Raising performance in power plant operationSPPA-T3000 Cue – success starts in the control room

Instrumentation, Controls & Electrical

siemens.com/sppa-t3000

Control is the core for high-performance plant operation

05 Comprehensive expertise

06 Operator needs

09 Clever HMI

15 Flexible connectivity

17 Lifetime strategy

18 24 / 7 service

Conditions in today’s power generation industry are getting tougher. Now more than ever, power generators have to rely on top plant performance, which is ultimately powered by dependable and predictable operation.

Power plant control and automation solutions can help reach those goals. More specifically, the Human Machine Interface (HMI) – the focal point for the operator’s management of the plant – is where critical advancements can be made. Siemens focuses on making the operator’s job efficient by providing faster response to disturbances, an intuitive design, smooth handling, and reduced chances for unwanted operation. This has a direct effect on the availability of the plant as a whole.

SPPA-T3000 Cue, the new release of Siemens’ distributed power plant control system, has evolved under this operator centric approach. Based on proven technology that has been successfully applied in over 2,700 units worldwide, it is infused with innovations specially designed for effective and efficient operation. By supporting operators with the right tools, targeted cues, and guided procedures for sound operation, SPPA-T3000 Cue provides the platform to increased power plant performance.

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Get the most out of your plant

At Siemens, we have handled power plant engineering, design, and construction in-house for decades; so we are intimately familiar with all the tasks surrounding power plant automation. Having automated more than 2,700 units worldwide over the past 50 years with great success, we have the most extensive automation experience in the power plant market.

Plant automation – the brain of the power plantIn automation, process engineering is cast in bits and bytes. The intelligent use of this data forms the very basis of the availability, reliability, and efficiency of your plant. The SPPA-T3000 design is tailored to power generation – with specific electronic technology, control algorithms, function libraries, and concepts developed on our deep plant expertise, and focused on

time-proven standards. You get automation and controls from power plant experts for power plant experts.

We gained a great deal of experience on the design of a vast power plant fleet

across the globe. And we have translated this knowledge into beneficial control

system technology.

Comprehensive expertise for best-in-class automation

Valuable know-how: Siemens boasts 160 years of experience in the power plant business.

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Market-leading technology: Siemens’ equipment automates power plants worldwide.

Operator in focus: While developing SPPA-T3000 Cue, we put ourselves in the operator’s shoes.

Ultimately, the power plant’s output is formed by thousands of sensors and signals, motors and pumps, drives and fans. The daily responsibility of the operator is to monitor, readjust, and correct all of these components. Smooth periods spent working through the various required tasks can suddenly be interrupted by periods of hectic activity to counter disturbances in the plant’s operation or failures of the plant equipment.

Less is moreIn these situations, operators need to focus on what really matters. They need less raw, unfiltered information. Information floods, unfiltered messages, alerts, or inappropriate analysis reporting simply complicate the operator’s ability to adequately respond to a plant disturbance. Their ability to function in an appropriate manner is supported by a control system which delivers the right information, in the right manner, at the right time.

Features that give cues ▪Accurate information from process engineering – for a comprehensive overview ▪Proactive forecasts of component and process status – to ensure availability and simplify maintenance planning ▪ Inventive alarm handling – to keep the message flood under control ▪ Intelligent help functions – to answer questions intuitively ▪Real-time health display – to evaluate the plant’s condition at a glance ▪Precise handling instructions and direct access to analysis and data – to be able to act, and react, quickly

Operators deserve an HMI that supports them in every manner.

Because it is the operator’s capability to be in control that defines

the performance of the entire plant.

Operator needs for more effective and efficient plant operation

The human factor: A recent ARC study* reveals a huge potential for greater system availability.

* “Minimizing Operational Risk trough Procedural Automation”, Larry O’Brien, ARC Advisory Group, Presentation on 18th Annual ARC Industry Forum, Orlando, FL, 2014-02-11

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SPPA-T3000 Cue offers specific tools for all operator tasks

Operation and monitoring

Running the plant, having the process under control

Predictive assurance of business continuity

Detecting deviations early, analyzing and

initiating remedy

Management of unavoidable incidents

Reacting safely and quickly to disturbances

and failures

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Focus on what really matters

Give your operator the right tools

areas of the daily routine. Highly advanced diagnostic tools visualize detailed facts about the plant systems or specific equipment at a glance. Built-in operations management and shift logs make handovers and scheduling more manageable than ever. All critical information is recorded for all necessary parties, while integrated access reduces the potential for errors or lost information: The user can easily tap into non-local applications, such as maintenance management, equipment diagnostic systems or task lists all from the HMI workplace. So all plant data can be in sight.

Support in the event of an alarmRoutine, daily responsibilities are sometimes thwarted with unavoidable incidents. Pumps fail, motors stop. Often, the things that go wrong are random and unforeseeable. Though controlled safety mechanisms can

A control system that is intuitive to operate – with an HMI that provides the operator with complete control of his plant. SPPA-T3000 Cue, with its ergonomic design, achieves maximum ease of operation, e.g. through:

▪ Information at the touch of a button ▪ Intuitive, icon-based navigation ▪One-click access to important functions and to Siemens’ own and further applications ▪Comprehensive help in the event of faults, such as automatic first-value searching and suppression of subsequent messages ▪Customizable user interfaces geared to the operator’s specific needs

Less stress in day-to-day businessAnalyses, diagnoses, shift handovers, logs and report documentation – these are all time-consuming tasks that get done easier and faster with the right HMI. SPPA-T3000 Cue offers well thought-out support for various

ensure that workers, machines and the environment are safe – the operator must respond quickly and prudently to keep the unit up and running. For these reasons, we have further improved the alarm management. It classifies alarms, directs critical information to the operations, and re-directs unimportant messages to be either archived or dealt with at a more opportune time. The SPPA-T3000 HMI manages torrents of messages and automatically guides the user through root cause analysis in the event of a fault. Alarms and warnings are accompanied by detailed information and guidance for rapid resolution. Special alarm classes, specifically designed to avoid a plant trip or forced outage, include an alarm control window with clear instructions for action – this is ideal for fast, precise action when required to keep the plant running.

You can have confidence that everything is under control when a capable operator can

perform with a cool head. Supported by the control system when the situation calls for it.

Optimized workflows thanks to a clever HMI

Beyond the usual scope of a DCS: SPPA-T3000 Cue facilitates direct access to third-party systems as well as the integration of Siemens’ own or further applications – all in one spot.

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Key Performance Indicators (KPI) are customizable in order to provide optimum support to operators and may include production data, output, emissions values, trend reports on pressures and temperatures, and other values where needed.

Alarm Counts provide transparency about the plant’s situation and allow for quick and targeted reaction. Each alarm class is shown with the numbers of raising, unacknowledged and pending alarms; double clicking opens the alarm class- specific ASD.

“DR“ Diagnostic Recommended is a new message class that detects the status of availability-relevant components by using model-based condition monitoring. It then reports subtle changes before DCS limit values are reached.

Group Alarm Indicators reduce reaction time in critical situations: When an alarm is shown in a Plant Display, it will be indicated in the Group Alarm Indicator. By clicking the alarm class of the Group Alarm Indicators, the operator has direct access to the corresponding Plant Display.

SPPA-T3000 Cue highlights

New alarm classes: ▪Trip Stop ▪Trip Warning ▪Diagnostic Recommended

Wake-up Alarms

Scroll-down Side bar

Buttons to own and further applications

The SPPA-T3000 HMI makes the daily operations and maintenance routine simple, facilitating preparation for component repair. One mouse click takes the user directly to the status display for the damaged equipment; at which point the operator can open the associated Faceplate, deactivate the component and quickly apply the lockout-tagout protocol. Any necessary work can then be easily confirmed with the integrated shift logging, and the appropriate time stamp.

The daily shift handover can be performed very efficiently – if it is managed electronically and intelligently. SPPA-T3000 Cue allows going through the five basic displays: plant overview, alarm sequence display with open alarms, shift schedule with resources, pending repairs, and open tasks. Operators can then load the tasks at the click of a mouse onto the task list for the following shift. This gapless information flow saves time and promotes safety and reliability.

Maintenance routines made easyIdeal shift handover

To control the power plant reliably and

predictively. To recognize discrepancies

early, and – in the worse-case scenario –

to be in position to manage a disturbance.

The operator’s job is to ensure that the

power plant is up and running on a daily

basis, contributing in turn to the plant’s

ultimate success. And operators supported

by SPPA-T3000 Cue are positioned to

manage unfavorable circumstances which,

in turn, promotes increased plant availability

and reduces the chances of unplanned

outages.

Cues and tools for smooth operation

Safe handling of common warningsPreventive condition monitoring

This message might appear during any shift: Warning – the level in the lube oil tank for a feedwater pump has fallen to “minimum”. At the click of a mouse, the operator can access information about the disturbance. Just one look at the status display reveals: The feedwater pumps are intact, but the disturbance relates to the oil level. A quick check shows a fault in the inlet valve. After this has been rectified, the operator enters the activity into the shift log – directly from the workstation. A convenient way to deal with smaller interruptions.

“Diagnostic Recommended” (DR) flashes – attention is advised. This special alarm class detects the status of components by using model-based condition monitoring. The alarm reports unexpected deviations before limit values are reached. With one click, the “DR” simplifies root-cause analysis by showing plain text messages and opening all relevant displays. “Advanced Diagnostics”, a related application, then allows for in-depth analysis. This integrated condition monitoring makes a substantial contribution to increased availability.

The system provides direct access to diagnostic information and clear handling instructions.

Fast reaction in case of alarm Trip Warning with guided procedures Trip Stop for faster reaction

If issues develop with a feedwater pump’s oil supply, a warning message is displayed. Though this is generally a manageable problem, what if the automatic switch- over to the redundant feedwater pump does not respond? In a conventional DCS, the unit would now be lost since time would be too short for a manual switch- over. With “Trip Stop”, a visual and acoustic alarm is issued and clear instructions are displayed together with the relevant Faceplate. Within seconds, the operator can activate the switch manually to attempt to rescue the unit.

A trip-relevant disturbance occurs – a feedwater pump has failed. Operators now need the right information, fast. The alarm class “Trip Warning” of SPPA-T3000 Cue crucially channels their attention and their scope of action. It triggers visual and acoustic alarms. The operator can quickly request context-relevant information on predefined scenarios containing specific details of the cause and precise guidance about what to do. Consequently, they can take fast action to avert a trip.

Alarm! The oil level has decreased again – this time below “minimum”. Just one click and the system status display shows the protection-off function of the lube oil pump for feedwater pump #1. The indication: The feedwater is still running, but the lube oil pump is expected to fail shortly. The loss of a main unit is critical. Normally, the operator will now reach for the telephone and send service an alarm message. During the call, the fault might escalate and a “Trip Warning” will appear. The response time is limited.

Make security a top priority

plant and corporate world just as secure as the connection to external service partners and the central fleet management.

Innately high level of securityIn stand-alone operation, not connected to intranet or Internet, SPPA-T3000 is proven to operate securely without additional measures. Hardening and protocol changes between the application, the automation, and the field level speak volumes for the security of SPPA-T3000. The system is designed to block intrusions and report attempted intrusions electronically. Regular updates in the form of patches and checks maintain this high level of security.

Essentially, SPPA-T3000 supports all relevant protocols of power plant automation.

* ISO 27019 = Standard for critical infrastructure DMZ = Demilitarized Zone NIDS = Network Intrusion Detection System VPN = Virtual Private Network

Secure communication into internal and external networks, access to third-party systems using a specially qualified terminal server, the integration of internal and external systems – SPPA-T3000 is designed for the highest demands on communication security and openness. It supports common standards in industry communication as well as future-oriented IEC standards. Traditional control systems based on proprietary protocols can be connected to the HMI, and individual HTML or RDP applications can be accessed within the operator’s work environment. SPPA-T3000 opens up a world of communication opportunities.

Versatile protective barriersThe comprehensive security zone architecture of SPPA-T3000 is based on the relevant cyber security standards from NERC, VGB, and ISO*. In addition, the clearly structured DMZ*, NIDS*, firewalls, terminal servers, and VPN* encryption, make communication with the

A control system that is easy to operate should be just as easy to integrate. Its connections

should be just as open to variable protocols as they are barred against unauthorized access.

Flexible connectivity plus built-in security

Uncompromisingly secure: SPPA-T3000 communicates with internal and external systems via a vast variety of protocols.

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Rely on enduring business continuity

During the life of a power plant, power producers can benefit from control system migrations and upgrades. These investments pay dividends and are readily accepted, providing the system is designed to accommodate such updates – by keeping a maximum of the existing hardware, by maintaining the engineering data, and by minimizing outage time.

Durable investmentThe advantages of a state-of-the-art system strategy are obvious: With Siemens power plant control technology, you can bank on investment security for the lifetime of your plant.

The goal is to keep your power plant running reliably throughout its lifetime.

We support this with a control system that is designed to last.

Constantly up to date with a lifetime strategy

One HMI for everything: Vintage and recent control systems are seamlessly united under the SPPA-T3000 HMI.

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Evolving progressSiemens designs systems for the entire lifetime of a power plant. Upgrades, migrations and concepts for the transition to new technologies are an integral part of our system development from day one. The possibility to run different generations of control systems in parallel provides the flexibility to tailor life cycle concepts to your requirements. Our innovations and technical advances are designed to be integrated without system interruption providing operations benefit from gradual transitions.

Retaining hardware platformUsing the operator-centric approach, a conversion to SPPA-T3000 Cue can often be easily carried out as an upgrade: without re-engineering, without the need for new optimizations and certifications, without making any changes to the automation systems, and in many cases without updating hardware at the HMI level.

Engineering data retained: When introducing a new generation of automation devices, data transfer minimizes effort.

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On site, fast: Our teams for spare parts, troubleshooting or engineering service can be at your plant quickly.

Comprehensive service: You get the support you need – no matter when or where.

Of course, problems sometimes arise at the least convenient time: for example, at night when engineering and maintenance personnel are not available. To support your on-site staff, we have Remote Expert Centers (RECs) on three continents available around the clock, 365 days a year. And with an average problem-solving time of less than 60 minutes, Siemens experts are the best in their field.

System specialists for full serviceRemote Expert Centers provide direct access to qualified system specialists: project managers, developers and experienced engineers who have an in-depth knowledge of the system and the plant in question. When necessary, they can hook up to the plants – over specially secured lines – to diagnose and rectify a fault. They organize spare parts, provide engineering support, and install updates. But above all – and this service is growing in popularity – they take preventive action to reduce the likelihood that the need for traditional emergency service will arise.

Siemens’ system specialists support you – resolving your specific problems before they

become serious. So your on-site personnel can keep a cool head – at any time.

Contracts for your individual needsRegardless of how you use our services – to promote availability, as a leverage for minimizing maintenance costs, or as a task force that augments your staff when most needed – Siemens’ in-depth service is exceptional in every way.

Prescribed availability by our 24 / 7 service for life

Spare Parts LogisticsInvesting only what you need when you need it

Regional Service CenterYour local task force at your site

Remote Expert CenterPeace of mind when you need it

Field EngineerOn standby

for all events

Online CommunicationKnow-how as if we were there

Get the care your business deserves

Published by and copyright © 2015: Siemens AG Power and Gas Freyeslebenstrasse 1 91058 Erlangen, Germany

For more information, please contact sppa-t3000.energy@siemens.com siemens.com/energy/sppa-t3000

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Subject to change without prior notice. The information in this document contains general descriptions of the technical options available, which may not apply in all cases. The required technical options should therefore be specified in the contract.