Web-based Process Control System The Next Step Towards the Control System of the Future

Related Vendors

Glatt Ingenieurtechnik GmbH

Maag Pump Systems AG

TRM Filter d.o.o.

Siemens AG

Extremely long life cycles are typical for many plants in the process industry. With the new version 3.1 of Simatic PCS neo, Siemens has completely rethought the plant life cycles in the process industry and, in addition to a variety of new functions, the completely web-based process control system shows how the challenges of long life cycles will be mastered in the future. Users of all process technology sectors already benefit from it today.

Introduced in 2019, the Simatic PCS neo system software uses the hardware portfolio and application architecture of the proven Simatic PCS 7 process control system. This continuity allowed Siemens to offer its customers a risk-free switch to the new system software and thus to protect their investments to the greatest possible extent.

Since Simatic PCS neo is based on modern web technologies, a classic installation via dedicated client software is no longer necessary. The web client only requires Windows 10 and an HTML5-capable web browser. All project information, licenses and security mechanisms are installed and managed on central servers. This saves time and money: upgrades are simply loaded at server level, while functions such as monitoring, process control and engineering are provided via lean web clients.

Thanks to the web technology, flexibility and scalability in process control technology have also increased. Additional control stations can be added within a few minutes, and users can access the information they need via different types of devices — comfortably, securely, and regardless of their location. The web foundation means that Simatic PCS neo uses the latest IT technology, including the functions required for secure authentication and communication. At the same time, users can operate the system completely on-premises, without direct access to the internet and with no restrictions on functionality.

The Challenges of Long Life Cycles

The new system software not only has to seamlessly integrate future innovations, but should also protect investments and help to solve some notorious challenges in the process industry. Due to long plant lifetimes of 20, 30 or more years, operating companies often face a patchwork of partly modernized plants, extensions, and different versions of hardware, software and firmware. We know the consequence: system upgrades require intense planning effort, extensive shutdowns, production downtime, and sometimes unpleasant surprises.

With its latest release, Siemens has brought to the market an ideal solution to these life cycle challenges: a combination of innovative technical features and a completely rethought concept for software maintenance. This benefits not just plants that must always be state-of-the-art, but also those that have to operate over long periods of time without major changes or maintenance.

To make this possible, in addition to using the latest web technology Simatic PCS neo distinguishes between three layers: the system, the library, and the project layer. Hardware signals arrive at the system layer, which is separated from the other layers by a Signal Abstraction Layer (SAL). This means that changes to the plant configuration and communication no longer affect the process engineering project planning.

This means that maintenance, changes to project planning, system extensions and, above all, system updates and upgrades are very simple — and the operation of such a system remains extremely flexible over many years, in line with the individual requirements and software maintenance strategies of the particular plant operator. Changes to the system or the project planning can be made independently and decoupled from each other in terms of time.

One part of the library layer is the Advanced Process Library (APL). This is suitable for 99 percent of all plant types and applications, and significantly improves engineering efficiency. What makes it special is that engineering project planning that is done with APL remains upwardly compatible.

Simatic PCS neo allows the flexible creation of engineering templates, which, thanks to the layer concept, can be reused independently of plant configuration and hardware — even cross-plant. Pre-tested engineering templates increase efficiency in engineering, reduce error sources, and give enormous advantages during commissioning.

Instead of using conventional hardware drivers, devices in Simatic PCS neo are implemented as Device Types. Once added, they always stay up to date. The integration of third-party devices has also become more flexible, ensuring compatibility through the whole life cycle of the plant. In fact, it is part of Simatic PCS neo’s DNA that Siemens has completely rethought plant life cycles in the process industry. Simatic PCS neo meets all the technical requirements for long plant life.

The new paradigm for software maintenance also supports long plant life. Depending on the customer’s wish, plants and system functions can always be kept up to date with the latest technology; alternatively, thanks to the long-term support concept, they can run for long periods with minimal maintenance. In the latter case, customers receive precisely those updates, such as security updates, required for long-term operation.

Scalable and Secure

Version 3.1 of Simatic PCS neo is suitable for large plants with up to 32,000 process objects. But the smallest plants, which until now have not been a use case for process control systems, can also be efficiently automated, thanks to easy engineering with reusable templates and scalable system architecture. In addition to its high level of scalability, Simatic PCS neo has become even more secure due to its “security by default” approach. Pre-installed security steps ensure plant security, system integrity, and network safety.

Additionally, the new control system uses Siemens’ superior defense-in-depth strategy as a standard to ensure multi-layer protection of the plant. It meets all IACS security requirements and offers network and system security. Thanks to location- and role-based access management, intellectual property is protected against unauthorized access.

With version 3.1, a system version of Simatic PCS neo is available that can be used in all industries running continuous processes. The new control system is already giving well-known companies worldwide, secure, and direct access via various devices, multi-user engineering with consistent data thanks to object orientation, and the ongoing implementation of the Module Type Package (MTP) guideline, which allows the flexible integration of modular subsystems into the control system. The new version already meets the published MTP guidelines and is prepared for all future updates.

* The author is Product Manager Simatic PCS neo with Siemens

(ID:48397184)