Basic Structure of the Display Area
PA Module P02-01
SIMATIC PCS 7 HMI Generation
HMI GENERATION
TRAINING OBJECTIVE
After working through this module, the students will be able to design and implement a graphic user interface for efficient process monitoring and control. To this end,
they will be familiarized with the objective of process management. They understand the basic concepts of representation and are acquainted with different
representation techniques. This enables the students to generate a graphic user interface in PSC 7 that is useful and efficient.
THEORY IN BRIEF
A modern process control system such as PCS 7 offers operating staff different screen based windows to the process; with it all process control tasks can be handled.
Based on the large amount of information the operator has to take in and process from the technical process, structuring the information makes sense. In addition,
certain rules have to be adhered to for navigation and representation in order to establish an interface to the technical process that can be operated well and that
supports operators as well as possible in their manifold process control tasks.
PCS 7 supports the design process of process screens for operator control and monitoring in multiple ways. First, for many of the elementary blocks and individual control
functions used in basic automation, operator icons and operator panels are defined that enable project-wide uniform interaction with similar technical equipment.
Second, the plant hierarchy can be used to advantageously structure the represented information.
Based on this structure, very many elements of the operating system that have to be executed manually in other systems can be generated automatically and error-free
by means of a generation run. The two essential remaining tasks when designing the process screens are the representation of the static process structure (containers,
pipes, etc.) for better orientation, and inserting elements to navigate along process flows on a plant hierarchy level.
Figure 1: From individual drive function to the operating screen
By means of the generation run, icons are set up for all operable blocks of a hierarchical level. The icons then only have to be moved and enhanced with static elements in
order to obtain a complete operating screen (see Figure 1).
THEORY
OBJECTIVES OF PROCESS CONTROL
The task of an operator in a process plant is to perform the intended operation of this plant economically and environmentally sustainable. This task is called process
management. Operators have to ensure consistently high product quality and amount (yield) and keep the amount of rejects as low as possible; they also have to
compensate for disturbance factors such as varying characteristics of the raw material used and for faults in the plant or fluctuating throughput. Operators have to see to
it that the availability and life of the plant is maximized. Moreover, they have to ensure that the emission limits are observed and energy and material consumption is
minimized [1].
To attain these goals, operators have to be constantly in a position to monitor the plant, to diagnose faults and to intervene in the running process to remove faults. The
operators workplace is the operator station at a control desk. This operator station has available all displays and intervention capabilities that operators need to perform
their task. The control system provides them with a user interface that enables them to carry out their tasks according to ability, skills and requirements [1].
CONCEPTS OF VISUALIZATION
The visualization of data and information in the graphical user interface has a deciding influence on operators performance. For this reason, it has to be in line with their
abilities, skills and requirements. The following questions should therefore be answered:
1. For whom and for what are we visualizing?
2. What is to be visualized?
3. How is it supposed to be visualized?
These questions depend on the plant to be configured and, therefore, have to be answered for the respective project. However, the following aspects always have to be
considered:
Organization of what we want to visualize
The information and data to be visualized has to be organized suitably for the visualization. We have to specify how the existing elements are structured and arranged,
how they relate to each other and how it is possible to navigate among the visualizations. To this end, we have to specify how much data and information is to be
visualized overall (quantitative aspect). We also have to specify which information and data is to be visualized simultaneously and jointly (qualitative aspect).
We have to decide in this case what the ratio is to be of what is new (information, dynamic display share) to what is known (data, static display share). The aim is to share
information as much as possible but with sufficient data for a correct interpretation of the information suitable to the purpose.
The result is the distribution of information and data to the different operating screens. Now, we still have to define how the operator gets from one operating screen to
another (navigation).
Print growth
Depending on the user interface, only a limited area is available for simultaneously displaying data and information. To ensure that the information and the data is legible
and distinguishable in all operating situations, only a certain share of this area is to be assigned characters. This share is called print growth of the visualization.
The recommended print growth depends on the type of characters and the display elements as well as on the necessary arrangement of these elements. Thus, it depends
on the visualization technique used. For example, the print growth of a process flow diagram should be no more than 50%; for a message page, on the other hand, it may
be up to 80% [1].
Coding
Coding specifies how certain information is represented. Information can be coded through color, shape, form, extension, direction (angle), position and dynamics
(flashing). Uniform coding facilitates the assimilation and evaluation of information for the operator.
Good coding is clear, distinguishable and does not contradict existing conventions. For example, the color green should never be used for a STOP signal. If instead a red
flashing signal would be used as coding for STOP, this coding should be used consistently for the entire user interface. Also, this coding should not be used for any other
information in order to rule out confusion. In addition, good coding should be plausible: the operator learns and remembers it easily.
Conspicuousness
A central task of the user interface is directing the operators attention to important information. Because different information is usually displayed on an operating
screen, it is advisable to design this information with varying conspicuousness corresponding to its relevance and priority. The more conspicuous the information, the
sooner it is discovered. In addition, based on its conspicuousness, the operator recognizes the information that requires the most attention at the moment. Table 1 shows
the stepped increase of conspicuousness of the visualization for different information, based on a few examples.
Table 1: Application of stepped conspicuousness according to [1]
Consistency
Often, certain information occurs in several visualizations at the same time. In this case it is important that this information is visualized consistently in the entire user
interface. This means the information looks identical in all visualizations, and behaves identically. The same terms and icons have to be used. The operation sequence
should always be the same, and the system reaction to operations should be similar with respect to time and content.
VISUALIZATION TECHNIQUES
The display area should always be structured the same for all types of visualization. For the operator, it facilities orientation, information assimilation and thus process
management.
The recommended basic structure according to VDI 3699 [1] is shown in Figure 2. A message line is located in the upper area where the most current messages are
displayed as group messages. Below it is an overview field where the available visualizations (for example, process pictures in PCS 7) are listed. From here, any
visualization can be opened. The working area occupies the largest part of the display area. Here, the currently selected visualization is displayed. The lowest area
contains the key field for activating general functions. In the working area, windows with supplementary information (such as different views of PCS 7 blocks) can be
opened in addition. All areas except the working area are reserved and are permanently displayed.
Figure 2: Basic structure of a display area
Flowcharts
A flowchart is the "schematic representation of components including their connection through (flow) lines to show relationships in a control plant and in control
engineering" [1]. It represents a simplified plant structure and provides information about the paths of material, energy and signal flows between the different plant
units. With the aid of flowcharts, process and control information is represented and interventions in the process are made possible.
Flowcharts consist of static and dynamic elements. The static display elements are represented by the root screen. This root screen contains the dynamic display
elements that are continuously updated.
The static root screen provides the context for the dynamic picture elements, which means it indicates the meaning of the represented objects and their relationship
among each other. The root screen represents all data that remains unchanged during the display. This data is the display background, the headings and labels as well as
the plant units and the devices (if their representation is not to change).
The dynamic picture elements provide the information for process control. Display elements represent the changes, characteristics and relationships of the process
values. They reflect the state of the plant, of the control system or of the process. Selection and operator control elements make it possible for the operator to intervene
for process control. Furthermore, additional information such as function charts or curves can be inserted in the flowchart as a window.
Flowcharts are subdivided as follows:
Control flowcharts represent only the components of control systems such as regulators, sensors and controllers as symbols. They are connected to each other with
signal flow lines.
Process flowcharts graphically represent plant units in a simplified way using symbols. Here, three different kinds are differentiated:
A basic flowchart represents plants, sub-plants or plant units in the form of rectangles. They are connected to each other with flow lines for materials, energy or energy
sources.
A process flowchart represents processes using (simplified) graphic symbols. The symbols represent the corresponding plant units and are connected to each other with
flow lines.
A pipe and instrument diagram (P&I diagram) represents the technical equipment of the plant using graphic symbols. In addition, process tags, control blocks and
actuators are represented. The symbols are connected to each other by lines for pipes and signal paths.
In PCS 7, flowcharts are called process pictures. In the step by step instructions, different process pictures are generated for the configured plant.
HMI GENERATION IN PCS 7
PCS 7 has an extensive operator control and monitoring system that consists of the following subsystems [2]:
A graphic system for displaying process information and for process operation.
A curve system to represent and analyze time sequences of stored process values.
A message system for diagnosing the process.
A log system for documenting the process.
An archive system for storing and maintaining process values, messages and logs
In this chapter, the PCS 7 graphic systems is introduced. The message system will be described in the subsequent chapter Alarm Engineering.
The graphic system represents the plant in a plant overview, shows process pictures in the working area of the user interface, makes available elements for process and
system operation and indicates alarm states. The corresponding user interface is generated on the systems operator station (OS). Thus, the OS is the central station for
monitoring and operating a PCS 7 plant [2].
Configuring the User Interface in PCS 7
The selected plant hierarchy of the project is the basis for the organization of the user interface. The plants and subunits that were set up are represented in the user
interface with corresponding process pictures. Picture names and directory names of the plant hierarchy are included automatically. In the process mode, the process
pictures are represented in the overview area corresponding to the plant hierarchy.
First, the process pictures of a project are set up at the corresponding location in the plant hierarchy and assigned to an OS. The OS then has to be compiled. After that,
the process pictures can be configured in the Graphics Designer of the WinCC Explorer. The Graphics Designer is an editor where static and dynamic picture elements can
be inserted, arranged and interconnected.
Configuring the Process Pictures in PCS 7
Technological blocks from PCS 7 libraries that can be operated and monitored include corresponding graphic representations, so-called block icons. When the process
pictures are configured, they are inserted automatically in the corresponding screen. Overview-like, block icons provide the most important information about the
represented block in the process picture.
By means of the block icons, different pre-configured faceplates can be called that open as a window in the working area. Faceplates are dynamic diagram elements that
are connected to the parameters of the represented block and are updated automatically. They make it possible for the operator to extensively monitor and operate the
associated technological block. Depending on the block type, different views exist for the associated faceplates. These views enable the access to parameters for very
specific tasks. For example, in addition to the standard view there often also is a parameter view for assigning parameters, a message view for diagnostics, or a limit view
for setting operational limits of the setpoint. It depends on the represented technological block which views are offered.
The Graphics Designer makes additional dynamic standard objects available that can be inserted manually. These objects can be interconnected directly with the I/Os of
the blocks in the CFCs and SFCs and thus realize the desired dynamic behavior. Examples for standard objects are input and output fields for entering and displaying
values, status indicators for displaying binary states of an object as well as bars for the relative representation of values.
In addition, the Graphics Designer provides different libraries with pre-assembled graphic elements such as piping or valves that can be used to generate the static root
screen. You can also create and use our own graphics.
In the step by step instructions below, additional characteristics and capabilities of the Graphics Designer are presented. Moreover, important WinCC tools are
introduced.
LITERATURE
[1] VDI/VDE 3699 (Ed. 2014-01): Process control using display screens
[2] SIEMENS (2014): Process Control System PCS7: OS Process Control (V8.1). A5E32785344-AA.
STEP BY STEP INSTRUCTIONS
TASK
In this task, the operator station (OS) is created after a few presettings on the SIMATIC Manager. 26. In the Unit tab, set PLCSIM(TCP/IP) as the logical device name.
We are creating the following: an overview screen of the multi-purpose plant, and one unit picture each for the educt tank, the reactor and the product tank. First, a (Unit Logical device name PLCSIM(TCP/IP) OK)
solution for a tank is generated for each unit. 27. Now close Tag Management. (Close)
TRAINING OBJECTIVE
In this chapter, the student: 28. Once you have opened WinCC again, open the Picture Tree Manager.
Learns to generate the operator station (OS) in the SIMATIC Manager (Picture Tree Manager Open)
29. In the Picture Tree Manager we specify the sequence in which the pictures are called later. Retain the structure, save and close the editor. (Save Close)
Is familiarized with the WinCC configuration environment

Learns to build pictures in the Graphics Designer 30. Then open the OS Project Editor. (OS Project Editor Open)

These instructions are based on PCS7_SCE_0108_Ueb_R1504_en.zip. 31. In the OS Project Editor, we can now select under Layout the motor configuration and the screen resolution. In addition, settings are provided for message display,
PROGRAMMING the visible areas, window arrangement in the Runtime window, and other basic settings. Set the desired layout, the number of area keys and the monitor configuration.
1. First, change the object properties of your picture on level A1_multipurpose_plant. Exit the dialog with OK. (Select layout Number of area keys: 4 OK)

(A1_multipurpose_plant Picture(2) Object Properties) 32. The operating screens are generated in the Graphics Designer. Individual screens are opened best by double clicking on the name in the window to the right.
(Graphics Designer A1_multipurpose_plant)
33. The Graphics Designer provides the most diverse functions for generating process pictures. They can be hidden or shown in the menu with View/Tools.
2. As the name, enter A1_multipurpose_plant.
(General Name A1_multipurpose_plant) (View Toolbars)
3. Derive the block icons from the plant hierarchy.
These toolbars have the following functions:
(Block icons Derive the block icons from the plant hierarchy) Standard tools: contains icons and buttons to carry out frequent commands quickly.

4. In the levels T1 to T4, insert pictures with a right click and Insert New Object. Assign names to them as shown in the example below for T2. (Insert New Object
Picture Object Properties Name)
5. Then, the block icons have to be generated and updated. (A1_multipurpose_plant Plant Hierarchy Create/Update Block Icons)
Color palette: used to assign colors to selected objects (one of 16 standard colors or a user defined color).
Zoom palette: sets the zoom factor (in percent) for the active window.
Style palette: changes the appearance of a selected object. Depending on the object, the line/border type, the line/border weight, the line end styles or the fill pattern
can be changed.

Standard: contains the standard objects (polygon, ellipsis, rectangle, etc.), smart objects (OLE control, OLE element, EA field etc.) and Windows objects (button, check
6. In the window that opens, set Chart under components of the HID and the included lower level hierarchy levels to 1. Confirm with OK. (Chart Lower hierarchy
box etc.).
levels included 1 OK)
Dynamic Wizard: provides a variety of frequently needed functions. They can be generated using a dialog that guides the operator and also lends support.
7. Now the block icons are created and updated.
Layer palette: selects which of the 32 levels (level 0 to 31) is visible. Level 0 is selected by default.
8. After Create/Update Block Icons, have the log displayed. (Yes)
Alignment palette: used to change the absolute position of one or several objects, to change the position of selected objects relative to each other, or unify the height
and width of several objects.
9. The log shows that no errors occurred. (X)
Object properties: enables you to view and change all properties of the selected object.
10. We can now start compiling the OS from the Component view. (OS PLC Compile and Download Objects)
Object palette: shows you which object is currently selected and offers different options for manipulation.
11. Before starting, check the settings for compiling the OS. (OS(1)Edit)
34. Through creating the faceplates, the block icons are already included in the pictures. They can be positioned within the pictures as desired.
12. The assignment of areas to operator stations remains unchanged.
(Next) 35. In the properties of the block icons, the displayed name can be specified. Otherwise, a very long name is displayed that includes the path.
13. In the next dialog step, the network connection is checked. (Properties Object name A1_multipurpose_plant/SFC_Product01)

(S7-Program(1) Select Network Connections)

36. Now, we change the background color of the picture to white. To this end, left click in the background of the picture with activated object properties toolbar. The
properties of the picture object open.
14. As WinCC Unit, TCP/IP should be set. (WinCC unit TCP/IP OK)
37. For each object as well as the picture, a variety of properties is provided that can be changed statically or dynamically (for example, interfaced with process variables).
15. Now go to the next dialog step.(Next) Here, the background color is edited.
(Picture Object Colors Background Color Edit)
16. In the last setting window, apply the values shown below.
(Apply)
17. Because the operator station (OS) is started on the engineering system (ES) for this plant, we only select Compile here, not Download. After the compile run is started, 38. Now, select white as the color (255 255 255). (White OK)
the warning is confirmed with Yes. (Start Yes)
39. For the change of the background color to become effective, the global color scheme has to be deactivated. (Picture Object Effects Global Color Scheme No)
18. The log that is now displayed shows no errors. ()
40. Now, change the picture geometry for it to be shown completely at a resolution of 1024x768.
19. After the compilation, the operator station can be opened (OS(1) Open Object)
41. Next, in the Standard palette, click on Rectangle and draw a large rectangle in the picture. (Standard palette Rectangle)
20. If the computer name in the WinCC project does not match the local computer name, you will receive the following message which you confirm with Yes. Then you
should change the name of the computer. (Computer Properties). 42. Arrange the icons for the SFCs as shown below next to the rectangle you just drew.

21. If the computer name is the same as the local computer name, no changes need be made. If the computer name does not match, it has to be set with the button Use 43. Open the selection for the toolbars if the Dynamic Wizard is not displayed yet. (View Toolbars Dynamic Wizard)
local computer name. Exit the window with OK.
(Use local computer name OK) 44. When the toolbar for the Dynamic Wizard is displayed, select here from the Picture Functions the Picture exchange in workspace. (Picture functions Picture
exchange in workspace). For this function to be applied to the rectangle you have just created, it must be highlighted first.
22. The change of the computer name is applied only after the restart. This means, you have to close WinCC if the computer name is changed.
45. Read the explanation and go to Next. (Next)
23. The WinCC project can be reopened from the SIMATIC Manager.
46. As trigger select 'Mouse click. (Mouse click Next)
24. To set the network configuration, open Tag Management.
(Tag Management Open) 47. Now select the picture to which you want to change. ()
25. Here we can change the system parameters. To this end, select the system parameters in the SIMATIC S7 Protocol Suite under TCP/IP.
48. In the picture browser, select T1_educt_tanks.Pdl. (T1_educt_tanks.Pdl OK)
(SIMATIC S7 PROTOCOL SUITE TCP/IP System Parameter)
49. The name of the picture was accepted; continue. (Next) 79. Then, OS Runtime is activated (Activate)

50. The wizard is closed with Finish. (Finish) 80. First, open the plant overview by clicking on the area key A1_multipurpose_plant in the overview area. (A1_multipurpose_plant)

51. If you would like to view the result, the mouse and the mouse action are located under 'Events. With a double click on the icon you can then view the C-script that 81. Picture A1_multipurpose_plant with an overview of all areas of the plant and the sequential function charts (SFC) is shown.
was generated. (Events Mouse Mouse Click OK)
82. By clicking on the block icon of the sequential function chart, an SFC can be opened and operated. (SFC_Product01 Start OK)
52. Using static texts, rectangles and the dynamic wizard, design your picture as shown here. It is absolutely necessary to ensure that the language View menu
corresponds to the desired target language. Here: English (United States). 83. You get to the lower level layers either by opening the Picture Tree Navigator or by selecting the picture exchanges you generated.
(Arrow to the right of the A1_multipurpose_plant T1_educt_tank)
53. The next picture we open is T1_educt_tanks from the WinCC Explorer. 84. In the operating screen of the educt tank, the faceplates for the valves and the pumps of this level are shown. The faceplates permit the operating mode change and
operating the valves and pumps.
54. After you have changed the backgroundas in the picture multi-purpose plantto the color white, open the library. (Display Library)
85. To operate a valve (here: open; click on the command button next to Close, select Open and confirm your selection with OK.
55. From the library, first drag a symbol for the pump into the working field. ( Open OK)
(Global Library Symbols E-Symbols 20_2) 86. The open valve position is signaled through the rotation and the green coloring of the faceplate. Pumps can be controlled the same way.

56. After the symbol for the pump, drag the valve symbol into the working field.
(Global Library Symbols Valves 45)
57. The static symbols can be changed in their orientation by using the button Rotate. (Rotate)
58. After you have inserted additional lines and text fields as shown here, draw a rectangle to represent the tank, and select its properties. (Rectangle Properties)
87. The operator screen T2_Reaction has a faceplate for the PID controller, in addition to the faceplates for valves and pumps, which can be operated and monitored
through it. (A1_multipurpose_plant T2_Reaction Temperature control)
88. The operating screen T3_product_tank is represented with the faceplate for a valve whose operating mode is just being switched.
(A1_multipurpose_plant T3_product_tank Valve Manual OK)

59. To change the color, deactivate the global color scheme once again. 89. Runtime is terminated by first operating the button keyset change in the lower control bar.
(Properties Effects Global Color Scheme No)
90. Then, select Exit runtime and return to the WinCC Manager.
60. Now change the background color to white. EXERCISES
(Properties Colors Background Color) In the exercises, we apply what we learned in the Theory section and in the Step by Step Instructions. To this end, we are using and expanding the existing multi-project
61. Next, we configure a display of the digital level sensors. As shown here, draw a circle into the picture. Then, select its properties. (Circle Properties) from the step by step instructions (PCS7_SCE_0201_R1504_en.zip).
In the step by step instructions, only one element of the levels T1_educt_tank, T2_Reaction and T3_product_tank of the plant hierarchy was implemented. The objective
62. To have the color displayed dynamically, deactivate the global color scheme. of the exercise is to complete the pictures of the individual levels, or to generate the pictures of the missing levels.
(Properties Effects Global Color Scheme No) Then, generate a picture for the level T4_Rinse.
63. To implement a dynamic display, select the background color with the right mouse button and then the dynamic dialog. TASKS
The tasks below are based on the step by step instructions. For each task, the corresponding steps of the instructions can be used as an aid. Regarding the arrangement,
(Properties Colors Background Color Dynamic Dialog) the rules of the VDI3699 [1] have to be noted.
64. In the following dialog, first select Boolean as data type, then change the color at Yes/TRUE to green, finally select Tag for the dynamic expression. 1. Complete the picture of the levels T1_educt_tanks by adding the missing tanks A1T1B002 and A1T1B003. Use the template from the library for this so the
representations will be consistent. Adapt the labeling of the tank and of the binary sensors. Do not forget to adapt the variables for visualizing the binary sensors. The
(Boolean Yes/TRUE Tag) valves and motors are already set up, they only have to be positioned. Note, however, that the valves may have to be rotated once more.

65. At the variables, select as data source 'STEP 7 Symbol Server and there, at the symbols, input I70.0 for the 'level monitoring educt_tank B001 operating point H.
(Data source STEP 7 Symbol Server A1.T1.A1T1L001.LSA+.SA+ / I70.0 / level monitoring educt_tank B001 operating point H OK)
Note: If you use AS1/S7-400, select the symbols under S7 Program(1). If you are using the AS2/RTX Box, however, then you have to select the symbols under S7 Program
(2).
66. We now apply the settings in the Dynamic Dialog. (Check OK)
2. Now, also complete the pictures of levels T2_Reaction and T3_product_tank with the missing elements (tanks or reactors). Use the P&I diagram as a guide so that all
valves, motors and controllers are positioned correctly. Take note of the correct rotation of the valves.
3. Finally, design the operating screen for the level T4_rinse. To this end, adapt the background analogous to the step by step instructions. Generate a picture title and a
tank based on the educt and product tanks. Connect the variables of the binary sensors and arrange the valves and the motor using the P&I diagram as a guide.

67. The steps shown above are also performed for the sensor 'A1.T1.A1T1L001.LSA-.SA- / I70.1 / level monitoring educt_tank B001 operating point L. Then, the elements
shown here are jointly highlighted and grouped.
(A1.T1.A1T1L001.LSA-.SA- / I70.1 / level monitoring educt_tank B001 operating point L Group Group)
68. The group is then copied. (Copy)

69. Now we open the library and the group is inserted in the project library. Name the template educt_tank_V1_0. (Project Library Insert)

70. Next, in the picture T1_educt_tank.Pdl we position the faceplates for the valve A1T1X004 and for the pump A1T1S001 as shown here. It is advisable to bring the
symbols within the layer to the very front so they cant be covered up by other drawing elements. (ArrangeWithin the Layer Bring to Front).

71. The orientation of the dynamic valve faceplates is not yet correct. At runtime, the faceplates are animated in a way that in the closed state, they are situated
transversely to the position of the pipe and rotate when opened in the position direction. However, this orientation can be changed only via the CFC of the
respective valve. To rotate a valve, first open the associated CFC and then the object properties of the valve block.
(Plant view A1T1X004 Valve Object Properties)
72. Now, in the field Create block icon, enter a 2. This rotates the icons by 90 degrees.

(Create block icon 2 OK)

73. After you have made the changes for all valves that are located in a vertical pipe compile the changes.
(SCE_PCS7_Prj PLC Compile and Download Objects OS(1) Edit)
74. In the last dialog for settings, enter the changes at Scope and then start compiling the OS. (Scope ChangesApply Start)

75. In WinCC, the symbol of the valvefor which you made the change shownis now rotated according to standard. Next, insert a static text T1 educt_tank; it facilitates
orientation during operation. The result is shown below.

76. Just as for the picture T1_educt_tank, a tank/reactor is set up in the pictures Product Tank and Reactors, The two figures below can be used as examples. In addition,
generate a template for the library from the one reactor as well as from the product tank.

77. To test the HMI with SIMIT and PCLSIM, the charts have to be downloaded to PLCSIM. The plant simulation in SIMIT also has to be started. Set the CPU to the RUN-P
mode.

78. In the WinCC Explorer, activation on the ES has to be allowed in the properties of the OS. (Properties Allow activation on ES)
 Alarms should always be used purpose-oriented. We should clarify what is monitored, how it is done and when an alarm is triggered. Furthermore, we have to define
PA Module P02-02 how the operator can react to the alarm. Based on these criteria, alarms can be subdivided into a variety of alarm types (refer to [3]). The most important types are:
Absolute alarm: The alarm is generated when a specified limit is exceeded or dropped below.
SIMATIC PCS 7 Alarm Engineering Time delayed alarm: The alarm is generated when the alarm criterion for a specified time span is met.
ALARM ENGINEERING
Process alarm: The control system itself generates an alarm that requires immediate operator reaction.
TRAINING OBJECTIVE
In this module, the students are familiarized with the fundamentals of an alarm system. They understand the purpose and the areas of application of alarm and signaling
ALARM PROCESSING BY THE OPERATOR
systems, and they know the requirements for such systems resulting from this. They are familiarized with the possibilities of representation, and interactions with
The operator processes alarms in three phases: First, the operator has to recognize that a problem occurred (1st phase: recognition). To this end, the alarm system has to
messages and alarms. This enables the students to design a suitable and useable alarm management in PCS 7.
draw the operators attention to the problem. Then, with the aid of the control system, the operator has to identify the problem (2nd phase: identification). After the
THEORY IN BRIEF
operator located the cause, he can initiate steps to remove the fault and to compensate for the consequences of the problem (3rd phase: problem recovery).
Alarm systems play an extremely important role in modern process control concepts for the economic operation of process plants. Designed ergonomically, they inform
During each of these phases, the alarm system has to support the operator in a suitable manner. Table 1 lists the most important support capabilities of the alarm system.
the operating personnel specifically if there are unintended deviations of the process state from a defined normal state (refer also to the chapter Functional Safety).
Table 1: Options of the alarm system to support alarm Supporting options of the alarm system
Alarm systems make it possible for the operator to localize the cause of the malfunction directly, and to adjust the process control strategy through suitable intervention
processing Phase
in a way that, despite the fault, either specification-conforming products continue to be manufactured, or the process is stabilized in a way that the fault causes minimal
Recognition
production outage.
Effective guidance of attention
The control system PCS 7 includes a number of technical resources for implementing an alarm system. The palette ranges from function blocks for generating messages,
Suitable presentation of information
icons for representing alarm states, group alarms along the plant hierarchy to components for representing and managing messages in lists (refer to Figure 1).
Pre-processing and sampling information
By following a number of design rules for specifying message texts and assigning priorities, a very efficient alarm system can be implemented that meets all the
requirements of the national and international standards and guidelines currently valid.
Identification
Significant description of errors
THEORY
Tools for investigation of errors
ALARM SYSTEMS
Jumping to the appropriate operator display of PCS
Through the consistent use of modern process control engineering, process plants are highly automated and optimized regarding safety. For this reason, the operator of
such a plant monitors a largely automated process that requires operations only if, because of a fault of the process or of the plant, manual intervention is necessary. The
Troubleshooting
objective of such manual intervention is always to take the process back to the normal state (refer also to the chapter Functional Safety) before the automatic
Significant instructions for solving the problem
protection equipment is activated.
Jumping to the appropriate operator display of PCS for
Since in general, protection equipment takes the monitored technical facility to a safe state, this usually causes a loss in product quality, production delays or even the
operator intervention
standstill of the entire production. This has a considerable negative effect on the economic efficiency of the plant. For that reason, the possibility that an impermissible
fault activates the protection equipment has to be detected early so that it can be prevented through suitable manual intervention. In addition, the operator has to be
Generation
informed of protection equipment being activated so that he can monitor the consequences.
Messages and alarms are generated process-oriented in the devices of the control system equipment of the plant. Generation may be linked to certain conditions (for
The alarm system is the central interface between the operator and the monitored process, and makes available all setups for managing messages and alarms in the
example, timing conditions, and hysteresis) and is carried out always with time-synchronous stamping.
control system [2]. The alarm system makes it possible for the operator to detect deviations from specified conditions within the range of the intended operation early,
When defining messages and alarms, the operators reaction time has to be taken into account. After a message or an alarm occurred, the operator has to have sufficient
and to specifically counteract it. Figure 2 shows the four phases of interaction between the operator and the alarm system of the process control system.
time to remove the indicated problem before the next alarm is triggered.
Figure 2: Phases of interaction according to [2]
This can be easily illustrated using the overflow protection of a reactor as an example. Corresponding to the inflow rate of the reactor, a defined time elapses between
This means the alarm system has to provide the operator with the capability and the opportunity to respond suitably to a signaled event. To attain this, the system has to
the overflow indication and the corresponding overflow alarm. If the operators counter measures dont take effect in time, the indication is not useful to the operator
meet a number of requirements. Messages and alarms have to be represented clearly, transparently and consistently.
since the alarm and the automated protection function are triggered in any case.
The operator has to be supported in the situation-oriented evaluation of a message or an alarm as well as in the selection of suitable intervention. To this end, a suitable
Prioritization
action prompt has to be provided, depending on the process state.
Large process plants have a considerable number of alarm sources available that in turn can trigger different types of alarms. To keep this diversity controllable for the
To prevent the operator from being overburdened, the number as well as the frequency of messages and alarms has to be minimized. In addition, the operators operator, it is advisable to structure the alarm system. A suitable method for this is alarm prioritization. This refers to the unambiguous classification of all alarms of an
workload should be kept as low as possible when messages and alarms occur. Beyond this, the operator can be supported in his work with suitable tools for documenting alarm system according to their importance and urgency [2]. If several alarms are accumulating, a processing sequence can be suggested to the operator based on alarm
and evaluating messages and alarms. priorities.
When designing an alarm system, the performance capability limits of the future operators have to be taken into account. The totality of the tasks that an alarm system
requires of an operator to be performed must not exceed human performance limits either for short periods of time nor continuously. Figure 1: Example of a prioritization matrix according to [2]
On the one hand, a sudden rise in the number of alarms or of the alarm rate can cause the operator to be briefly overloaded (alarm shower). It has to be taken into To this end -as shown in Figure 1- a prioritization matrix can be set up. It depends on the requirements of the respective process plant and is usually used for the entire
account here that on the average, an operator cannot process, as a maximum, more than 7 items of information at the same time (72 rule). plant. Corresponding to this matrix, each individual alarm is assigned a priority (static prioritization).
On the other hand, a continuously high workload can cause the operator to be permanently overloaded through a constant high number of arriving alarms. This leads to Alternatively, alarms can also be prioritized depending on the current plant situation and the combination of other queued alarms (dynamic prioritization). Usually,
an increasing drop of the operators performance and reliability. alarms are marked by color regarding their priority.
An alarm system has to be designed that utilizes the characteristic features of human perception and takes their limits into account. Important alarms have to be
emphasized to be noticed quickly. Events that occur rarely have to be presented in a special manner to draw the attention of the user. Important information should be Prioritization is designed in a way that the long term average alarm rate for each operator station in normal operation is not more than one alarm every ten minutes [2].
presented redundantly to facilitate it being noticed. Moreover, several sense channels should be addressed for transmitting information (for example, using acoustical For that reason, useful priority distribution is the aim. For example:
warning signals). 5 % Priority High
Only if an alarm system meets these requirements can it actually support the operator in his tasks: to monitor and control the plant. 15 % Priority Medium
ALARMS AND MESSAGES
Alarm systems are used to manage messages and alarms in control systems. In general, Message means every report and every display referring to the occurrence of a 80 % Priority Low
specific event. However, in the narrower sense the term is used only for such messages that do not require immediate operator reaction [1]. Otherwise, the term alarm is
used; i.e., the term message is used as a generic term as well as subsidiary term. Below, the following definitions will be used consistently: The reduction of operator load resulting from this avoids overload consequences and ensures necessary time spans for monitoring and controlling [2].
Alarm: Refers to a display or report that an event occurred that requires immediate operator reaction. The reaction may be an activity; for example, performing an Representation
operation. But it can also be only a mental reaction; for example, increased attention. The representation of alarms is of essential importance to the usability of an alarm system. The representations below have proven themselves in practice and have
prevailed [2]:
Message: Refers to a display or report that an event occurred; no immediate operator action is required. Area overview of alarms: Arrangement of the alarms in an overall view that cannot be covered up (also called common status display). The alarms are arranged in a
way that they can be assigned directly to the corresponding plant units. Using corresponding jump functions, the assigned process and plant displays are directly
Alarms signal deviations of the process or of the plant from the desired state and make it possible for the operator to avert a danger situation or economic damage. To accessible.
fulfill this task, good alarms have to have the following features [3]:
Relevant: The alarm is justified and valuable to the operator. Representing alarms using an alarm list: Arranging the queued alarms in list form. The list can be sorted and filtered in many ways. Often, jump functions are provided
to the assigned process and plant displays in this representation also.
Clear: The alarm contains information for the operator. It does not repeat another alarm.
Alarm representation in schematic flow diagrams: Alarms are signaled through saturated colors (preferably red or yellow) of the corresponding symbols in the process
Timely: The alarm arrives close to the time when an intervention is necessary. It arrives in time for the operator to intervene. and plant display.
Prioritized: The alarm refers to the urgency of operator reaction. Initial message system: If alarms accumulate, the system determines the primary alarm and filters out the subsequent alarms resulting from it. For the operator, this
Can be understood: The alarm contains information that can be understood easily. decreases the number of alarms he has to process.

Diagnostic: The alarm makes it possible for the operator to identify the problem that occurred.
Instructional: The alarm provides suitable action instructions to solve the problem that occurred
Focusing: The alarm guides the attention to the most important problems
Often, the graphic representations are supplemented by optical or acoustical signal transmitters. They inform the operator in addition of an occurring alarm.
The operator has to acknowledge alarms and messages that occurred; i.e., he documents that he took notice of the state change,
Evaluation
In order to evaluate an alarm or a message, the operator has to be able to interpret the current process and plant state correctly. He is assisted in doing this by the types
of representation just discussed, by suitable message texts and alarm descriptions as well as suitable tools for pre-processing larger alarm volumes.
Operator Intervention
After the operator has evaluated the state of the plant and the consequences, he has to decide what to do appropriate to the situation, and implement it. This takes place 6. Nextas shown hereselect the objects for compiling and start the process as you learned in the previous chapters. (Start)
within the control system but outside the alarm system. For that reason it is extremely helpful to the operator if he can jump from the alarm system directly to the
corresponding screen where the necessary action can be taken. Often, alarm systems provide corresponding jump functions. In addition, decisions regarding operator 7. After the successful compilation, open the OS. (OS(1) Open Object)
action are supported with help texts that are assigned to the different alarms.
8. Within WinCC, open in the Graphics Designer the picture T2_Reaction.Pdl. (Graphics Designer T2_Reaction.Pdl)
ALARM MANAGEMENT IN PCS 7
PCS 7 has an efficient alarm system. It informs the plant operator about occurring events and indicates them in the process mode in the form of message lists and a group 9. In this picture, the block symbol for the MonAnS block A1T2L001 was set up through the compilation run. Position it to the right of the reactor and save the picture.
display. An additional list shows the operator interventions. The display for messages is configured in WinCC. (A1T2L001 )
PCS 7 differentiates three message classes [4]: 10. Now, in the Graphics Designer open the picture A1_multipurpose_plant.Pdl.
Control system messages: are generated in PCS 7 by driver blocks if they detect faults on their own components (AS, OS etc.) These messages dont have to be (Graphics Designer A1_multipurpose_plant.Pdl)
configured. 11. In this picture, drag an IO field from the smart object of the object palette to display the level of reactor A1T2R001. Then, open its variable selection. (Object palette
Smart Objects I/O Field )
Process messages: signal events of the automated process such as limit violations and operational messages. These messages dont have to be configured. However,
messages texts and message priority can be changed if needed. 12. Within the variable selection, select as data source the ES variables. In the left window you will then see the hierarchy of your project. Here you can easily locate your
MonAnS block. To display it in the IO field, select the connection PV#Value.
Operation messages: are generated when process variables are operated; for example, when the operating mode is changed. Operation messages are generated
(ES Variables A1_multipurpose_plant T2_Reaction Reactor R001 A1T2L001 2 PV#Value OK)
automatically if PCS 7 faceplates (picture blocks) from the Advanced Process Library are used, or own blocks that are configured in conformance with PCS 7.
13. This variable is now displayed in the configuration dialog. After the following changes, accept this configuration.
Messages for the AS and distributed periphery are configured when the CFCs are generated, or in the process object view. Messages of block types or individual block
(Update: Upon changeField type: Output OK)
instances can be changed and own message texts can be configured. SFCs. Types and instances can also generate messages.
14. At Properties of the IO field, the output format is set for 4 digits before the comma (period) without decimal places. (Properties Output/Input Output Format
Messages for the OS are configured using the application Alarm Logging in WinCC Explorer. There, the triggering event is specified for a message.
9999 OK)
When configuring messages, different aspects have to be taken into account:
Message text: Blocks with signaling behavior have preset message texts with the corresponding message class and message type. These texts and attributes can be
15. The following attributes for the font are selected. (Properties Font X-Alignment: Centered Y-Alignment: centered)
adapted depending on requirements. In addition, information from the process or the block comment can be added.

Message number: During compilation, each message configured in the ES is automatically assigned a unique message number in alarm logging. The message number 16. To better interpret the value in runtime, enter a tooltip text. (Properties Miscellaneous Tooltip Text: Level of Reactor R001 Close)
range is specified when the project is set up. Message numbers are assigned either project wide or CPU wide and are unique. The latter is the precondition for assigning
message priorities. 17. Next, position the I/O field under Reactor A1T2R001 and add two static texts Level and ml. (Object Palette Static Text)

Message priority: A message can be assigned a priority between 0 (the lowest) and 16 (the highest). Message lists can be sorted and filtered according to their priority. 18. Below the educt tank A1T1B003, we want to display with a text list whether this tank is empty. After we dragged the display from the object palette into the picture,
The message line in the overview area always displays the message that has the highest priority and was not acknowledged. open its variable selection. (Standard Palette Smart Objects TextList )

Technological blocks that are visualized on the OS have the function Loop-In-Alarm. It makes it possible to change directly from the message list to the corresponding 19. Within the variable selection, select this time as data source STEP 7 Symbol Server. In the window to the left, the symbols of the S7 program are displayed. Select
faceplate for process and control system messages. input. I70.5 A1.T1.A1T1L003.LSA-.SA-. (STEP 7 Symbol Server S7 Program(1) Symbols I70.5 A1.T1.A1T1L003.LSA-.SA- OK)
PCS 7 uses a central acknowledgement concept. If a message is acknowledged on the OS, the acknowledgement is sent first to the triggering block and from there
forwarded to all relevant OSs. 20. This variable is then displayed in the configuration dialog. After the following changes, accept the configuration.
LITERATURE (Update: Upon Change Field Type: Output OK)
[1] VDI/VDE 3699 (Ed. 2014-01): Process control using display screens 21. Next, we set the representation of the font in the properties of the text list. (Properties Font X-Alignment: Centered Y-Alignment: Centered)
[2] NAMUR NA 102 (Ed. 2008-10): Alarm Management.
[3] EEMUA 191 (Ed. 2013, Edition 3): Alarm Systems. 22. The texts are assigned to the values of the variable in the Properties also. (Properties Output/Input Assignments)
[4] SIEMENS (2015): Process Control System PCS7: Engineering System (V8.1). A5E32712311-AC.
23. To the value 0 we assign the indication empty and to the value 1 the indication OK. (Range type: Single Value Value range: 0 Text: empty Change Range
STEP BY STEP INSTRUCTIONS type: Single Value Value range: 1 Text: OK Append OK Close)
TASK
In this task, alarms and warnings are set up for the operator system (OS). As an example, we program level monitoring for reactor A1T2R001, and have the alarms and 24. You will need exactly such a text list once more for a textual display below the product tank A1T3B001. It indicates whether the tank is full. The text list we already
warnings we set up there displayed in WinCC. generated is now highlighted and duplicated. (Duplicate)
TRAINING OBJECTIVE
In this chapter, the students 25. For product tank A1T3B001, select input I70.6 A1.T3.A1T3L001.LSA+.SA+. (STEP 7 Symbol Server S7 Program(1) Symbols I70.6 A1.T3.A1T3L001.LSA+.SA+
Learn to integrate monitoring and alarm blocks in the CFC OK)
Become familiarized with the WinCC message system
26. Now, the assignment is changed for the attributes: To the value 0 we assign the indication OK and to the value 1 the indication Full. (Range type: Single Value
Learn representing alarms and warnings in the operator system (OS) Value range: 0 Text: OK Change Range type: Single Value Value range: 1 Text: Full Change OK)

Are familiarized with the WinCC Graphics Designer. 27. We now position the second text list below the product tank A1T3B001 and save the picture. (Save)
28. An illustration follows that shows how a warning is represented in runtime. In the message line, the warning or alarm that occurred last but has not been
These instructions are based onPCS7_SCE_0201_Ueb_R1305_en.zip. acknowledged appears. If the operator wants to switch directly to the picture where the alarm or warning was triggered, he can do this in two ways:
PROGRAMMING With the button Loop in Alarm in the message line
1. To program level monitoring, we first open the existing CFC A1T2L001 for the level of reactor A1T2R001. By clicking on the fault indicator in the display hierarchy ()
29. In the picture T2_Reaction, a display of the warning is provided in the block icon. By clicking on the block icon, additional information is displayed in the faceplate for
(A1_multipurpose_plant T2_Reaction Reactor R001 A1T2L001) the MonAnS block regarding the cause of the warning. Here, messages requiring acknowledgement can be acknowledged or limits can be adapted.
30. By clicking on the button Alarm System in the message line, all queued messages are displayed. ()
2. From the folder Monitor of the PCS 7 Advanced Process Library V81 in the library catalog, enter the block MonAnS and interconnect it as shown. (Libraries PCS 7 EXERCISES
AP Library V81 Blocks+Templates/Blocks Monitor MonAnS) In the exercises we apply what we learned in the Theory section and in the Step by Step Instructions. We are using and expanding on the existing multi-project from the
Note: The block MonAnS is used to monitor a measured value (analog signal) for the limit pairs: step by step instructions (PCS7_SCE_0202_R1504_en.zip).
Warning limit (high/low) In the step by step instructions, only the alarm for a level of only one reactor was implemented. In the exercise, we are completing the alarm configuration of the level for
Alarm limit (high/low) reactor R002 as well as implementing the alarms and warnings of temperature overrange for both reactors. Finally, we are adding to the overview picture the missing
displays.
3. In the block properties, the connections shown for setting the upper and lower alarm/warning limits are made visible. TASKS
(PV_AH_Lim PV_WH_Lim PV_WL_Lim PV_AL_Lim Visible(Invisible)) The tasks below are based on the step by step instructions. For each task, the corresponding steps of the instructions can be used as an aid.
4. At the connections that are now visible, the warning and alarm limits shown are set and the value of connection PV_Unit is set to 1040. It specifies the unit that is 1. Implement alarm generation also for the level of the second reactor. To this end, insert the block MonAnS in the CFC A1T2L002, assign a name and parameters to it.
displayed on the screen of the OS or in the faceplate. An excerpt from Siemens documentation for possible units is also shown below. After compilation, position the block in the operator screen T2_Reaction.pdl.
Here, the changes in chart A1T2L001Sheet1 are listed once more: 2. Next, in the overview display A1_multipurpose_plant.pdl insert an I/O field for the level of reactor A1T2R002 and visualize the current reactor level.
Table 2: New blocks in chart A1T2L001 Sheet1 3. Design alarms for the temperatures of the two reactors analogous to the levels. The temperature warning is to be triggered at 55C and the alarm at 60C. No
Table 3: Input wiring in chart A1T2L001 Sheet1 additional monitor blocks are needed to design the temperature warnings and alarms since the PidConL blocks include this functionality. The connections for the warning
Table 4: Output wiring in chart A1T2L001 Sheet1 limits and the alarm limits have the same name there as for the MonAnS blocks.
4. Now, set up I/O fields for the temperature below the level in the overflow display.
5. To compile and download AS and OS at the same time, highlight the project in the component view of the SIMATIC Manager. Then select for the PLC 'Compile and 5. Finally, add the missing text lists for all elements.
Download.
(SCE_PCS7_Prj PLC Compile and Download Objects)

PA Module P02-03
SIMATIC PCS 7 Archiving and Trend Reporting
ARCHIVING AND TREND REPORTING
TRAINING OBJECTIVE
After working through this module, the students know the basic requirements and objectives of archiving. They are able to apply different types of archiving to process
data and messages. The students know how suitable cycles can be determined for time controlled archiving and they also know the criteria according to which event
controlled data archiving is executed. They know the options that PCS 7 provides.
THEORY IN BRIEF
Archiving process values is an important resource for correct and optimized process management.
The archived data allows for the analysis of historical data to optimize the process, for tracking faults as well as for quality assurance.
However, not only process values are suitable for archiving, but also messages and events. Particularly in the case of fault states, the operator has to handle a large
number of messages so that only after a return to normal operation or at a plant standstill is it possible to determine the exact cause. To this end, the messages and
events in the archive can be resorted to, as well as the archived process values.
Process values are usually archived cyclically, messages and events event-controlled. In the case of process values, the exact cycle depends on the dynamics of the
process it is based on. Selecting a cycle independent of the process has great disadvantages. A cycle that is too short requires a large amount of memory and under
certain circumstances records the noise of the signal. A cycle that is too long leads to values that cannot be used since the development of the process value can no
longer be reconstructed.
In the case of signals that are barely subject to fluctuations or not subject to them at all, the acquisition of almost identical values does not make sense; for that reason, it
is possible to compress the data; for example, by setting a dead zone. Only when the process value exceeds or drops below the limit that was set is the value stored again
in the archive.
Trend reporting provides the operator with an overview of process development up to the current time. From the course of the process value he can determine whether
and perhaps how soon a fault state threatens to occur. Thus, countermeasures can be initiated before the protection mechanisms have to be activated.
THEORY
INTRODUCTION
Automating, safeguarding and monitoring processes are basic requirements for a process control system. Archiving the data that accrues offers the possibility of storing
historical data and making it available for analysis.
There are many reasons for the necessity to analyze data. There are legal regulations on the one hand, safety oriented and performance related causes on the other.
The legal regulations include logging faults -for example, exceeding limits or the occurrence of an event. Another legal reason for archiving is the verification for
certificates and for conditions such as emission limits. In connection with product liability and product safety, archiving of all process steps and materials used is required
for the gapless tracking of the product. [1].
Product related reasons for archiving data are the statistical evaluation of production quantities statistical long term analysis to optimize the process, determining the
performance, and reduction of production and material cost. The data is also very helpful to the subsequent analysis of faults regarding their effect and propagation as
well as the assessment and possibly the revision of existing countermeasures. Thus, plant shutdowns can be avoided and the economic efficiency of the plant can be
increased at the same time. Likewise, the data can be used to analyze normal operation and to locate optimization potential or identify possibilities to improve quality.
The data is also interesting with respect to the optimization of the maintenance of production resources based on the existing data.
Safety-oriented reasons refer primarily to the adaptation of operating parameters; i.e., limits and response timing. When performing tests to check safety locks and
EMERGENCY STOP functions, recorded data can be used to verify the provided functions. If the data should show safety deficiencies, the cause can be analyzed based on
the data.
In addition, storing the data in archives retains the performance capability of the process database and provides for data safety. By storing data in an archive database, it
is not necessary to maintain all process runs on paper.
Based on the reasons mentioned, archiving proves to be an important resource for correct and optimized process management. This results in different requirements for
archiving. It includes that the data is stored completely uniform and structured. Likewise, access to the data has to be possible in a structured manner, and through
filtering, for example, permit a selection of the criteria. This also requires, however, that the data is archived for different time spans or with different cycles, and at
different locations.
In principle, two types of data can be distinguished: process data that occurs cyclically, and messages and events that occur acyclically. This topic is discussed in greater
detail below.
PROCESS DATA
Process data refers to the analog and digital values that is determined by means of sensors and transmitted to the process control system. It is used to control and
visualize the process.
Process data is transmitted cyclically to the process control system. In this case, the changes of the analog process values that take place in a certain interval are very
different. The cause for this is the different process dynamics. For example, the process data of flow measurements usually has higher dynamics than temperature
measurement; i.e., process data of flow measurement changes within or in fractions of seconds, while the process data for temperature measurement changes rather in
time intervals of more than 10s.
Analog values should be archived time controlled. It has to be noted in this case that process data of very dynamic processes has to be archived at a considerably higher
rate than data of slow processes. One reason for this is that the size of the archive is not unnecessarily increased and the other that representing a slow process in
intervals that are too short is inefficient or can contain a strong noise signal.
Binary signals can only switch between two states; they should be archived event controlled.
MESSAGES AND EVENTS
According to [3], messages are reports about the occurrence of an event; i.e., of a transition from a discrete state to another. According to [3] an event is the
spontaneous occurrence of a defined state. Important information for an unambiguous and complete message is the state that occurred, the time and the location.
Additional details regarding messages and events are provided in chapter P02-02.
Messages and events occur acyclically and can therefore not be archived at fixed intervals. Here it is necessary to select the relevant messages and events to ensure
efficient archiving. One possibility would be, for example, to archive only safety-critical messages or messages with a certain priority.
Messages and events can only be archived event-controlled.
DATA COMPRESSING
The data volume in plants is large; usually, only a limited amount can be archived over a certain interval. The amount of data archived depends largely on the cost for the
memory medium and the data transmission rate. On the other hand, acceptable data loss has to be considered. The degree of compression results from weighing these
two criteria.
When data is compressed, not only the quantity of the stored data changes but also statistical characteristics such as average and variance. For that reason, such values
should be calculated from the original data and if needed, archived also. This should be done time controlled, analogously to the archived process data.
For data compression, direct and mapping methods can be used.
When the direct method is used, the data is archived in real time. There are rules that govern the archiving of individual measured values. The data is reconstructed by
connected the data points.
When mapping methods are used, the data is not archived in real time since in the transformation the previous courses are included. The original data is mapped in
another area. When this procedure is used it is possible to design the compression adaptively, since the algorithms often have a parameter that decides on the quality of
the compression in dependence on the process.
TREND REPORTING
The term trend reporting refers to the representation of process values in trends; i.e. dependent on the time. The time interval for trend reporting includes the present
and the recent past. It is important that the trend curves, in contrast to pure history curves, are updated [2].
By representing process values in curves, process values can be monitored, changes identified, actual values compared with setpoints, and faults analyzed. In distinction
to the pure display of the process variable, curve diagrams provide information about amplitude, ascents, frequency and the course of a process variable.
ARCHIVING IN PCS 7
In the process control system PCS 7, different data can be archived that was generated during the process mode. These are: process values that are stored cyclically in
two different types of system archive, and messages that are written event-controlled to the alarm log. This data is archived on the OS server by default for short term
archiving as shown in Figure 1. If in addition a central archive server (CAS) is configured, OS logs and batch logs can also be archived in addition to the data mentioned
above. The data archived on the CAS is used for long term archiving and can be transferred periodically to external media. Storage Plus is also available; it can be used to
generate views to the archived data that can then be viewed using a Web browser [4, 5, 6].
Figure 1: Overview short-term and long-term archiving [Siemens]
Archiving System on the OS Server
On the OS server, archives for process values and alarms/events can be set up.
As shown in
Figure 2, these archives are organized as circular logs. They consist of segments that are defined either through a time interval or by specifying physical memory. When
one of these criteria is met, a segment is closed and a new one is started. If the memory of the server is exhausted, the segment that was set up first is overwritten
according to the FIFO principle (First In First Out). In Fehler! Verweisquelle konnte nicht gefunden werden., as an example, time spans are specified that the different
archives can have for a cycle. The time specified also is an indication of the time relationships between the individual archives.
The process values are stored in the database compressed. They are compressed by setting a hysteresis. Depending on the signal change, a compression factor between 2
and 10 is reached. By selecting additional calculation functions, important statistical characteristic values can be retained despite compression.
To estimate the required memory for an archive, the average quantity of process values per second or the average quantity of alarms per second is needed. These
averages are multiplied with the typical memory capacity for the data and with the desired archiving interval. The interval has to be specified once for one segment and
once for all segments together. Typical memory capacity is between 6 and 16 bytes for process values and 4000 bytes for alarms. For reasons of performance, the number
of individual segments should not exceed 200 [4].
Figure 2: Circular logs for short-term archiving [4]
In addition to the archives for the processes, user archives can be set up. There, characteristics from other sources can be entered. The operator can use them to compare
the actual course with desired course.
Central Archive Server (CAS)
The central archive server is located on the same level as the OS servers. In distinction to the OS servers, it is not connected to the plant bus, but exclusively to the
terminal bus, as shown in Figure 3. By means of the terminal bus, the CAS receives the data designated for long term archiving from one or several OS servers and from
the batch servers. The data is transmitted from the OS server to the CAS automatically after a segment is completed. The data from the batch server is directed by means
of the Batch Control Center (BCC) for archiving. For archiving OS logs, a script can be implemented that transmits the cyclically stored OS logs to the central archive server.
To increase data security, the CAS can be operated redundantly.
Figure 3: Classification of the Central Archive Server in the structure of the PCS [Siemens]
Fehler! Verweisquelle konnte nicht gefunden werden. shows the organization of the archives of the CAS. These archives also are designed as circular logs and work
according to the FIFO principle. To save the data periodically, backup strategies can be configured that allow for the transfer of individual segments to an external
medium; for example, DVD or network drive. For that reason, the size of the segments on the CAS has to be less than the external medium.
Figure 4: Logs of the Central Archive Server for long-term archiving [4]
Storage Plus
Storage Plus can be used alternatively or as a supplement to CAS. Storage Plus is always installed on a separate computer and is connected to the terminal bus (Figure 5).
In contrast to the CAS, Storage Plus cannot be operated in the redundant mode, but makes possible the display and analysis of the data that is stored in the CAS, in the
Storage Plus database or on external media; for example, the display of histories [2]. The archived data is displayed by means of views that filter the needed information
from the totality of all data. The data is represented in tables, diagrams or reports [7].
Figure 5: Classification of Storage Plus in the structure of the PCS [Siemens]
TREND REPORTING IN PCS 7
Below, the two possibilities for representing archived process values in PCS 7 are described. The OS servers are accessed exclusively in that case. This makes it possible to
quickly trace the development of one or several process values, and a negative trend can be detected or obviated.
Curve Groups
Curve groups can be called using a button on the PCS 7 operator interface. They dont have to be configured; they are provided as a matter of standard. However, certain
curve groups can be pre-configured that will then only have to be displayed at execution time. If curves are not pre-configured or if the process values needed at the
moment are missing in these groups, a new group can be set up any time.
Online und Function Trend Control
Within process displays, the following ActiveX Controls can be used to represent process value characteristics. Additional information for designing operating screens with
ActiveX Controls is provided in chapter P03-03.
Online Trend Control represents one or several process values over time
Function Trend Control represents a process value in dependence on another process value
Online Trend Control corresponds to the curve display (refer to section Trend reporting).
Function Trend Control can be used under certain conditions to display dependent process values in a trend: The process values to be represented have to be archived in
the same cycle and the archive has to be located on the same OS server. To facilitate analysis, a setpoint curve can be displayed in addition to the actual curve. The data
for the setpoint curve is configured and stored in a user archive [6].
SUMMARY
To archive process data, alarms and events, always an OS server has to be installed. The expanded archiving capabilities are based on it; the data for CAS and Storage Plus
is read by the OS servers.
Table 1: Overview of Short Term and Long Term Archiving according to Servers
To display data that is located on the OS servers, curve groups and Online Trend Control can be used. Regarding Function Trend Control, only such value pairs can be
displayed that are stored on the same OS server and with the same archiving cycle.
Storage Plus has a Web interface for displaying long term archived data.
Table 2: Overview of Short Term and Long Term Archiving
LITERATURE
[1] TU Dresden (2010/07): Vorlesung Prozessrechen- und -Leittechnik
[2] VDI/VDE 3699, sheet 4 (Ed. 2014-01): Process control using display screens Curves.
[3] VDI/VDE 3699, sheet 5 (Ed. 2014-09): Process control using display screens - Alarms/messages.
[4] SIEMENS (2014): Configuration Guidelines Compendium Part A. A5E35031757-AA. (http://support.automation.siemens.com/WW/view/en/107196780)
[5] SIEMENS (2015): Process Control System PCS7: Engineering System (V8.1). A5E32712311-AC. (http://support.automation.siemens.com/WW/view/en/90663380)
[6] SIEMENS (2015): Configuration Manual Operator Station (V8.1). A5E32785103-AC. (http://support.automation.siemens.com/WW/view/en/90682677)
[7] SIEMENS (2008): MDM - Storage Plus Information System. (http://support.automation.siemens.com/WW/view/en/37436169)
STEP BY STEP INSTRUCTIONS 16. In the parameters we can select, for example, if we want to archive the corresponding message. (OK)

TASK 17. In the shortcut menu of the messages, under the item Archive Configuration, you can now select the Properties of the Message archive (Messages Archive
Configuration Properties)
This task deals with process value and message archives for the operator station (OS) and their variants and setting possibilities.
18. Under Archive Configuration, we can now parameterize the size of the entire archive and the distribution into the segments.
As an example, set up archiving of the level for reactor A1T2R001 and display the archived values in WinCC Runtime as a curve using curve groups, and as printout using
the Report Designer for display. (Archive Configuration Archive size Time of the segment change)

TRAINING OBJECTIVE 19. Under Backup Configuration it is possible to activate storing the archive data in a destination path to ensure gapless process documentation. By default, backup is
started after the first time related segment change. After the settings were applied with OK, exit Alarm Logging .
In this chapter, the student is familiarized with the following:
(Backup Configuration OK )
Activating the archiving of process variables in CFCs
20. Now, in the WinCC Explorer open Tag Logging for configuring the process value archives. (Tag Logging)
The settings for alarm characteristics and alarm archiving in CFCs
21. Process values can be archived according to different time patterns. This is important in order not to generate data volumes that are too large in the case of large
The process object view as tool for archive configuring archives. The shortest time is 500ms. (Timers 500ms)

Archive settings for messages in Alarm Logging of WinCC 22. A Process Value Archive called SystemArchive is set up automatically for the PCS 7 project. Additional archives can be set up in the subitems Process Value
Archives and Compressed Archives. We are doing this now for a Compressed Archives. The differences between these two types of archive are described in the
Archive settings for process variables in Tag Logging of WinCC
property dialogs in the pages below. (Archives Compressed Archives)
Curve groups for displaying archive variables in WinCC runtime
23. Then, assign a name to the Compressed_Archive.
Report Designer for printing curves with archive variables
(Archive Name Compressed_Archive)
These instructions are based on PCS7_SCE_0202_Ueb_R1504_en.zip.
24. Now, look at the properties of such a Compressed Archive.
PROGRAMMING
(Compressed Archive Properties)
1. To program the archiving of the process variable level of reactor A1T2R001 using level monitoring, first open the existing CFC A1T2L001.
25. In the section General you can specify if this archive is already enabled when WinCC is started (not locked) and archiving of the data is to start, or if this is to take
(A1_multipurpose_plant T2_Reaction A1T2L001) place at a later time by means of a C script. You can also link an action under General archive properties with the start/enable of the archive.

2. To adapt the properties, the object properties of monitor block MonAnS are opened. (MonAnS Object Properties) (General Archiving disabled: No)

3. First, for the block MonAnS enter the comment Level monitoring A1T2L001. By clicking on the button Messages, we can perform the settings to configure the 26. In the section Compression, the compression time period and the processing method are selected.
messages. These settings are retained. Here, we see the relationship of the text for Event through key word + Text, for example: $$BlockComment$$ Alarm above; after
(Processing method: Calculate Compression time period: 1 day)
compilation of the OS, this becomes Monitoring level A1T2L001 Alarm above.
27. Tags are assigned to the compressed archives from the tags that were set up in the process value archives. (Compressed Archive SystemArchive
(CommentMonitoring level A1T2L001Messages Event Save)
A1_multipurpose_plant OK)
4. By clicking on the button OCM, the variables of the MonAnS block Monitor_A1T2L001 which are set up there during OS compilation are displayed as variables. Only
28. For the properties of the compressed tag archiving we want to display above all the parameters for editing or calculating the compression.
such variables of a CFC block can be archived. (OCM WinCC Attributes OK)
(Compressed Archive Tag name Properties Parameters Processing: Average value Unit: ml OK)
5. Now, we specify in the block properties the archiving of analog input values PV. To this end, select the input PV and in its structure the connection Value. In the
properties of Value archiving is activated. 29. Now look at the properties of the process value archive. (Process value archives SystemArchive Properties)
(PV Value Archiving OK Close) 30. In the section General, again specify whether this archive is to be enabled when the OS is started, or whether an action is to be linked with the enable/start of the
archive.
6. To see and also further edit these changes also have to be compiled in the process object view, AS and OS. To do this and download the AS at the same time, highlight
the project in the component view of the SIMATIC Manager. Then select for the PLC Compile and Download Objects. (General Archiving disabled: No)
(SCE_PCS7_MP PLC Compile and Download Objects) 31. In the section Memory location, select where the archive is to be stored. If the main memory was selected, memory consumption has to be limited.
7. Next, select -as shown here- the objects to be compiled and start the process as you learned in previous chapters. (Start) (Memory location Hard disk)
8. For performing several or even very many changes at the same time in one or different blocks, you have become acquainted with the process object view. Archive 32. Now, look at the Properties of the process tag that you set up previously in the CFC.
entries can be edited here, too. (View Process Object View)
(SystemArchive Tag name Properties)
9. Next, in the process object view, select the CFC A1T2L001. After you have selected the option Messages, change the entries for Event as shown here.
33. In the section General, basic settings have to be made for the Archive Tag, such as Supplying tags through WinCC and not through Manual input, or the possible
(CFC A1T2L001 Messages Event) assignment to a central archive server (CAS) via Long term relevant
10. The settings for the archive tags can be made in the process object view also. Under the option Archive tags, change the Archiving cycle to 10 seconds. (Tag supply: System Archiving disabled: No)
(Archive tags Archiving cycle 10 seconds) 34. The archive tag is recorded according to a fixed data collection cycle. The following can be set: whether archiving follows an archiving cycle (acquisition cycle) also
cyclically or whether it is to be acyclical (event controlled/if there is a change). In the field Hysteresis we specify if only the process value is archived that is located
11. We accept these changes by only compiling the OS this time. To this end, highlight the OS in the component view of the SIMATIC Manager. Then, select for the PLC
absolute (abs.) or relative (in %) above or below the specified threshold.
Compile and Download Objects.
(Archiving Archiving type: Cyclical, continuous Acquisition cycle: 1 second Archiving/display cycle: 10 seconds)
(OS PLC Compile and Download Objects)
35. For the other parameters, functions can be specified that are to be calculated also during archiving. The unit of the respective value can be defined here also.
12. Next, select -as shown here- the objects to be compiled and start the process as you learned in the previous chapters. (Start)
(Parameters Processing: Actual value Unit: ml)
13. After the successful compilation, open the OS. (OS(1) Open Object)
36. Now, we turn to the Archive configuration. At Tag Logging, there are two Archive types: TagLogging Fast and TagLogging Slow. The differences become evident in
14. Then, in the WinCC Explorer, first open Alarm Logging to configure the alarm system. (Alarm Logging)
the parameters. Here, first TagLogging Fast.
15. Select the AS messages. In the center window of Alarm Logging, you will find the individual messages and can edit their properties in the Properties area in the right
(Archives Archive Configuration TagLogging Fast Properties)
margin. (AS Messages PV Warning full)
37. Under Archive Configuration, the size of the entire archive and the division into segments can be parameterized. For the archive type TagLogging Slow, this option
looks like this.
(Archive Configuration Archive size Time of the segment change)
38. Under Backup Configuration, it is possible to activate archive data storage in a Destination path to ensure gapless process documentation. The backup is started by
default after the first time related segment change. (Backup Configuration)
39. In the tab Archive contents the difference regarding TagLogging Slow becomes evident. Here, the archiving criteria for TagLogging Fast are specified. The other tags
with longer cycle time are located in TagLogging Slow. For the archive type TagLogging Slow this option does not exist. After accepting the settings with OK close Tag
Logging with .
58. Now, we are ready to print. To save paper, the print job can be previewed. (@Report Tag Logging RT Curves New Preview print job)
EXERCISES
In the exercises we apply what we learned in the Theory section and the Step by Step Instructions. The existing multi-project from the step by step instructions
(PCS7_SCE_0203_R1504_en.zip) is used for this and expanded.
The objective of this exercise is this: to configure two trend groups that represent different archive values for the reactors. To this end, combine the temperature and
controller relevant data in the first trend group and the level relevant data in the second trend group.
TASKS

(Archive contents OK ) 1. Archive all values that are level, temperature and controller relevant. Edit the corresponding blocks in a way that these values are archived.

Note: An additional individual variant of archives are the user archives. User archives 2. Now, define a trend group for reactor R001 that represents the values of the PID controller. Add all relevant archive tags. Do the same for reactor R002. Try different
time and value axis settings.
are database tables where users can set up their own data fields. User archives are
3. Next, the level relevant data of the reactors is to be visualized together. Select them and display them.
used to store data and offer standardized access to this data according to SQL
4. Test different settings in the configuration dialog. Search for a function that can be used to select and deselect individual trends and trend groups.
database description. However, this variant is not shown here, since generating it is
The tasks below were not realized in the exercise project. However, they are typical for planning archive systems.
very individual and complicated. (User Archive Open )
5. Which process values should be archived for an easy-to-follow and gapless representation? Develop a concept and implement it.
40. To display the archive data, OS Runtime has to be started first, of course.
6. Calculate the memory needed for the tag Tag Logging Fast. As the number of process values, utilize the results from the first task. For the analog process values, once
(Activate OS runtime) assume 6 bytes for each process value and once 16 bytes for each process value. One segment is to store the process values for 2 weeks and all segments at least half a
year.
41. To display the plant, select the down arrow to the right of A1_multipurpose_plant and then T2_Reaction.
7. Now calculate the memory requirement for Alarm Logging by assuming 4 messages per minute. One message requires 4000 bytes memory.
( T2_Reaction)
8. Based on the results, distribute the assumed 10 GB memory to Archive Tag Logging Fast, Alarm Logging and Tag Logging Slow. Then set the properties of the archives in
42. The simplest method to display archive data in curve form is by clicking on Assemble groups/Call. your project.
(Assemble Groups/Call )

43. In the dialog below, assign a name to the New Trend Group and select Archive as content. That means: the displayed values come from an archive. As an
alternative, all other online variables can be displayed directly. (New Name:Trend_Group01 Contents: Archive Create)

44. In the tab Trends select at data connection Tag name the folder icon and in the next dialog the tag A1_multipurpose_plant/. (Tag name SystemArchive
A1_multipurpose_plant/ OK)

45. In the second tab Value axes deselect Automatic and set the value range to 0 1000. (Value axes deselect AutomaticValue range: 0 ... 1000)

46. In the tab Time Axes select the time range 1 x 1 minute. (Time Axes Time range: 1 x 1 minute OK)

47. You now have a trend display for the archive tag that you can modify conveniently using the task bar in the window Trendgroup01 regarding range and segment. To
display it, the corresponding SIMIT model as well as the simulation has to be started in PCS7.

48. Another variant for displaying trends from the archives is using the Report Designer as printout. Here it is important that WinCC remains started in runtime. In the
Report Designer, print requests with the layout they contain can be started. For this reason, first select a layout @CCTlgRTCurves_ENU.RPL matching the archive data in
order to adapt it.

(Report Designer Layouts English @CCTlgRTCurves_ENU.RPL)

49. In the Report Designer Layout, the layout can now be edited as in the usual graphic tools. Here we show how the dynamic view of the tag trend has to be
parameterized. (Tag Logging Runtime.Trend Properties)

50. In the following dialog, select under Connect the Tag Selection for editing. Likewise, the time range, time base and the format can be specified here. (Connect
Tag Selection Edit)

51. We still have to select a tag. Click on Add. (Add)

52. From the SystemArchive: select A1_multipurpose_plant as tag.

(SystemArchive A1_multipurpose_plant OK OK)

53. Close the Properties dialog and save the modified layout under the same or a different name. (Close Save )

54. In the print request for online trends @Report Tag Logging RT Curves New the properties are now set.

(Report Designer Print jobs @Report Tag Logging RT Curves New Properties)

55. In the dialog General, a suitable Layout file: @CCTlgRTCurves.RPL is displayed. If own layouts were created, they can be selected here also.

(Layout file: @CCTlgRTCurves.RPL)

56. Under Selection of the print job properties, the pages and the time range are specified. (Selection Page Range Time range)

57. In Printer Setup, several printers can be specified sorted according to priority. (Printer Setup OK)