die zellstoff- und papierindustrie als vorreiter der ......distributed control system (hardware and...

Restricted © Siemens AG 2018

Dr. H. SchwarzUnrestricted © Siemens AG 2018

Die Zellstoff- und Papierindustrie als Vorreiterder Digitalisierung in der Prozessindustrie

Jahrestagung der Vereinigung der Gernsbacher Papiermacher e.V.Gernsbach am 4. und 5. Mai 2018

Restricted © Siemens AG 20182018-05 H.Schwarz / PD SLN FI

Agenda

Digitalization1

Advanced Process Control, on-site solution2

Control Performance Analytics, off-site solution3

Mindsphere, cloud based open platform4

Outlook5


Managing Board

Siemens since October 2017/18Flat and market driven organization along the value chain

1) Commonwealth of Independent States

Corporate CoreCorporate Services

Americas Middle East, CIS1) Asia, AustraliaEurope, Africa

Div

isio

ns(G

loba

lP&

L)G

o-to

-mar

ket

2018-05 H. Schwarz / PD SLN FI


Process Industry and Drive

Siemens offers the most comprehensive portfoliofor Process Industry and Drive

• Helical gear units• Bevel-helical gear unit• Planetary gear units• Application specific gear units for

industries• Couplings• Gear units and couplings services, spare

parts

• Closed ring power system (drilling)• BlueDrivePlusC™ diesel electric

propulsion system (drilling and marine)• Pipeline solutions• Tankfarm & refinery solutions• Fiber-, mining- and cement industry

Systems and solutions• Off shore & on shore production

solutions

• Low voltage motors and low voltageconverters

• High voltage motors and medium voltageconverters

• Motors, converters, control units andgears for traction, including rail, hybriddrives and mobile mining

• Wind generators• Products, solutions and systems

for cranes• Hydrogen solutions

• Distributed control system (hardware andsoftware) and plant engineering software

• Process instrumentation for flow, level,pressure, temperature, weighing andpositioners

• Process analytics and analyticalsolutions

• Wired and wireless industrialcommunication, rugged communication

• Industrial identification• Industrial power supplies

Large DrivesProcess Automation Mechanical Drives (Separate) Process Solutions

Integrated drive systems

Life cycle services

Portfolio for cement, chemicals, cranes, fiber industry, food & beverage, glass & solar, marine, mining, oil & gas, pharmaceuticals, water


PD SLN FI (P&P)


Fiber Industry – a Process Industry demanding integratedsolutions and a complete product portfolio

Power Generation Process Control System Integrated Engineering Integrated Service Data Analytics

Power Distribution, MotorControl Centers, Drives

Instruments Quality Control Sectional Drives Process MotorsGear Units


SIPAPERDrive Systems

SIPAPER Drives APL

SIPAPER Winder APL

FLENDER Gear Unitsfor SIPAPER

SIPAPEROperations

SIPAPER Services

SIPAPERProcess Automation

SIPAPER DCS APL

SIPAPER QCS APL

SIPAPER DPO

SIPAPER PPA

SIPAPERPower Distribution

SIPAPER Power

Drive TechnologySINAMICS, SIMOTICS, FLENDER, .

Industrial AutomationSIMATIC, SIPLUS, …

Energy ManagementSIMOCODE, SIVACON, SIPROTEC, ...

Industry ServicesLife Cycle Services, Plant Data Services, …

Driving the Digital Enterprise in the Fiber Industry– with SIPAPER!

World-class products + perfectly matching, industry-specific modules

The SIPAPER Portfolio

Integrated SIPAPER Solutions


Digitalization is the next level to yield productivity in theprocess industry

Time

Technology is readyData AnalyticsComputing PowerConnectivitySensors

DigitalizationNext level ofproductivity

AutomationSiemens as experiencedpartner for Automationand Electrification

Pioneer for Electrificationin industry

Electrification

6/1/2018 Schwarz / PD SLN FI PPM


Agenda

Digitalization1

Advanced Process Control (APC), on-site solution2



Outlook5


Digitalization will speed up changing the entire industry!

The megatrend Digitalization …

• covers all areas of consumer life…• will continue to change the entire industry sector (products, business

models) in a disruptive and sustainable manner!

Current drivers of Informationand CommunicationTechnology

• Computing power

• New sensors• Virtualization• Cloud computing• Ubiquitous

networking• Simulation• Augmented reality


End User behavior is radically changingbased on new business models


Value creation processes are radicallychanging based on new distribution


Products are augmented digitally for differentstakeholder along their entire lifecycle


Massive pervasion of technologies driven byexponential growth of computational power


Future challenges in industry

• Shorter time to market• Increased flexibility

in volatile, heterogonous,global markets

• Optimized productivity• Energy and resource

efficiency• Mitigation of

demographic change• Continuous, safe and

reliable operations

Digitalization is key to provide answers to futurechallenges in industry

DIGITALIZATIONResearch areas

• Horizontal integration of thevalue-add networks

• Vertical integration andnetworked production systems

• Seamless integration of theengineering along the entirelife cycle

• Cyber Physical Systems (CPS)• Reference architecture model• Integration of human creativity

and innovativeness


The Cornerstones of Industrie 4.0 also address challengesin process industries

*) Source: acatech, April 2013 “Umsetzungsempfehlung für das Zukunftsprojekt Industrie 4.0”

Cyber Security / Industrial Security

Seamless interoperability and communication based on standards

Optimization of resources alongvalue-add networks from raw materialsto product• Remote operations via Internet• Cloud computing• Data driven services, e. g. predictive

maintenance

Increased flexibility and optimizationof production in volatile and globalmarkets• Integrated Operations• Plant Asset Management• Seamless interoperability (Plug & Produce)• Decision support / assistance systems

Cutting engineering time throughconsistent data storage along plantlife cycle• Integrated Engineering• Augmented Reality• Digital Twin of the “as-is”-plant status• On-site training simulation

Modelling and Simulation

Horizontal integration through value-addnetworks*

Vertical integration and networkedproduction systems*

Seamless integration of the engineeringalong the entire life cycle*

Industrie 4.0 is originally driven by discrete industries but also valid for process industries with a specific interpretation


Siemens Calls its way to Industrie 4.0 the Digital Enterprise.Comprehensive Portfolio for the Digital Enterprise in process anddiscrete industries

Digital Enterprise

Productdesign

Productionplanning

Productionengineering Production ServicesProduct

designProcess &plant design

Engineering &commissioning Operation Services

Discrete IndustriesProcess Industries


Siemens portfolio for Digital Enterprise covers complete lifecycle

Digital Enterprise

Productdesign

Productionplanning

Productionengineering Production ServicesProduct

designProcess &plant design

Engineering &commissioning Operation Services

COMOS COMOS

Communication / Security Communication / Security

SIMATIC PCS 7 / SIMIT SINUMERIK Integrate

Data Driven Services /XHQ / ASM Data Driven Services

Manufacturing Execution Systems SIMATIC IT

Automation / Drives PortfolioTIA PortalPIA Selector Automation / Instrumentation andDrives Portfolio

TIA: Totally Integrated Automation

Teamcenter

NX TecnomatixMCD

Digitalization ⇓ Different forms in industries

Discrete IndustriesProcess Industries


Breadcrumb⇓ Topic

Siemens realizes Digital Enterprise for Process industriesthrough Integrated engineering to Integrated operations

Digital Enterprise for Process Industries ⇓ Focus of Siemens

Integrated Engineering optimizes engineering and life cycle management …

… Integrated Operations improves productivity and flexibility

Cloud-enabled services and analytics

Next generation of control systems

Digitalization at field level

Reliable connectivity

Simulation

Common data model

Integrated engineering tools

Product design Process & plant design Engineering & commissioning Operation Service



SIPAPER Process Automation –COMOS, SIPAPER DCS APL CMTs, SIMIT and CPAS – a real example

COMOS

Seamless integration of engineeringdisciplines, steps and tools

H.Schwarz / PD SLN FI

SIPAPER DCS APL

SIMIT

CPAControl Performance Analytics - Details

COMOS MRO

Pumpenbeispiel Bentley


Agenda

Digitalization1




Outlook5


Automation HierarchyISA 95 Level Definitions

H. Schwarz / PD SLN FI2018-05

DCS/QCSDistributedControlSystem

Raw materials paper

Level-2-SystemModel-based online simulation and optimization

Prod

uctio

nC

ontr

olLe

vel

MESManufacturingExecutionSystem

Invoices

ERPEnterpriseResourcePlanning

Orders


SIPAPER APC DrySec – Functioning of level 2 system

Process model

Model coefficients(plant specific)

Operator input (e.g. limits)

Leve

l2sy

stem

DC

S/Q

CS

Measurementvalue

preprocessing

Modeladaptation

Optimization of energyconsumption• At steady-state production

conditions

Process monitoring• Detection of saving potential• Value consistency Measurement

Physical model

Sensors


SIPAPER APC Bleach – The level 2 system

Standpipe

Press

Bleach TowerDead Time 1 (2-3 Min.)

SpecifcEnergy

Brightness afterBleach Tower

SIPAPER APC Bleach

PeroxideNaOH

Levelƒ Brightnessƒ Flowƒ…

Dead Time 2 (50-70 Min.)

Dosage

Brightness

Disperger


SIPAPER APC Bleach – Reliable quality with optimized chemical consumption


Set point for peroxide dosage Set point for dithionite dosage

SIPAPER APC Bleach – Coordination of two bleaching stages

Process values

Set point brightness (calculated) Set point brightness (from operator)

Process values

Coordination

I. III.II. IV. VI.V. VII.

Pre-flotation

Inkremoval 1

Disperser-bleaching 1

Peroxidebleaching

Disperser-bleaching 2

Dithionitebleaching

Post-flotation

Inkremoval 2


Sensors / Actuators

SIPAPER APC – Integration into DCS system

Level-2 PC• Operation & monitoring

• Engineering Station Terminal bus(office Ethernet)

DCS Server 1 .. x(redundant)

Mill bus(fast) Industrial Ethernet

AS 1 AS 2 AS x…

Operator Station 1 ... n

PROFIBUS-DP

Communication to any DCS:• OPC• Profibus• TCP/IP• Modbus• ...


APC is more and more becoming commodity

PLC

IntroS5

IntroS7

CommodityData processing

Time1980 1990 2000

DCS

IntroPCS 7

APC

APC inPCS 7

2010


The right tool for the right job:Improved Process Control through embedded APC

Industrie 4.0 use case – Optimizing operation: Embedded APC with SIMATIC PCS 7Initial situation Full flexibility

Value-add• Powerful controllers allow more embedded functionality and capabilities• Set of functionalities available depending on application:

• PID Tuner• Gain scheduling, override control, disturbance compensation, Smith

Predictor• Model Predictive Control (MPC (4x4) or MPC10x10)• APC interface blocks with watch dog, central switch-over, etc.

• Control- and equipment modules (CM, EM), unit templates with APC

• Realize economic plant potential• Reduced variability• Reduced energy and raw material• Increased quality and throughput• Increasing trend

Variations

Challenges

SeparatePC

(External)

DCSintegrated(Embedded)

• Low barrier for small applications

• Sophisticated functionality for large applications

• Standardized across the company with central support

• High availability and same look and feel in operation

• Reduced cost of technology (design, implementation)

• Low lifecycle cost (e.g. Migration, transfer to other units)

• Low training expense

APC interface blocks with all functions for external solutions

customer solutions3rd party software

Challenges

Value Proposition


Agenda

Status1




Outlook5


Cost Efficiency through a Managed Service ApproachProcess Data Analytics

Customer

Siemens

Visualization andrecommendations

Secureconnection

Data analyticsand simulation

Consulting andimplementation

support

Secureconnection

Datacombinationand securestorage


Optimized process based on transparent controlperformanceProcess Data Analytics

• Long-term plant overview on controlperformance of all control loops

• Visualization of important indicators forprioritized optimization actions

• Stiction* recognition KPI

• Analytics of historic data from 3rd partyDCS

* static friction

• Detailed information on controlperformance of each single loop

• Detailed KPIs for varying time frames

• Visualizes process data and characteristicdiagrams like scatterplot, FFT spectrum,cross correlation for stiction recognitionetc.

Provides expert statements about theperformance of individually analyzed controlloops on request

• Optimized control parameter forincreased control loop performance

Performance Reporting Characteristics Reporting

Optimization Reporting Consultants Report


Continuous Process Improvement with SiemensProcess Data Analytics

PDAData Collector

Customer Siemens

Process Plant with PCS 7 DCS

User Transmission Mode

System Transmission Mode*

SiemensCloud for Industry

Raw Data Analytics

Process Industry Experts

Consultants Reports& Expert Consulting

Reports &Recommendations

Improvement

Realization

Quality

Transparency

* Development


Control Performance AnalyticsControl Loops Optimization as Part of Managed service

…. only 50 % control loops are optimized1)

1) Source: Control Engineering

Percentage of not optimized control loopsat…

• Pulp Mill in Sweden 61 %

• Pulp Mill in Finland 77 %

• Paper Mill in Sweden 83 %

• Paper Mill in Germany 86 %


Process EfficiencyMaintain Mill Operability Industry Security

Machine Tool Analytics

Drive Train Analytics

Control PerformanceAnalytics

Dynamic ProcessOptimization

Industrial NetworkAnalytics

Process Event Analytics Implement Security

Manage Security

Assess Security

Siemens Value ServicesPlant Data Services

Energy efficiency

Energy Analytics

Already available Roll Out Process

Mind your digital future

MindSphere – SiemensCloud for Industry


Funktionsprinzip DPO

Optimierungsablauf1. Aufnahme von Messdaten2. Modellierung des stationären Zustands3. Optimierung eines gewählten

Optimierungsziels unter Einhaltung vonProzess-Nebenbedingungen

4. Ausgabe eines Sollwertvorschlages5. Übernahme oder Änderung des

Vorschlages6. Bis Optimum erreicht weiter mit 1.

0100

1110

1010

1100

0001

0100

1010

011⇒

1001

0010

0100

10⇒

0000

1010

1000

1010

0010

1010

1010

0101

0101

0101

011⇒

Sollwert-vorschlag

Sollwerte

Ι10101010001000100110111101100100100101110011110110101010010101010101010101010101010110001

Prozess

Kontrolle,Anpassung,Ablehnung

I II IIIDisV

SP

ProV

Modell-generierungOptimierer

Optimierungsziel& Nebenbedingungen

DPOiterativ

Black-box Betrachtung

Automatische I/O Modellgenerierung

Kleine, sichere ÄnderungsschritteKontrolle bleibt beim Anlagenfahrer

Flexible Anbindung via OPC

Stationäre Zustände im laufenden Betrieb


Agenda

Status1




Outlook5


Optimization of plants and machinesas well as energy and resources

• Open standards for connectivityof Siemens and Third-party products

• Plug & play connection of Siemens products(engineering in the TIA Portal)

• Cloud for industry with open applicationinterface for individual customer applications

• Transparent pay-per-use pricing model• Opportunities for completely new business

models (e.g. selling machine hours)

MindSphere – an open cloud platform for the Industry



Digital Fiber Initiative – Forming an Ecosystem of differentpartners contributing to the evolution of Digitalization

TechnologyProvider

ConnectivityDeveloper

Go-2-MarketPartner

AppDeveloper

OEM

PlantOperators

10010111

10010111

10010111

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1001

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001110010011

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New fiber applicationsProcess SimulationVirtual commissioningOperator training

Process AutomationRemote Monitoring

Process Analytics &Optimization

Digital EnterpriseSoftware

to Integrated OperationsFromIntegrated Engineering

6/1/2018 Hofmann / PD SLN FI PPM


Participation in the Ecosystem – The contribution of everysingle member is key to success

Consulting / Strategy partners• Provide digital transformation services

based on MindSphere

• Develop vertical apps

Application Developer / ISV• Develop vertical apps

• Sells apps based on MindSphere

System Integrator• Connect other enterprise systems on

the cloud (ERP, CMMS, etc.)

• Provide connectivity & implementationservices

Technology Partners• Enhance capabilities as well as adoption of

MindSphere platform utilizing analytics, AI &Big Data

Hybrid OT Partners• Partners from automation, instrumentation

background who will develop IoTapplications and provide services

Connectivity Partners• Develop connectivity into products

• Sell connectivity products

MindSphere

10010111

01001110

10010111

10010111

10010100

01001110

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001001

1001011101

10010100

001110010011

10010111

100101110010

MindApps

Optimization of the performance of assets, energy and resource consumption,maintenance, services…



10100011010011010011001011000011101010110011010101011100010011010010010

01100011010011010011010010110000

10100011010011010011001011000011101010110011010101011100010011010010010

01100011010011010011010010110000

Open ecosystem of applications

10100011010011010011001011000011101010110011010101011100010011010010010

01100011010011010011010010110000

10100011010011010011001011000011101010110011010101011100010011010010010

01100011010011010011010010110000

10100011010011010011001011000011101010110011010101011100010011010010010

01100011010011010011010010110000

10100011010011010011001011000011101010110011010101011100010011010010010

01100011010011010011010010110000

SINAMICS

SIMATIC

PCS 7

SINUMERIK

SCALANCE

Third-party products

101 00 011101 00 011 101 00 011

€

101 00 011End customer Apps

MindSphere Apps

OEM Apps

Developer Apps

App Store

Own Apps


Field devices

Siemens Software and Digital Services

AnalyzeMyDrives

OmnetricPlanning

and OutageIntelligence

EnergyManager

Pro

GridDiagnostic

Suite

MindConnect

EdgeAnalytics

AnalyticsStarter Kit

Enabler: Infrastructure as a Service (storage, processing power, provider agnostic)

MindSphere The cloud-based, open IoT operating systemPlatform as a Service

Siemens Software and Digital Services –operational or soon to be released on MindSphere

ReclaimBelt

Monitoring

Manage MyMachines

O²M – OrderOEE

Monitor

ProductIntelligence

DriveSystem

AnalyzerSimotics IQ

Electrifica-tion FleetManager

Dock andYard Mgmt

LogicalOperationsManager

(LOM)

ConditionAnalyzer forProd. Mach.

SIDRIVE IQSecurity

VulnerabilityInformation

Climatix IC BuildingOperator IC

SmartThermostat Synco IC

Manufac-turing

Intelligence

SIMATICPerformance

Insight

SIMATICMachineInsight

SIMATICMachineMonitor

SIMATICEnergy

Manager

SIMATICNotifier

Railigent1) EnergyIP1)Navigator)

(82 serviceapps)

1) Application suite powered by MindSphere

Manufac-turing

Performance

> 100 inpreparation

SIRIUSApp


Digitalization Maturity Assessment –The SIPAPER first step in the digital transformation

Customer-centric approach• Top-down• Holistic and multi-disciplinary

Assessment of the whole value chain• From Product Design to Services

Industry-specific approachAddressing the challenges and the states of the art in the industry

Your benefits• Overview of your company digital maturity• Benchmark based on industry data• Easy access to dedicated consulting


Restricted © Siemens AG 20182018-05 H. Schwarz / PD SLN FI

Outlook

Main target is to stay competitive in global markets1

In many branches and levels Digitalization is in progress already,Pulp&Paper is advanced in the Process industry compared to others2

Digitalization tools are on the market and integrated already in theprocess industry and discrete manufacturing3

4

On-site and Off-site solutions are applicable5

6

APC is becoming more and more commodity – and is merged at the same DCS level

Data is becoming more relevance than hardware to generate more value

siemens.com/sipaperUnrestricted © Siemens AG 2017

Thank You!

Dr. Hermann SchwarzProduct Manager TechnologyPD SLN FI PPMWerner-von-Siemens-Str. 6091052 ErlangenGermanyPhone: +49 9131 7-42917Mobile: +49 173 7031762E-mail: [email protected]

die zellstoff- und papierindustrie als vorreiter der ......distributed control system (hardware and...

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