Introduction6
Intelligent maintenance in process engineering
Despite the different tasks of operators and maintenance
staff, it is meaningful and necessary to map the informati-
on of both staff groups within one process control system
and not to use different systems.
There are various reasons for this:
• Uniform visualization for all components and devices.
• No limitation to selection of field devices.
• The same information sources (field devices) are relevant
to both automation and maintenance.
• There is a close link between automation and asset ma-
nagement functions because, for example, the current
control strategy of the plant plays an important role for the
assessment of a component status.
• Engineering data for automation can also be used for main-
tenance.
• Simplified handling of the system, since users need only be
acquainted with the engineering, operator control and mo-
nitoring tools of a single system.
The process control special interest group of the pharmaceuti-
cals industry (NAMUR) has formulated essential requirements
(NE 91) from the user's viewpoint. This attaches special signi-
ficance to the integration of the Plant Asset Management into
the process control system.
• Plant Asset Management is a part of the process control
system
• Recording and assessing the status of the assets
• Inclusion of all assets (process control devices and plant
components)
• Separation of maintenance-relevant information and pro-
cess data
• Uniform visualization for all assets
• No limitation to selection of field devices
In addition, there is a requirement (NE 107) that all field de-
vices must provide standardized status messages about their
status as follows:
• Good
No known restriction of function
•Uncertain
Operation outside the specified range
• Device failure
Need for maintenance
•Maintenance required
Function check (process value manipulated)
• Function check, local operation
Failure (process value invalid)
Processing plants, whose open and closed loop control is per-
formed with SIMATIC PCS 7 and components of Totally Integ-
rated Automation, satisfy the user requirements formulated
by NAMUR.
The resulting information is divided up to prevent the plant
operators and maintenance staff from being flooded with in-
formation. To achieve this, a Maintenance Station (MS) is int-
roduced in addition to the operator station (OS). Mainte-
nance-relevant information is kept away from the operator
station. This information is collected and presented on the
Maintenance Station. The same HMI tools are used for the
operator station and the Maintenance Station and the HMI
philosophy is identical.
Plant Asset Management with SIMATIC PCS 7
■Process engineering plants with SIMATIC PCS 7 and com-
ponents of Totally Integrated Automation meet the re-
quirements of NAMUR.
■Automation and Plant Asset Management run on the
same system.
■The information for plant operators maintenance staff is
divided between the operator station and the Mainte-
nance Station.
■Shared configuration and uniform user interfaces mini-
mize the expense of an effective Plant Asset Manage-
ment.
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