Learn-/Training Document | PA Module P01-00, Edition 02/2020 | Digital Industries, FA

Learn-/Training Document
Siemens Automation Cooperates with Education
(SCE) | As of Version V9 SP1

PA Module P01-00
SIMATIC PCS 7 – Introduction

siemens.com/sce

For unrestricted use in educational / R&D institutions. © Siemens 2020. All rights reserved.
 Learn-/Training Document | PA Module P01-00, Edition 02/2020 | Digital Industries, FA

Matching SCE Trainer Packages for this Learn-/Training Document

• SIMATIC PCS 7 Software Package V9.0 (set of 3)

Order No.: 6ES7650-0XX58-0YS5
• SIMATIC PCS 7 Software Package V9.0 (set of 6)
Order No.: 6ES7650-0XX58-2YS5
• SIMATIC PCS 7 Software Upgrade Packages (set of 3)
Order No.: 6ES7650-0XX58-0YE5 (V8.x V9.0)
• SIMIT Simulation Platform with Dongle V10
(contains SIMIT S & CTE, FLOWNET, CONTEC libraries) – 2500 simulation tags
Order No.: 6DL8913-0AK00-0AS5
• Upgrade SIMIT Simulation Platform V10
(contains SIMIT S & CTE, FLOWNET, CONTEC libraries) from V8.x/V9.x
Order No.: 6DL8913-0AK00-0AS6
• Demo-Version SIMIT Simulation Platform V10
Download
• SIMATIC PCS 7 AS RTX Box (PROFIBUS) only in combination with ET 200M for RTX –
Order No.: 6ES7654-0UE23-0XS1
• ET 200M for RTX Box (PROFIBUS) only in combination with PCS 7 AS RTX Box –
Order No.: 6ES7153-2BA10-4AB1

Note that these trainer packages are replaced with successor packages when necessary.
An overview of the currently available SCE packages is available at: siemens.com/sce/tp

Continued training
For regional Siemens SCE continued training, get in touch with your regional SCE contact
siemens.com/sce/contact

Additional information regarding SCE

siemens.com/sce

Information regarding use

The SCE Learn-/Training Document for the integrated automation solution Totally Integrated Automation
(TIA) was prepared for the program "Siemens Automation Cooperates with Education (SCE)" specifically
for training purposes for public educational facilities and R&D institutions. Siemens does not guarantee
the contents.

This document is to be used only for initial training on Siemens products/systems, which means it can be
copied in whole or part and given to those being trained for use within the scope of their training.
Circulation or copying this Learn-/Training Document and sharing its content is permitted within public
training and advanced training facilities for training purposes.

Exceptions require written consent from the Siemens. Send all related requests to
[email protected].

Offenders will be held liable. All rights including translation are reserved, particularly if a patent is granted
or a utility model or design is registered.

Use for industrial customer courses is explicitly not permitted. We do not consent to commercial use of
the Learn-/Training Document.

For unrestricted use in educational / R&D institutions. © Siemens 2020. All rights reserved. 2
p01-00-introduction-v9-tud-0719-en.docxp01-00-introduction-v9-tud-0719-en.docx
 Learn-/Training Document | PA Module P01-00, Edition 02/2020 | Digital Industries, FA

We wish to thank the TU Dresden, particularly Prof. Dr.-Ing. Leon Urbas and the Michael Dziallas
Engineering Corporation and all other involved persons for their support during the preparation of this
Learn-/Training Document.

For unrestricted use in educational / R&D institutions. © Siemens 2020. All rights reserved. 3
p01-00-introduction-v9-tud-0719-en.docxp01-00-introduction-v9-tud-0719-en.docx
 Learn-/Training Document | PA Module P01-00, Edition 02/2020 | Digital Industries, FA

Table of contents
1 Overview.......................................................................................................................................... 5

2 Structure of the individual chapters ................................................................................................... 5

3 Interrelationship of the chapters........................................................................................................ 6

3.1 Module P01 ..............................................................................................................................7

3.2 Module P02 ..............................................................................................................................8

3.3 Module P03 ..............................................................................................................................8

4 Simulation ........................................................................................................................................ 9

5 Summary ....................................................................................................................................... 10

6 Notes for compact Train-the-Trainer workshops ............................................................................. 10

7 Additional information ..................................................................................................................... 11

For unrestricted use in educational / R&D institutions. © Siemens 2020. All rights reserved. 4
p01-00-introduction-v9-tud-0719-en.docx
 Learn-/Training Document | PA Module P01-00, Edition 02/2020 | Digital Industries, FA

Introduction – Process Control

Engineering Module
1 Overview
The Process Control Engineering Module deals with current topics for managing technical plants
with a process control system. To this end, a laboratory process plant consisting of two reactors
and several tanks for input materials and products is to be automated and visualized. In addition,
a process plant simulation is provided to allow the project to the implemented even without
hardware.

2 Structure of the individual chapters

All chapters of the module follow the same basic structure (Figure 1).

After introduction of the Learning objective, the theory underlying the learning objective is
briefly described in Theory in brief. Then, various aspects of the theory are described in
greater depth under Theory. A list of references provides information for more in-depth
independent study of the subject matter, if needed. Step-by-step instructions allow the
reader to immediately put the theory into practice on the engineering station (ES) of the PCS 7
process control system. Each chapter concludes with Exercises for deeper understanding of
the subject matter of the respective chapter.

Objective

Theory in brief

Theory

Step by step instruction Literature

Exercises

Figure 1: Structure of the chapters

For unrestricted use in educational / R&D institutions. © Siemens 2020. All rights reserved. 5
p01-00-introduction-v9-tud-0719-en.docx
 Learn-/Training Document | PA Module P01-00, Edition 02/2020 | Digital Industries, FA

3 Interrelationship of the chapters

The order of the chapters is based on the usual procedures for planning a process control
system. Through the step-by-step instructions and the exercises, the complete basic automation
is created for the example process in the control system. However, it was ensured for that all
chapters and exercises can be used independently. All intermediate results obtained in the
course of the module are available as project files. This means it is possible to start/continue at
any point, and trainees can compare their own solutions with the sample solutions. Figure 2
provides a detailed overview of the chapters and their interrelationships.

P01-00 Introduction

Process

P01-01 Process description

Automation structure

P01-02 Hardware configuration

P01-03 Plant hierarchy

Basic automation

P01-04 Individual
drive function

P01-05 P01-06 P01-07 Importing

Functional safety Control loop plant-design data

P01-08 Sequential
function chart

Higher process control functions

P02-01 P02-02 P02-03 Archiving

HMI generation Alarm engineering and trendreporting

Advanced process engineering

P03-01 Advanced P03-02 Vertical P03-03

layout of UIs integration with OPC Batch control

Figure 2: Interrelationship of the chapters

For unrestricted use in educational / R&D institutions. © Siemens 2020. All rights reserved. 6
p01-00-introduction-v9-tud-0719-en.docx
 Learn-/Training Document | PA Module P01-00, Edition 02/2020 | Digital Industries, FA

3.1 Module P01

Reading the chapter P01-01 Process description is recommended regardless of prior
knowledge, since it introduces the process plant that is to be automated.

In chapter P01-02 Hardware configuration, the project is created and the structure of the
automation components (automation station and remote I/O) is implemented. In the exercise, an
additional automation station based on the AS RTX Box is integrated.

Chapter P01-03 Plant hierarchy introduces an essential structural element of PCS 7. It allows
the automation of complex systems to be broken down into smaller sub-tasks (refer to P01-04 to
P01-06). In addition, the plant hierarchy provides a possible structure for the visualization (P02-
01) and serves as a basis for reusable elements and structural units (P01-07). The standardized
implementation of the plant hierarchy also serves as a basis for recipe control (P03-03).

Chapters P01-04 to P01-08 describe various aspects of automation.

Chapter P01-04 Control module functions introduces the reader to the use of available
software objects (function blocks, templates) for real objects. As an example, the control of a
pump motor is implemented with a function block of the PCS 7 Standard Library in a Continuous
Function Chart (CFC).

The result is tested for the first time in a plant in this chapter. If no plant is available, the
simulation presented below can be used.

Chapter P01-05 Functional safety presents the interfacing of the software-side interlocking
for the intended use of the plant. The previously implemented control of a motor is limited by
given constraints in such a way that no serious danger can arise for humans or the plant.

Chapter P01-06 Control loop deals with the topic of closed-loop control. The temperature
control of a reactor is used as an example for implementing a PID controller.

Chapter P01-07 Importing plant design data shows the possibilities of reuse of control
modules and/or entire structural units.

This is illustrated using the example of a CFC and a tank as a template, which are used for
generation of additional CFCs and tanks. To work through this chapter, extensive knowledge of
the plant (P01-01) and its structure (P01-03) is required.

Chapter P01-08 Sequential control systems introduces the Sequential Function Chart (SFC
for short). The process cell recipe is realized with the SFC. The exercise in this chapter
concludes the first module, and as a complex exercise it also includes contents of the previous
chapters. The exercise examples of these chapters are created in such a way that they complete
the engineering of the plant step-by-step. Nevertheless, each aspect can be learned individually
with the available project files.

For unrestricted use in educational / R&D institutions. © Siemens 2020. All rights reserved. 7
p01-00-introduction-v9-tud-0719-en.docx
 Learn-/Training Document | PA Module P01-00, Edition 02/2020 | Digital Industries, FA

3.2 Module P02

Module P02 builds on the results of module P01.

Chapter P02-01 HMI generation shows the reader how to configure a graphical user interface.
Building on the results of the first module, the operator station is configured, and the plant units
configured so far are visualized by the PCS 7 OS.

Chapter P02-02 Alarm engineering deals with the implementation of an alarm system. Using
a function block available in the PCS 7 Advanced Process Library as an example, the monitoring
of the level is implemented.

Chapter P02-03 Archiving and trend reporting provides an overview of archiving process
data, messages, batch logs and OS reports. Using a process value as an example, the archiving
and display of archived values are implemented in OS runtime under PCS 7.

3.3 Module P03

Module P03 builds largely on the results of modules P01 and P02.

Chapter P03-01 Advanced layout of UIs describes the function of trend characteristics in
detail. It presents additional OS elements for customizing detail displays for the segment
displayed and providing meaningful information for the detail level. ActiveX controls and user-
defined objects are created based on the reactor. This chapter is based on P02-01 and P02-02.

Chapter P03-02 Vertical integration with OPC shows the integration of automation systems
into higher-level programs of the plant control level. It explains the required basics for the
structure and operating principle of OPC as well as options for integration using PCS 7. Using a
Microsoft Excel sheet as an example, the query of a previously configured OPC server is
demonstrated.

Chapter P03-03 Batch control with recipes describes the use of the Batch Control Center
for creating and maintaining recipes. A recipe is implemented with Batch using a mixing process.
Based on a different Batch approach, a project template is provided for the known plant. This
chapter requires the reader to be familiar with the process description (P01-01) and the plant
hierarchy (P01-03).

For unrestricted use in educational / R&D institutions. © Siemens 2020. All rights reserved. 8
p01-00-introduction-v9-tud-0719-en.docx
 Learn-/Training Document | PA Module P01-00, Edition 02/2020 | Digital Industries, FA

4 Simulation
To enable you to immediately start work, even without a plant and process control components,
an interactive, simulation-supported learning environment is implemented for the modules. This
allows you to experience results immediately and gain practical experience. It consists of the
following components:

SIMIT model: This model is used to simulate the process with tanks, pumps and valves as well
as sensors and actuators. The local operator panel of the plant is also included in the model.

It must be noted, however, that the model is only used to generate sensor and actuator signals.
The user should not confuse this display with a visualization interface. Operator control and
monitoring takes place in the project with PCS 7 OS.

SIMATIC PLCSIM: The automation system is simulated here. The functionalities can be largely
configured in Module P01. This means that changes within the automation – regardless of
whether these are hardware configuration or software changes (SFC, CFC) – only take effect
after reloading them to the simulation.

By combining the process model (SIMIT model) and control model (PLCSIM with its implemented
and loaded functionality), the entire system can be simulated and tested as shown in Figure 3.

REAL - World SIMULATED - World

Plan Simulated Plant
SIMIT

Plan simulated OS-Visualization

OS OS
AS Simulation ES Engineering

AS AS

ES ES AS = Automation System
OS = Operator Station
ES = Engineering Station

Figure 3: Similarities between the real and simulated worlds

For unrestricted use in educational / R&D institutions. © Siemens 2020. All rights reserved. 9
p01-00-introduction-v9-tud-0719-en.docx
 Learn-/Training Document | PA Module P01-00, Edition 02/2020 | Digital Industries, FA

5 Summary
Modules P01 and P02 provide sufficient subject material, exercises and instructions to conduct a
course of one to two semester periods per week. Depending on the desired depth of coverage of
the material, 30 to 60 work hours are to be scheduled for completion (including exercises,
homework, preparation and follow-up). This corresponds to 1 to 2 credits within the scope of the
European Credit Transfer and Accumulation Systems (ECTS).

For Module P03, with addition of your own material, a course of one semester period per week
can be planned.

6 Notes for compact Train-the-Trainer workshops

5-day PCS 7 training for trainers and instructors:

A 5-day workshop is needed to present the Process Control Engineering modules (Modules P01,
P02 and P03) with the lecture slides and to perform practical exercises based on the available
learning/exercise materials.

2-day PCS 7 training for trainers and instructors:

For experienced engineers with PCS 7 software knowledge, a 2-day course should be sufficient.
Normally, chapters P01-01 to P01-04 including exercises are worked through on the simulator in
chronological order. Then, it is recommended that one chapter from P01-05 to P01-08 be
completed followed by chapter P02-01.

1-day PCS 7 training for trainers and instructors:

Without knowledge of modules P01 and P02, the presentation of Module P03 can be used to
briefly present the complete content and to then concentrate on implementing Chapter P03-03
Batch control with recipes.

For unrestricted use in educational / R&D institutions. © Siemens 2020. All rights reserved. 10
p01-00-introduction-v9-tud-0719-en.docx
 Learn-/Training Document | PA Module P01-00, Edition 02/2020 | Digital Industries, FA

7 Additional information
More information for further practice and consolidation is available as orientation, for example:
Getting Started, videos, tutorials, apps, manuals, programming guidelines and trial software/
firmware, under the following link:

siemens.com/sce/pcs7

Preview "Additional information"

For unrestricted use in educational / R&D institutions. © Siemens 2020. All rights reserved. 11
p01-00-introduction-v9-tud-0719-en.docx
 Learn-/Training Document | PA Module P01-00, Edition 02/2020 | Digital Industries, FA

Further Information
Siemens Automation Cooperates with Education
siemens.com/sce
Siemens SIMATIC PCS 7
siemens.com/pcs7
SCE Learn-/Training Documents
siemens.com/sce/documents
SCE Trainer Packages
siemens.com/sce/tp
SCE Contact Partners
siemens.com/sce/contact
Digital Enterprise
siemens.com/digital-enterprise
Industrie 4.0
siemens.com/future-of-manufacturing
Totally Integrated Automation (TIA)
siemens.com/tia
TIA Portal
siemens.com/tia-portal
SIMATIC Controller
siemens.com/controller
SIMATIC Technical Documentation
siemens.com/simatic-docu
Industry Online Support
support.industry.siemens.com
Product catalogue and online ordering system Industry Mall
mall.industry.siemens.com

Siemens
Digital Industries, FA
P.O. Box 4848
90026 Nuremberg
Germany

Subject to change and errors

© Siemens 2020

siemens.com/sce

For unrestricted use in educational / R&D institutions. © Siemens 2020. All rights reserved. 12
p01-00-introduction-v9-tud-0719-en.docx