Total Transparency in Plants

Total Transparency in Plants
Technical Article
Total Transparency in Plants
A well-known SCADA system has become one of the world’s most frequently
used visualization systems due to its flexibility and openness. In over 15
years, it has conquered applications in all industries. The new version
comes with multitouch support, as well as plant-wide long-term archiving,
and new analysis and report functions. It has thus grown into a plant
information system.
In fierce global competition, the crucial factors
for plant operators, next to monetary concerns,
are maximum possible productivity, availability
and quality. The SCADA system used must meet
these requirements to be successful in the market. Over the total service life of a plant, adaptations, expansions or new requirements such
as legal stipulations are not just probabilities
but certainties. Thanks to its system scalability,
Simatic WinCC can grow with requirements –
from single-user systems to distributed server/
client systems. Redundant servers guarantee
maximum availability – and the Web clients
enable remote control and monitoring via the
intranet or Internet.
All-inclusive archiving
Processes in all industries can only be optimized if all the relevant process data is avail-
able. For this reason, Simatic WinCC places
the greatest value on efficient and powerful
archiving. Reliability and security thanks to integrated redundancy concepts are provided, as
well as flexible data display and analysis. With
Version V7.2, the system now offers gap-free
archiving and automatic compression algorithms for weekly, monthly and yearly cycles
as the basis for comprehensive and detailed
reporting. Powerful compression according to
the “swinging-door algorithm” significantly reduces memory requirements. Integral statistical
calculations (min, max, total, average, integral)
are now supplemented with automatic calculation of the difference and retrospective input
or correction of “manual” or lab values. In the
case of manual change within automatically
generated archives, however, special precautions need to be taken: Labeling of the value as
“manual”, recompression, and updating of the
documentation via an automatically generated
operation message are indispensable. Pharmaceuticals and food & beverages are just two of
the industries where this traceability of operator
actions is demanded. In combination with documenting changes to the configuration, it is one
of the foundations of validation in accordance
with FDA (21 CFR Part 11) and EU 178/2002
(Food Law).
Long-term archiving of the highest quality
In Version 7.2, the “Process Historian” option, a
powerful long-term archive, has been added to
the archive functionality included in WinCC. Process Historian archives all the process values and
messages occurring during production centrally
and in real time. The maximum system configuration is not restricted to one WinCC system in
a plant. The data of several WinCC projects can
also be archived together. Managing the huge
data volumes generated in the process presents
the database system used with particular challenges. The Microsoft SQL Server 2008 is used
as a reliable and secure platform. Process Historian is integrated into the WinCC system on an
additional computer. If maximum security and
availability are required, it can also be configured
redundantly. The database is set up in the “Process Historian” configurator. This supports users
in all database-specific settings. Thanks to its
scalability, Process Historian can be adapted to a
change in data volume at any time and without
interrupting production. WinCC trend windows
or message displays enable transparent access to
all archived data at any time. Integral statistical
functions provide the first indication of potential
problem spots here.
Information advantage instead of data deluge
However, reliable archiving of long-term-relevant
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data is just the basis for later optimization. Only a
plant-wide reporting system enables meaningful
linking of the collected information. In a second
step, this allows plant operators to detect critical plant areas and to carry out optimization that
generates genuine value added with regard to
cost efficiency and productivity. The “Information
Server” option is such a reporting system. On the
basis of field-proven microsoft Reporting Services, the data is available in a Web-based reporting
platform – target-group-oriented, anywhere, any
time. Transparent access to WinCC archive data
means the data can be used to create detailed
reports for the highest demands, quickly and easily. a host of tools support users in creating and
managing reports. Supplied templates stimulate
ideas and indicate different applications. Reports
can be initiated cyclically, on an event-driven
basis, or on a demand-driven basis. Finished reports are available via Web-based interfaces in
microsoft Internet Explorer, and they can also be
forwarded in parallel to an e-mail recipient. Information Server supports the classic pdf format.
Thanks to add-ins in microsoft Word and Excel,
these widely used microsoft Office applications
can also be used for creating reports. The functionality of Information Server is rounded off by
standardized programming interfaces via which
developers can implement links between the archived WinCC data. Thus, for example, end users
can use microsoft’s integrated Report Designer to
easily create and publish reports that are precisely tailored to their requirements. access to process data enables fast optimization of production
sequences, as well as plant asset management
via the Internet. In this way, suitable analyses
can be created for all corporate levels. The manager receives key production figures, the quality
coordinator receives the quality report, and the
maintenance personnel get information on current faults. The information level can be precisely
adjusted here to the respective target group. This
helps to detect weak points faster, minimize
downtimes, and thus offers effective value added
with regard to boosting productivity and availability, and reducing costs.
A SCADA system for global use thanks to
It is well known that machine manufacturers
in Europe export their systems globally. This
means special challenges must be met, especially in asia, but also in regions using the Cyrillic alphabet. It must be possible at any time
to switch the display language of all interfaces
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during the engineering phase and at runtime.
This applies not only to the operating system,
but also to the WinCC options. If, for example,
the target language Chinese is activated, a European service engineer (even a very experienced
one) will find it extremely difficult if not impossible to find his bearings. Thanks to Unicode
support in Simatic WinCC V7.2, all texts can be
exported to the standardized Unicode format,
translated, and then imported again. Even regional sub-languages can be set. During operation, users are then in the position to set their
language of choice: and this can be done at any
time, at the touch of a button, without delay,
and both for local operation and for access via
the Internet. The benefits for use in the global
market are obvious. multitouch operator control
concepts, now also in automation. Efficient operator control concepts and up-to-date and clear
visualization of industrial plants have always
been trademarks of WinCC. However, the popularity of consumer devices like smartphones has
an increasing influence on the operator control
concepts of traditional production plants. Intuitive gestures like zooming or swiping across
the screen make operator actions even simpler
and more intuitive. The latest version of Simatic
WinCC supports the use of multitouch gestures
for two-finger operator inputs.
The familiar WinCC zooming functionality can
be used optimally with multitouch systems.
In addition, WinCC offers “decluttering” as a
way of showing screen elements dependent
on the set zoom factor (e.g. visible at a zoom
factor greater than 150%). However, multitouch
gestures can also be implemented for a type of
navigation between process screens that is new
to industry. Screens are selected here by swiping across the screen instead of using a button.
another benefit is support for two-hand operation. Switching operations are only possible if an
additional enabling button is activated simultaneously. This prevents accidental or inadvertent
switching operations.
More than just SCADA
all Simatic WinCC V7.2 innovations have been
presented at the SPS/IPC/Drives 2012 trade
fair. as well as full SCaDa functionality anywhere and any time, they offer an adjustable,
optimal plant overview for all users and all
43211 at
HMI/SCADA Stilutititi
30 years tif SCADA experietice, thtiusatids tif licetises itistalled wtirldwide
ARC Itiftirtiatitititi
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