﺷﺒﻜﻪ ﻛﻨﺘﺮﻟﺮﻫﺎ ﻣﺘﺼﻞ‬
‫ﻫﺴﺘﻨﺪ‬

‫‪Multiple Station‬‬
‫ﺳﻴﺴﺘﻢ ﻫﺎي اﭘﺮاﺗﻮري ﻛﻪ ﺑﺼﻮرت ‪Clinet / Server‬‬
‫ﻣﺘﺼﻞ ﻫﺴﺘﻨﺪ‬

‫‪Multiple Station Redundant‬‬

‫ﺳﻴﺴﺘﻢ ﻫﺎي اﭘﺮاﺗﻮري ﻛﻪ ﺑﺼﻮرت ‪Clinet / Server‬‬
‫ﺑﺎ ‪ Server‬اﻓﺰوﻧﻪ ﻣﺘﺼﻞ ﻫﺴﺘﻨﺪ‬

‫‪11/07/1394‬‬ ‫‪DCS ESD Seminar – Part1 ‐ Maher‬‬ ‫‪58‬‬

 OS Limitations
‫ﺗﻌﺪادﺳﻴﺴﺘﻢ ﻫﺎي اﭘﺮاﺗﻮري‬

Few OS Single Station

5000 POs per OS Single

•Max 12 Redundant Server

•Max 32 Client Per Server
•8500 POs per OS Server

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 59

‫ﻣﺎﻧﻴﺘﻮرﻳﻨﮓ ﺗﺤﺖ ‪web‬‬
 OS Limitations
‫ﻣﺤﺪودﻳﺖ ﻫﺎي ﺳﻴﺴﺘﻢ اﭘﺮاﺗﻮري‬

OS quantity framework
Max. number of OS servers / pairs of servers 12
Max. number of AS per OS server / pair of servers 64
Max. number of OS clients (per multi‐user system) 32
Max. number of process objects:
• Per OS single station 5000 Pos
• Per OS server 8500 POs

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 61

‫ﺳﺨﺖ اﻓﺰار ﭘﻴﺸﻨﻬﺎدي ‪IPC :‬‬
‫اﻣﻜﺎن اﺳﺘﻔﺎده از ‪ PC‬ﻣﻌﻤﻮﻟﻲ‬
‫اﻣﻜﺎﻧﺎت ﮔﺮاﻓﻴﻜﻲ‬

Ami Drori, Siemens Israel June 2011

 Build in Faceplate

Valve One Feedback Motor Analog Indicator

PID controller Totalizing time counter

Operation List

Journal List
Alarm View
 Alarm statistics and analysis

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 67

 Alarm Hidding

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 68

 ‫ﺳﻨﻜﺮون ﺳﺎزي ﺗﺎرﻳﺦ و زﻣﺎن ﺳﻴﺴﺘﻢ ﻫﺎ‬
‫‪Time Synchronization‬‬
‫ﺗﺎرﻳﺦ و زﻣﺎن آﻻرم ﻫﺎ از ‪ AS‬ﮔﺮﻓﺘﻪ ﻣﻲ ﺷﻮد‬
‫اﮔﺮ ‪ AS‬ﻫﺎ ﺳﻨﻜﺮون ﻧﺒﺎﺷﻨﺪ ‪:‬‬
‫ﺗﺮﺗﻴﺐ آﻻرم ﻫﺎ و‬
‫ﺗﺮﺗﻴﺐ ‪ event‬ﻫﺎ و‬
‫ﺗﺮﺗﻴﺐ ﻛﺎرﻫﺎي اﭘﺮاﺗﻮري‬
‫درﺳﺖ ﻧﻴﺴﺖ‬

‫‪11/07/1394‬‬ ‫‪DCS ESD Seminar – Part1 ‐ Maher‬‬ ‫‪69‬‬

 Time Stamp Alarm

Process alarms : e.g. "Analog value high"

• Time stamping cyclic in the AS
• Precision: AS scan rate, e.g. 100 msec.

Error messages of the I/O : e.g. "wire break"

• Time stamping acyclic in the AS
• Precision : approx. 20 msec.

Digital signals on the input/output station

• Digital signals via IM153‐2 / IM151‐2
11/07/1394 DCS ESD•Seminar
Precision : 1 msec
– Part1 ‐ Maher 70
 ‫‪Batch system‬‬
‫در ﻓﺮآﻳﻨﺪﻫﺎﻳﻲ ﻛﻪ اﻟﮕﻮﻫﺎي ﺗﻮﻟﻴﺪ ﺑﺴﻴﺎر ﻣﺘﻨﻮع اﺳﺖ ﻛﺎرﺑﺮد دارد‬

‫‪11/07/1394‬‬ ‫‪DCS ESD Seminar – Part1 ‐ Maher‬‬ ‫‪71‬‬

 ‫‪Route Control‬‬
‫در اﻧﺘﻘﺎل ﻣﻮاد و ﺳﻴﺎﻻت ﻛﻪ داراي ﻣﺴﻴﺮﻫﺎي ﻣﺘﻨﻮع دﺳﺘﺮﺳﻲ ﻫﺴﺘﻨﺪ ﻛﺎرﺑﺮد دارد‬

‫‪11/07/1394‬‬ ‫‪DCS ESD Seminar – Part1 ‐ Maher‬‬ ‫‪72‬‬

 ‫ﺳﺮور آرﺷﻴﻮ ﻣﺮﻛﺰي‬
11/07/1394 Central Archive Server CAS
DCS ESD Seminar – Part1 ‐ Maher 73
 ‫‪Central Archive Server‬‬
‫ﺳﻴﺴﺘﻢ آرﺷﻴﻮ ﻣﺮﻛﺰي‬
‫روش ﻫﺎي آرﺷﻴﻮ ﺳﺎزي ‪:‬‬

‫آرﺷﻴﻮ ﻫﺎي ﻛﻮﺗﺎه ﻣﺪت روي ‪ OS Single‬ﻳﺎ ‪OS Server‬‬ ‫•‬ ‫‪ Short Term .١‬در ﺣﺪ ﭼﻨﺪ ﻫﻔﺘﻪ‬
‫آرﺷﻴﻮ ﻫﺎي دراز ﻣﺪت روي ‪CAS‬‬ ‫•‬ ‫‪ Long Term .٢‬در ﺣﺪ ﭼﻨﺪﻳﻦ ﻣﺎه‬

‫‪11/07/1394‬‬ ‫‪DCS ESD Seminar – Part1 ‐ Maher‬‬ ‫‪74‬‬

 Central Archive Server
‫ﺳﻴﺴﺘﻢ آرﺷﻴﻮ ﻣﺮﻛﺰي‬

CAS ‫ﻣﺤﺪودﻳﺖ ﻫﺎي آرﺷﻴﻮ در‬

Central Archive Server (CAS)

Long-term archiving Up to 11 servers/server pairs

Data input for process value archiving by ١ server Approx. 1 000/s

Data input for process value archiving by all servers Approx. 10 000/s

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 75

 Maintenance
Monitoring Diagnostics Maintenance
Request

SIMATIC PCS 7 Plant Asset Management

‫ﺳﻴﺴﺘﻢ ﺗﻌﻤﻴﺮاﺗﻲ‬
Maintenance Station
 Maintenance Station
‫ﺳﻴﺴﺘﻢ ﺗﻌﻤﻴﺮاﺗﻲ‬

Asset Management:
• Corrective Maintenance
• Preventive Maintenance
• Predictive Maintenance

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 77

 Diagnostics
‫ ﻫﻤﺮاه ﺑﺎ ﺟﺰﺋﻴﺎت ﻓﺎﻟﺖ‬online ‫ﻧﻤﺎﻳﺶ وﺿﻌﻴﺖ اﺟﺰاي ﺳﺨﺖ اﻓﺰاري ﺑﺼﻮرت‬ •

‫ﻧﻤﺎﻳﺶ وﺿﻌﻴﺖ وﺳﺎﻳﻞ ﻫﻮﺷﻤﻨﺪ ﻓﻴﻠﺪﺑﺎس‬ •

SIMATIC S7‐400 a nd
PROFIBUS Network

status and selection of

underlying hierarchy
ET 200M
diagnosis symbol
of the component Sta ti on

Clear hierarchical structure PROFIBUS

As s ets
„ Plant overview
„ Overview all controllers
„ Controller (with sub-hierarchy)
„ PROFIBUS Assets
„ DP station (e.g. ET 200M)
„ Intelligent field device Fa ceplates
for i ntelligent
devi ce
‫ﺳﻴﺴﺘﻢ ﻣﻬﻨﺪﺳﻲ‬
Engineering Station
11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 79
 ‫اﻣﻜﺎﻧﺎت ﻳﻜﭙﺎرﭼﻪ ﻣﻬﻨﺪﺳﻲ‬
‫• ﻃﺮاﺣﻲ ﮔﺮاﻓﻴﻚ ﺳﻴﺴﺘﻢ ‪OS‬‬ ‫• ﭘﻴﻜﺮ ﺑﻨﺪي ﺳﺨﺖ اﻓﺰار ‪ AS‬و ‪OS‬‬
‫• ﭘﻴﻜﺮ ﺑﻨﺪي ‪Fieldbus‬‬ ‫• ﺷﺒﻜﻪ ﺑﻨﺪي ‪ AS‬و ‪OS‬‬
‫• ﻋﻴﺐ ﻳﺎﺑﻲ‬ ‫• ﭘﻴﺎده ﺳﺎزي ﻣﻨﻄﻖ ﻛﻨﺘﺮل‬

‫‪Ami Drori, Siemens Israel‬‬

 Programming Method
‫روش ﻫﺎي ﺑﺮﻧﺎﻣﻪ ﻧﻮﻳﺴﻲ‬
SFC ‫ و‬CFC : ‫اﺑﺰار اﺻﻠﻲ ﺑﺮﻧﺎﻣﻪ ﻧﻮﻳﺴﻲ‬

LAD LAD/FBD/STL ‫ ﻳﺎ‬SCL ‫ﻃﺮاﺣﻲ ﻓﺎﻧﻜﺸﻦ ﻫﺎ ﺑﺎ‬

SCL STL

PCS 7

SFC FBD

CFC
 CFC
Continuos Function Chart
 SFC
Sequential Function Chart
 Comprehensive Library
‫ﻛﺘﺎﺑﺨﺎﻧﻪ ﺟﺎﻣﻊ ﻧﺮم اﻓﺰار‬
CFC Library•
PCS7 Library•
PCS7 Advanced Library•
.... ‫• ﻭ‬

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 84

 Control Templates
‫ﻗﺎﻟﺐ ﻫﺎي ﻛﻨﺘﺮﻟﻲ آﻣﺎده‬
PID Control •
Analog Monitoring•
Digital Monitoring •
Motor•
Valve•
……•

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 85

 APC ‐ Advanced Process Control
Available tools
APC Method

Embedded
in PCS 7
MPC
lean large

Smith Fuzzy
Predictor Control
Lead‐Lag
Feed‐Forward Control Operator
Control Performance Training
Monitoring Simulator
Override
Control PID
Tuning
Gain
Scheduling Integrated / interfaced
3rd party tools
low APC Complexity high
 APC Tools embedded in PCS 7

APC Engineering Tool APC OS Faceplates

Î Modeling & Test Î Operation & Control

OS Clients

Engineering OS-LAN Ethernet

Station ES
OS-Server
(redundant)

Industrial Ethernet / Fast Ethernet

APC Runtim e Function Blocks

Î Runtim e Calculations
 ‫‪Model Design‬‬
‫اﻣﻜﺎن ﻃﺮاﺣﻲ ﻣﺪل‬
‫ﺳﺎﺧﺖ ﻣﺪل ﺑﺎ ﺗﺮﻛﻴﺐ ﻗﺎﻟﺐ ﻫﺎي آﻣﺎده‬ ‫•‬
‫ﺳﻬﻮﻟﺖ ﻛﻨﺘﺮل و ﻣﺎﻧﻴﺘﻮرﻳﻨﮓ ﻓﺮآﻳﻨﺪﻫﺎي ﻣﺸﺎﺑﻪ‬ ‫•‬

‫‪11/07/1394‬‬ ‫‪DCS ESD Seminar – Part1 ‐ Maher‬‬ ‫‪88‬‬

 Design Monitoring
‫اﻣﻜﺎﻧﺎت ﻃﺮاﺣﻲ ﻣﺎﻧﻴﺘﻮرﻳﻨﮓ‬

Graphic Design •
Alarm Management •
Archive Design •
Scripts •

Integrated with Logic

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 89

 ‫‪Fieldbus Engineering‬‬
‫اﻣﻜﺎﻧﺎت ﻛﺎر ﺑﺎ ﻓﻴﻠﺪ ﺑﺎس‬
‫• اﻣﻜﺎن ﭘﻴﻜﺮ ﺑﻨﺪي وﺳﺎﻳﻞ ﺳﺎزﻧﺪﮔﺎن ﻣﺨﺘﻠﻒ )ﻓﺎﻳﻞ ‪( GSD‬‬
‫• اﻣﻜﺎن ﺑﺮﻧﺎﻣﻪ ﻧﻮﻳﺴﻲ ﺑﺎ ﺑﻠﻮك ﻫﺎي اراﺋﻪ ﺷﺪه در ﻛﺘﺎﺑﺨﺎﻧﻪ ﻧﺮم اﻓﺰار‬
‫• اﻣﻜﺎن ﻣﺸﺎﻫﺪه و ﺗﻨﻈﻴﻢ ﭘﺎراﻣﺘﺮﻫﺎي وﺳﺎﻳﻞ ﻓﻴﻠﺪﺑﺎس )ﻓﺎﻳﻞ ‪( EDD‬‬
‫• اﻣﻜﺎﻧﺎت ﻋﻴﺐ ﻳﺎﺑﻲ ﻓﻴﻠﺪﺑﺎس ﺑﺼﻮرت ‪Online‬‬

‫‪11/07/1394‬‬ ‫‪DCS ESD Seminar – Part1 ‐ Maher‬‬ ‫‪90‬‬

 PDM
Process Device Manager
‫ﭘﺸﺘﻴﺒﺎﻧﻲ از‬

Engineering Operator Station OS Profibus –PA , FF , Hart •

Station ES (e.g. Win CC)

Ethernet

.... .... ....

S7‐ 400H S7‐ 400 S7‐ 300 IE/PB Link

PROFIBUS DP 45.45 kBit/s

PROFIBUS PA

PROFIBUS DP redundant PROFIBUS DP

DP/PA link ET 200M ET 200iS

PROFIBUS PA

RS232/
RS485

Possible SIMATIC PDM

connection point Any device
with any
 ‫‪Simulation Services‬‬
‫اﻣﻜﺎﻧﺎت ﺷﺒﻴﻪ ﺳﺎزي‬
‫• ﺷﺒﻴﻪ ﺳﺎزي و ﺗﺴﺖ ﻻﺟﻴﻚ ﻛﻨﺘﺮل ﺑﺎ ‪S7-PLCSIM‬‬
‫• ﺷﺒﻴﻪ ﺳﺎزي ﺷﺒﻜﻪ ﭘﺮوﻓﻲ ﺑﺎس ﺑﺎ ‪SIMBApro‬‬
‫• ﺷﺒﻴﻪ ﺳﺎزي ﻓﺮآﻳﻨﺪ ﺑﺎ ‪SIMIT‬‬

‫‪SIMIT‬‬

‫‪11/07/1394‬‬ ‫‪DCS ESD Seminar – Part1 ‐ Maher‬‬ ‫‪92‬‬

 ‫ﺳﻴﺴﺘﻢ ﻫﺎي ‪ESD‬‬
‫‪Emergency Shut Down‬‬
‫ﻣﻘﺎﻳﺴﻪ ﻋﻤﻠﻜﺮد ‪ DCS‬و ‪ESD‬‬ ‫•‬

‫ﻣﻔﺎﻫﻴﻢ و اﺳﺘﺎﻧﺪارد ﻫﺎي ‪Safety‬‬ ‫•‬

‫اﻧﻮاع ﺳﻴﺴﺘﻢ ﻫﺎي ‪ ESD‬زﻳﻤﻨﺲ‬ ‫•‬

‫ﺳﺨﺖ اﻓﺰار و ﻧﺮم اﻓﺰار ‪ESD‬‬ ‫•‬

 SIS ‫ و‬DCS ‫ﺟﺎﻳﮕﺎه ﺳﻴﺴﺘﻢ ﻫﺎي‬

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 94

 SIS ‫ و‬DCS ‫ﻣﻘﺎﻳﺴﻪ ﻋﻤﻠﻜﺮد‬

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 95

 SIS ‫ و‬DCS ‫ارﺗﺒﺎط‬

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 96

 SIS ‫اﻧﻮاع ﺳﻴﺴﺘﻢ ﻫﺎي‬
• HIPPS : High Pressure Protection System

• ESD : Emergency shutdown

• F&G : Fire and Gas

• BMS : Burner Management System

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 97

 De‐energised to trip (ESD)
Process pipe Process pipe

Transmitter +
4 ‐ 20 mA

Normally energised Spring‐loaded

I output loop Solenoid Valve
Logic
Solver
I
Pressure Solenoid Spring
switch

‐
Normally energised
input loop

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 98

 Energised to trip (F&G)
+

Normally de‐energised
I output loop
Logic
Solver
I
Gas
+
‐
Normally
de‐energised
input loop I
Logic
Solver
I

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 99

 ‫‪IEC ‐ Safety Standards‬‬

‫‪IEC 61508‬‬ ‫اﻳﻤﻨﻲ ﺳﻴﺴﺘﻢ ﻫﺎي ﻛﻨﺘﺮل‬

‫‪IEC61511‬‬ ‫اﻳﻤﻨﻲ ﺳﻴﺴﺘﻢ ﻫﺎي ﻛﻨﺘﺮل در ﻓﺮآﻳﻨﺪﻫﺎي ﺻﻨﻌﺘﻲ‬

‫‪IEC61513‬‬ ‫اﻳﻤﻨﻲ ﺳﻴﺴﺘﻢ ﻫﺎي ﻛﻨﺘﺮل در ﺻﻨﺎﻳﻊ ﻫﺴﺘﻪ اي‬

‫‪11/07/1394‬‬ ‫‪DCS ESD Seminar – Part1 ‐ Maher‬‬ ‫‪100‬‬

 Process Risk
Residual Tolerable Risk inherent
risk level risk level in process

Risk reduction
SIS Other External

Process

Risk

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 101

 Risk graph
SIL ‫ﻧﺤﻮه ﺗﻌﻴﻴﻦ‬
• Consequence (C) ‫ﻧﺘﻴﺠﻪ اﺗﻔﺎق‬
– C1: ‫آﺳﻴﺐ ﻛﻢ‬ w3 w2 w1
– C2: ‫ اﺣﺘﻤﺎل ﻣﺮگ ﻳﻚ ﻧﻔﺮ‬، ‫آﺳﻴﺐ ﺟﺪي‬ C1
– C3: ‫اﺣﺘﻤﺎل ﻣﺮگ ﭼﻨﺪ ﻧﻔﺮ‬ - - -
– C4: ‫اﺣﺘﻤﺎل ﻣﺮگ ﺗﻌﺪاد ﻧﻔﺮات زﻳﺎد‬ P1
F1 S IL1 - -
• Frequency of exposure (F) ‫ﻣﻴﺰان در ﻣﻌﺮض ﺧﻄﺮ ﺑﻮدن‬ P2
S IL1 S IL1 -
– F1: ‫ﻛﻢ‬ C2
P1
– F2: ‫اﻏﻠﺐ ﻳﺎ داﺋﻤﻲ‬ F2 S IL2 S IL1 S IL1

• Possibility of avoiding hazard (P)‫اﺟﺘﻨﺎب از ﺧﻄﺮ‬ P2

S IL3 S IL2 S IL1
– P1: ‫اﻣﻜﺎن ﭘﺬﻳﺮ اﺳﺖ‬ F1
– P2: ‫اﻛﺜﺮا اﻣﻜﺎن ﭘﺬﻳﺮ ﻧﻴﺴﺖ‬ C3 S IL3 S IL3 S IL2
F2
• Probability of event (W) ‫اﺣﺘﻤﺎل رﺧﺪاد‬ S IL4 S IL3 S IL3

– W1: ‫ﺧﻴﻠﻲ ﻛﻢ‬ C4

? S IL4 S IL3
– W2: ‫ﻣﺘﻮﺳﻂ‬
– W3: ‫زﻳﺎد‬

DCS ESD Seminar – Part1 ‐ Maher

 Probabilities / Safety Integrity Level
SIL = Pfd target
Pfd=Probability of failure on demand

Pfd loop = Pfd sensors + Pfd logic solver + Pfd final elements
Trip
amplifiers
Vent
TR
Fail safe Air
output
TR Safety Interlocks

Safety valve
TR

Sensors Logic Solver Final Elements

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 103

 Requirements Safety Instrumented
System
• From the risk graph a Target SIL for the SIS will result
• The target SIL indicates the maximum average Probability of
failure on demand (Pfd) the safety system may have

Safety Average Probability of Safety Risk Reduction

Integrity failure on demand Availability Factor
Level
4 ≥ 10‐5 to < 10‐4 > 99.99% > 10 000
3 ≥ 10‐4 to < 10‐3 99.9 ‐ 99.99% 1 000 ‐ 10 000
2 ≥ 10‐3 to < 10‐2 99 ‐ 99.9% 100 ‐ 1 000
1 ≥ 10‐2 to < 10‐1 90 ‐ 99% 10 ‐ 100
0 (Control NA)

DCS ESD Seminar – Part1 ‐ Maher

 Relation AK classes and SIL levels

(TÜV) IEC
AK Class SIL level
AK 1 SIL 0
AK 2 & 3 SIL 1
AK 4 SIL 2
AK 5/6 SIL 3
AK 7 & 8 SIL 4

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 105

 Redundancy for sensors and
final elements
1oo1

1oo2

2oo2

2oo3/2oo4

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 106

 Controller Redundancy
1oo1
SIL 1 / No SIL

Input Module Control Module Output Module

+
Sensor Inputs CPU Outputs
Final Element

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 107

 Controller Redundancy
1oo1D
SIL2 / AK4

Input Module Control Module Output Module

+
Sensor Inputs CPU Outputs

Diagnostic Diagnostics Diagnostics

Final Element

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 108

 Controller Redundancy
1oo2D SIL3 AK5/6
Input Module Control Module Output Module
+
Input Output
Circuit CPU Circuit

Diagnostic Diagnostic Diagnostic

Ci rcui t Ci rcui t Ci rcui t
SENSOR

Input Module Control Module Output Module

Input Output
Circuit CPU Circuit
Diagnostic Diagnostic Diagnostic
Ci rcui t Ci rcui t Ci rcui t

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 109

 ‫ﻃﺮاﺣﻲ ﺧﺎص ﺳﻴﺴﺘﻢ ﻫﺎي ‪Safety‬‬

‫ﺷﺮاﻳﻂ ﻛﺎري ﺳﺨﺖ‪:‬‬

‫ﮔﺮﻣﺎ‬ ‫•‬
‫رﻃﻮﺑﺖ‬ ‫•‬
‫ﺧﻮردﮔﻲ ﺷﻴﻤﻴﺎﻳﻲ‬ ‫•‬
‫‪Design for‬‬ ‫ﻟﺮزش‬ ‫•‬
‫!‪NO FAILURES‬‬ ‫ﺷﻮك ﻫﺎي اﻟﻜﺘﺮﻳﻜﻲ‬ ‫•‬
‫ﻧﻮﻳﺰ‬ ‫•‬

‫‪11/07/1394‬‬ ‫‪DCS ESD Seminar – Part1 ‐ Maher‬‬ ‫‪110‬‬

 ‫ زﻳﻤﻨﺲ‬Safety ‫ﺗﺎرﻳﺨﭽﻪ ﺳﻴﺴﺘﻢ ﻫﺎي‬
Certified up to SIL 3

S7 F System s Distributed Safety

S7-400FH / PROFIsafe S7 151F/315F/317F/416F
(1999) (2002/2003)

Safety Matrix
(1999)

QUADLOG
(1995)

SIMATIC S5-
95F
SIMATIC S5- (1994)
110F
(1980) SIMATIC S5-
115F
(1988)

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 111

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 112
 Safety Control System, SIMATIC S7 – 300/400 F/FH

S7-417-4H *)
Redundant systems 30MB
S7-414-4H *) 3000 F-I/Os
2.8MB
600 F-I/Os
S7-412-3H *)
768kB
100 F-I/Os
S7-319F-2DP
1.4MB
1000 F-I/Os
S7-317F-2DP
1MB
500 F-I/Os
S7-315F-2DP
192kB
300 F-I/Os Certified up to SIL 3

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 113

 TUV Certificate

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 114

 F‐ Hardware

SIL2
if the PLC fails, then the process will
be guaranteed to shutdown ‐ just like
it would with "normal" safety relays. SIL3
F ‐ Panel
 F System ‐ Architecture

Standard-Progr. software F-Programmingtool

PC • STEP7 • F-FB-Library
• CFC • F-Tool
• HW-Config • OMs for F-SMs
• WinCC
→ Integration in PCS7/ TIA

1 Standard-CPU 417-4H
RUN- P
RUN
STO P
CM RES

F-SMs in ET 200M

11/07/1394 Standard-ProfibusDP
DCS ESD Seminar – Part1 ‐ Maher PROFISafe-Safety profil117
 FH System ‐ Architecture
PC

Programmes Standard- et de securite- dans une CPU

red. CPU
RUN

RUN- P
R-UP

RUN

S7-400FH
N

Standard- et F-SMs redondant redondant

STO P

STO
CM RES

CM R
PES

un seul Profibus DP F-SMs Standard-SMs

redondant
Profibus DP
Communication Standard- et PROFISafe- via Profibus DP
11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 118
 Fail Safe and High Availability

AS 414 F AS 414 F
AS 417 F AS 417 F

PROFIBUS-DP
PROFIBUS-DP

ET 200M F-I/O Modules ET 200M

F-I/O Modules
2x Safety redundant
IM 153-2 Module
Standard
I/O Modules

n redundant S7-400FH n redundant S7-400FH

n redundant PROFIBUS-DP n redundant PROFIBUS-DP
n F-E/A Moduls n redundant F-E/A Moduls
n SIL3, AK6 n SIL3, AK6

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 119

 Flexible Modular Redundancy ™

• Make any component redundant

DO

DO
AI

DI
 Flexible Modular Redundancy ™

DO
AI

DI

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 121

 Flexible Modular Redundancy ™

• Make any component redundant

DO

DO
AI

DI

n Physically separate redundant resources

AI

DI
 Flexible Modular Redundancy ™

• Make any component redundant

Dual

DO

DO
AI

DI

n Physically separate redundant resources

n Mix and match redundancy

DO
AI

DI

AI

Simplex
AI

Triple
 Flexible Modular Redundancy ™

• Make any component redundant

8

Dual
8 8 8
DO

DO
AI

DI

n Physically separate redundant resources

n Mix and match redundancy

88
DO
AI

DI

AI

n Tolerate multiple faults with no impact on safety

Simplex n Safety is not dependant on redundancy; all components
are SIL3‐capable
8 n Redundancy only for availability; No degraded mode
AI

Triple
 Flexible Set‐up‘s

n Multiple Fault Tolerant

8
u Fieldbus architecture allows system to tolerate multiple
faults without interruption
u I/O redundancy independent of CPU redundancy
n All components rated for SIL3
u No degraded mode

8 88 8 u Safety not dependent on redundancy

DO

DO
AI

AI

DI

88 8
DO

DO
DI
AI

AI

2oo3

8
AI

1oo2 Valves 2oo3 PT

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 125

 S7‐400F/FH
Structure of program
Program Standard
OB1
program Failsafe
(OB35)
Programme Standard
OB1

program Failsafe
(OB35)
Program Standard
OB1

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 126

 Fail Safe DO Modules (sample)

F‐Digital Output, with built in redundancy, self verification and degrading

Bus interface

Dual‐
Microcontroller port Microcontroller
RAM

Output
Second
driver
disconnection facility

If ”Output driver” fails to bring

output to safe state, ”0”, the
Read back microcontroller does, based on
Output the read back, order the ”Second
VSupply
disconnection facility” to shut
L+
the card down

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 127

 SIL selection for Signal Modules

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 128

 Wiring DI /DO
SIL3

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 129

 Basic concepts for communication to SIL3 and SIL2

enabling
failsafe fieldbus
applications ....
11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 130
 Profisafe on ISO – OSI Layers

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 131

 Basic concepts for communication to SIL3 and SIL2
Add required safety layer to a standard protocol

e.g.. Diagnostics Program

Safety Safety Safety

Input Control Output
Standard‐ Standard
I /O Control
Safety-Layer Safety-Layer Safety-Layer
7 7 7 7 7
2 2 2 2 2
1 1 1 1 1

„Black/Gray Channel": ASICs, Links, Cables, etc. are not safety relevant

Non safety critical functions, like e.g. diagnosis

"ProfiSafe": Parts of the safety critical communications systems: Adressing, Watch Dog Timers,
Sequenzing, Signatur, etc.

Safety relevant, but not part of the ProfiSafe-Profils: Safety I/O and the Safety Control Systems

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 132

 Standard Profibus DP Message ...

Standard-Message

S S S S S S

Sync Data Unit = Standard‐

SD LE LEr SD DA SA FC or Failsafe‐Data FCS ED
time

33 TBit 68H ... ... 68H ... .... ... 1... 244 Bytes ... 16H

1 Cell = 11 Bit
LE
SB ZB ZB ZB ZB ZB ZB ZB ZB PB EB
0 1 2 3 4 5 6 7
Data Unit = Failsafe-Data
max. 244 Bytes
TBit = Clock-Bit = 1 / Baudrate FCS = Frame Checking Sequence
SD = Start Delimiter (here SD2, var. Data Length) (across data w ithin LE)
LE = Length of Data ED = End Delimiter
LEr = Repeated LoD, not in FCS SB = Start-Bit
DA = Destination Address ZB0...7 = Character-Bit
SA = Source Address PB = (even) Parity Bit
FC = Function Code (Type of Message) EB = Stop-Bit

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 133

 ... and a ProfiSafe Message ...
(the extra layer included in the user telegram)

Standard-Message-Frame (user telegram)

S S S S S S

F-I/O-Data Status / Sequence CRC Standard-

Controlbyte Number I/O-Data

Sender across
based F-Data
Counter and
F-Parameter
*) 2 Byte for a max. of
12 Byte F I/O data
4 Byte for a max. of Max. 12 / 122 Bytes 1 Byte 1 Byte 2/4 Bytes *) (240/238 - F-Data)
122 Byte F I/O data

Max. 244 Bytes DP-Data

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 134

 CPU‐Software Architecture

F‐User Program
Standard‐ F‐User Blocks F‐Control
User Blocks
Program F‐Standard‐ F‐System‐
blocks blocks
Program Program
execution execution

Communications Self tests

Safety‐relevant sections of the operating system

Standard‐
Operating System F‐Access protection Safety‐relevant Safety‐relevant
System Func. Calls Self tests

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 135

 Programming
Graphical programming CFC
acc. to IEC 1131

F‐Library

Certified (TÜV)
function blocks

Links are structs

CFC

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 136

 Safety Instrumented Function (SIF)
• Example Process
– Heat used to separate petroleum
into various components in
distillation column

• Hazard identified
– Column C‐51 Overpressure, with
Possible Overloading of Flare
System
• Safety Instrumented Function
– High Pressure on Column C‐51
Causes Steam Supply to Reboiler E‐
52 to Close

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 137

 Conceptual Design (I)
PT‐51

Logic

2oo3
PT‐52 1oo2
Solver

PT‐53 S S

XV-51 XV-52

SIF Ite m Haz ard De scription Inputs O utputs Targe t

SIL
SIF 1 Column C-51 High Pressure on Column C- PT-51 XV-51 Close 3
overpressure, with 51 causes Steam Supply to PT-52 XV-52 Close
possible overloading of Reboiler E-52 to close. PT-53
flare system. (1oo2)
(2oo3)

Note: Target SIL and input / output voting are for illustrative examples only and are not to be taken as typical, suggested or recommended.

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 138

SIMATIC Safety Matrix for HIPPS Example

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 139

 Safety Matrix
QUADLOG

11/07/1394 DCS ESD Seminar – Part1 ‐ Maher 140

 ‫ﺑﺎ ﺳﭙﺎس‬
‫از ﺗﻮﺟﻪ ﺷﻤﺎ ﺑﻪ ﻣﻄﺎﻟﺐ اﻳﻦ ﺑﺨﺶ‬

‫‪11/07/1394‬‬ ‫‪DCS ESD Seminar – Part1 ‐ Maher‬‬ ‫‪141‬‬