Download - process news - Siemens · 35 Dialogue. process news | 3-2008 3 Editorial ... intelligent Sipart PS2 positioner, or with an add-on product for the Simatic S7-400FH safety system, allow

Integrated solutions for asset management

A Turn Toward Greater Effi ciency

processThe Magazine for the Process Industry

Volume 13, Number 3, 2008

news

C o n t e n t s

p Cover

Asset Management 4 Proof of Performance

Infracor, Germany

7 Pump MonitoringKSB, Germany

8 Optimized OperationRWE, Germany

12 Right on TrackRFID

p Technology

Process Control 14 Reach Far, Know More

Telecontrol

16 APC Made EasyAdvanced Process Control

p Industry

Water 18 Steady Flow

Veolia/SIDEM, Bahrain

Chemicals 20 Full Circle

Evonik Industries, Belgium

Siem

ens

AG

Siem

ens

AG

CSL

Beh

rin

g

The new pump test bench at Infracor in Marl, Germany, improves pump maintenance services and supports new approaches in training and qualifi cation

Page 4

Simatic PCS 7 TeleControl enables the fl exible integration of distant substations into a uniform and seamlessly integrated automation solution

Page 14

The HMI level of two existing process control systems at CSL Behring was migrated to Simatic PCS 7 in a mere six weeks

4

p r o c e s s n e w s | 3 - 2 0 0 8

2 process news | 3-2008

Food & Beverage 22 Fresh with Technology

Granarolo, Italy

Pharma 24 Qualifi ed Upgrade

CSL Behring GmbH, Germany

26 Less Is MoreEnergy Effi ciency

Solar 28 Sunny Side Up Conergy AG, Germany

Water 30 Fresh Water Technology

Aguas de la Cuenca del Segura S.A., Spain

Infrastructure 32 Sinamics Steams It Up

Valorec Services, Switzerland

34 In Brief

35 Dialogue

process news | 3-2008 3

E d i t o r i a l

Dear Readers:

Every production facility has countless assets: simple ones such as vessels, tools, and valves, but also complex units such as entire reactors and machines, and each has its own specifi c requirements for maintenance and repair. This issue of process news focuses on the topic of asset management because integrated solutions for asset management are indispensable for cost-effective and reliable production.We have extended the asset management functions so that all the important components for the plant are integrated into the monitoring and control process. This is a signifi cant step that helps increase our customers’ competitiveness by signifi cantly reducing lifecycle costs.Mechanical assets such as pumps play a central role in the process industry. We have developed special asset management modules for pumps, which can be smoothly integrated into our Simatic PCS 7 process control system. These modules allow the user to ascertain the current condition of a pump – an important prerequisite for preventive maintenance.The application at Infracor, which is described on page 4, is one example of how plant operators benefi t from this functionality.But asset management also plays an important role in the operation of distributed systems. RWE, for example, benefi ts from a gas store being integrated into the master control system at the company headquarters via the asset management functionality of PCS 7. See page 8 for more about this application.We hope that these and the other articles in this issue of process news will provide interesting ideas and valuable suggestions.

Miguel Fernandez

Competence Center ChemicalsSiemens Industry


Phot

os:

Sie

men

s A

G

Erosion damage on a pump impeller: personnel can be trained to avoid such problems on the new pump test bench

C o v e r A s s e t M a n a g e m e n t


A s s e t m a n a g e m e n t w i t h P a r t i a l S t r o k e T e s t

The Partial Stroke Test (PST) is used mainly in the course of checking plant safety to verify and maintain the function of safety valves. But the PST is also suitable for automatic and systematic testing of normal valves without disturbing plant operation. The results of the PST with the intelligent Sipart PS2 positioner, or with an add-on product for the Simatic S7-

400FH safety system, allow an estimation of the current valve condition and can be integrated into PCS 7 asset management so that the valves are included in the consideration of overall plant availability and the planning of maintenance measures.

as to reduce maintenance costs and redundancies. On the basis of this strategy, Infracor decided to install a new pump test bench that was developed and imple-mented in close collaboration with Siemens. The pump test bench is automated with the Simatic PCS 7 Box compact process control system, including the latest asset management functionality for pumps.

Infracor, Germany p

Proof of Performance

Marl Chemical Park is the third-largest inte-grated chemical production site in Ger-many. Thirty companies cover an area of

approximately two and a half square miles, including such well-known names as Evonik, Sasol, Vestolit, Ineos, and Lanxess. Marl Chemical Park is operated by Infracor GmbH. Infracor provides infrastructure and a full array of other services for chemical and related companies operating at the chemical park, ranging from custom-tailored services to support for com-plete production processes to the operation of com-plex chemical production facilities. The comprehen-sive infrastructure and services are grouped into four divisions: Supply and Disposal, Technology, Logistics, and Site Management.

Services for greater performance

The extensive range of services that Infracor offers its customers at Marl Chemical Park also includes mea-sures for maintenance, plant revision, and plant sup-port. Infracor continuously improves its services to be able to offer its customers optimum support at all times. The company is responsible for the mainte-nance of about 20,000 pumps at Marl, of which about 6,000 are repaired annually by the pump service. The next step of development is the new fully automatic pump test bench.

More service for pumps

Infracor analyzed the challenges and trends in the market based on customer requirements. The aim was to use innovative solutions to continuously in-crease the availability of the production plants as well

With a new pump test bench that makes use of the asset management functions of Simatic PCS 7, Infracor optimizes and extends its range of services for pumps at Marl Chemical Park.


A n o v e r v i e w o f t h e t e s t b e n c h

For all pumps up to a hydraulic performance of 100 m 3 3/hAdjustable in height for pumps of different sizes 3Different fi ttings to enable the correct mechanical connection 3of the pump to the hydraulic circuitSimatic PCS 7 Box with Simatic PDM (for parameterization and 3diagnosis of the process instruments)Demonstration of the versatility of the control technology for 3training purposes based on three connection variants for the process level:

uProfi bus uProfi bus PA (connected to Profi bus line with DP/PA link) uEx-safe connections with ET 200iSP (via Profi bus)

Pump drive with 500V/63A (45 kW) Siemens Loher motor, 3control with Simovert Micromaster 440Sitrans P for measuring the input and output pressure before 3and after the pumpHydraulic fl owmetering at the output of the pump with Sitrans 3F MAG 6000 and MAG 5100 W measuring sensorSipart PS 2 positioner for controlling the valves for maintaining 3the operating pointsSiwarex load cell weighing technology and Siwarex U measuring 3transducer module on the water tank

infocontact

www.infracor.de/[email protected]

Siem

ens

AG


Asset management for pumps with PCS 7

The heart of the process automation in the pump test bench is the asset management via the PumpMon and AssetMon function modules that are integrated into Simatic PCS 7. The PumpMon module enables exist-ing process data that characterize the operating sta-tus of a pump to be prepared in such a way that they provide information about the current status, condi-tion, and hydraulic performance of the pump. With the AssetMon module, the information relevant for asset management can be interpreted and passed on from process data and calculated data.

This allows additional quality certifi cations to be carried out on fl ow machines, in addition to the pre-vious pump tests in which only the classic mechanical parameters are determined. The PumpMon module can measure and document the hydraulic perfor-mance and therefore the current condition of a pump in detail. “And that is precisely the advantage of the project for our technology. The quality certifi cations on fl ow machines are another component in our range of integrated services,” says Infracor’s managing di-rector, Andreas Bonhoff.

For example, the new test bench enables the confor-mity testing of new pump types with the manufactur-er’s data before they are installed in a production plant for the fi rst time. In addition, the exact perfor-mance of a pump can be documented after a repair, ensuring that the repair was successful and the pump is performing again as desired.

Advantages for qualifi cation and training

The employees also benefi t from the new pump test bench in terms of qualifi cation and training. The pump can be put in a cavitation state with a manual throttle in the water line for demonstration purposes, for example, so that the personnel can become famil-iar with detecting and avoiding this undesirable op-erating condition.

The installed Simatic PCS 7 process control system, with its different connection variants, also serves as a training system in the fi eld of process control technol-ogy. “The Pump Competence Center now offers even more intensive preparation for future maintenance and production specialists. At the same time, the fur-ther training options for company staff are extended so that our experts are learning continuously,” ex-plains training manager Hans Jürgen Metternich. p

infocontact

www.siemens.com/[email protected]


KSB, Germany p

Pump Monitoring

W ith sales of more than 1.7 billion euros, the KSB corporation is one of the leading pro-viders of pumps, fi ttings, and associated

systems. As the largest German pump manufacturer, KSB had a great interest in fi nding synergy potential with Siemens as an automation provider, to the ben-efi t of their common customers.

Pumps as part of asset management

Pumps are among the most important assets of a pro-cess plant. They are exposed to high stress and wear that is often hard to predict. Failure of a pump often means failure of the entire production plant, causing damage that is many times the value of the pump. In-tegration of the pumps into the monitoring and re-porting functions of the process control system is therefore highly desirable. For this reason, modern pumps often already have an integrated control or regulation, although integration into a master pro-cess control system frequently still requires expen-sive individual programming work.

For this reason, KSB and the experts at the Siemens Competence Center Chemicals developed a plug-and- play solution for integrating KSB pumps into the Simatic PCS 7 process control system to further sim-

plify asset management and minimize the engineer-ing effort required to integrate the KSB PumpDrive into the control system.

Simple integration of relevant information

The solution uses the standard Profi bus connection of the PumpDrive and an appropriate PCS 7 component. This enables the KSB pumps to be operated, visual-ized, and monitored easily by Simatic PCS 7. Pump di-agnostic messages, such as those indicating faults in the drive or a blocked feed, are sent to PCS 7 and pro-cessed there, so they can be displayed in the system with a uniform look and feel, indicated as alarms, logged, and archived. In addition, process values such as fl ow or current consumption are displayed on the standard operating screens of the process control sys-tem and visualized or archived as trends. These val-ues are therefore also available for further processing in master systems. p

KSB and Siemens are jointly developing a plug-and-play solution for

integrating KSB pumps into the Simatic PCS 7 process control system.

infocontact

www.siemens.com/chemicalsthomas.mueller-heinzerling@[email protected]


RWE, Germany p

Optimized OperationThe control technology of a gas cavern storage facility was brought

up to date with the Simatic PCS 7 process control system, including asset

management. The system ensures high facility availability.



RWE Westfalen-Weser-Ems AG, headquartered in Dortmund, is a regional company of RWE Energy and the biggest integrated electricity

and gas utility in Germany next to its sister company, RWE Rhein-Ruhr. As an energy services provider, RWE Westfalen-Weser-Ems is an important investor in and operator of the regional energy infrastructure. The company also plans and operates storage facilities for natural gas. One gas cavern storage facility of RWE Westfalen-Weser-Ems, with 10 caverns and a geomet-ric volume of approximately 3.4 million cubic meters

RWE

at present, is located in the German town of Epe, near Gronau and the Dutch border.

From early 2006 to early 2008, RWE Westfalen-Weser-Ems invested in the extensive renewal and ex-pansion of the plant automation. The old automation system was replaced by Simatic PCS 7, Version 6.1, and the existing low-voltage switching system was re-placed by a Sivacon switching system built in Leipzig. The project was successfully carried out by the certi-fi ed Simatic PCS 7 specialist Elpro GmbH of Berlin. “We placed great emphasis on familiar, proven strat-

E p e g a s c a v e r n s t o r a g e f a c i l i t y

Aboveground installationsGas processing plants (drying, preheating, metering) 3Buildings (functional building, compression halls, heating house) 3Cavern operating stations (automatic measuring and control 3installations, safety technology, inhibition systems)

Technical data of the aboveground systemGas injection:

Compressor plant: 3 two-stage piston compressors, 3total feed power 160,000 m3/hCompressor drive: 3 speed-controlled synchronous electric motors 3of 3.7 MW each

Retrieval:Retrieval lines:

Line I + II + IV: 140,000 m 3 3/hLine III: 240,000 m 3 3/h

Gas preheating:Heat pool: 3 x 4.5 MW, 1 x 8.9 MW 3

Gas drying system:3 absorption columns with 1 regeneration plant each for glycol: 32 plants with a capacity of 140,000 m3/h and 1 plant with a capacity of 240,000 m3/h1 vortex tube dryer = 140,000 m 3 3/h (Line IV)

Underground installationsCaverns:

Drilling rigs (vertical/defl ection drill rigs, pipe strings, cementations) 3Drill completion (production line, sealing and suspension 3installations, etc.)

Store horizon:Werra rock salt (late Permian) 3Depth approx. -1,400 m 3

Cavern parameters:10 caverns 3Geometric volume approx. 3 million m 3 3

Working gas volume 480 million m 3 3

Cushion gas volume 80 million m 3 3

Reservoir pressureMaximum 230 bar, minimum 55 bar 3

Geological composition of the gas storage caverns in the salt dome of the northern Rhine region

(illustration shows the Xanten facility)


RWE

egies and display methods to ensure that the new sys-tem would also be accepted by the operating person-nel,” explains Wilhelm Dreyer of Elpro GmbH. “So we combined the performance tests that we carried out at our facilities with the operator instruction courses prior to the implementation on-site – an approach that proved to be very benefi cial.”

Complex task

The systems in the gas cavern storage facility in Epe feature fully automated operation. The automation system complies with the standards for power station control technology and is divided hierarchically into individual control level, function group level, and master control level. Several subunits for gas injec-tion and retrieval had to be integrated into the over-all concept, including third-party systems such as the exhaust gas combustion furnaces for the glycol re-generation process, which can be connected to the Simatic PCS 7 system very easily.

The subunits also include the feeder stations with feed separators for the RWE West and RWE East pipe-line systems, which operate at different nominal pres-sures. Three two-stage, four-cylinder piston compres-sors with electrical drives and downstream gas cool-ers are used to inject the gas into the caverns until the maximum cavern pressure is reached, or for gas re-compression. The 10 caverns for natural gas storage are connected by high-pressure fi eld lines and the so-called manifold, a distributor station, to both the compressors and the gas delivery lines.

80 fully automated operation modes

The new automation system allows for a total of ap-proximately 80 fully automated operation modes. The coordination of all the function blocks of the subunits is carried out by the so-called route controller on the control level. It controls the gas volumes and limiting pressures – separately for the RWE West and RWE East transport systems, as specifi ed by the dispatcher – and coordinates the operating equipment available at the facility for the respective injection and retrieval modes. In the event of operating faults and subunit downtime, the control level ensures that the specifi ed parameters are maintained by substitute route strat-egies and fault changeovers.

Remote control from Dortmund

Since the reinvestment, three server pairs have each managed about 50,000 messages. Two additional server pairs for extensions were ordered in March 2008. To enable remote dispatching from the compa-ny’s main control unit in Dortmund, the required in-formation for Dortmund is provided additionally in the Epe plant by redundantly installed OLE for Pro-cess Control (OPC) servers. These are linked directly to the automation systems of Simatic PCS 7. The three operator stations in the control room in Epe are equipped with two monitors each.

The operator can switch between the “automatic re-mote” (dispatching Dortmund) and “local” settings. In local operation, all the function blocks can be op-

S o l u t i o n P a r t n e r A u t o m a t i o n E l p r o G m b H

Elpro GmbH is a leading specialist provider of control and electrical solutions in selected areas of industry and transportation. Based on the company’s excellent system technology competence, industry-specifi c knowledge, and process expertise, as well as a consistent customer orientation, Elpro serves as a single source for the planning, delivery, and installation of turnkey plants.

Headquarters:Marzahner Straße 34, 13053 Berlin, GermanyEmployees: 210Contact:Wilhelm DreyerPhone +49 (0) 30 / 98 61 22 73Fax +49 (0) 30 / 98 61 26 15E-mail: [email protected]

The systems of the cavern heads are integrated into the new control technology



infocontact


erated separately and independently of the control level in automatic mode and on the individual control level also in manual mode. When local operation is enabled, usually for maintenance purposes, the oper-ating authorization for subunits is switched to local operator panels of the Simatic MP 370 type or local control stations.

To ensure high plant availability, the technologi-cally independent subunits are automated in separate units and all relevant loops from the sensors to the actuators are set up redundantly. The critical signals that trigger the “Station Emergency Off” state, lead-ing to system vent and the depressurizing of all sys-tems, are designed as two-of-three circuits for avail-ability and safety reasons.

Combined engineering and maintenance station

One major responsibility of RWE Westfalen-Weser-Ems, in addition to operational management, is close-to-plant asset management. Elpro GmbH implemented this capability by using the asset management func-tions of Simatic PCS 7. As a result, RWE Westfalen-Weser-Ems now has direct access to the plant, right down to the fi eld device level. One of the two engineer-ing stations in Epe is used as a maintenance station for the management of the plant components. All diag-nostic functions in the process control system and its components are put at the disposal of the mainte-nance station and visualized here. The central dis-patching in Dortmund receives selected group signals for evaluation of the storage facility status and perfor-mance. Elpro GmbH used the Simatic PDM process de-vice manager for confi guration.

Where technically possible, the sensors and actua-tors are linked via Profi bus and Profi bus PA to obtain additional information about the acyclic DPV1 ser-vices – in addition to the basic signal processing and I/O – and process them within the framework of plantwide asset management.

Tailor-made solution

Asset management enables RWE Westfalen-Weser-Ems to quickly assess the condition of the plant and its components such as the fi eld devices and to take suitable and prompt measures to eliminate or avoid problems. The energy service provider also sees ad-vantages in Siemens’ use of the operating-system-in-dependent EDDL (Electronic Device Description Lan-guage) and in the products’ compatibility with the de-vices of other manufacturers.

RWE Westfalen-Weser-Ems can now react much more quickly to faults, use better diagnostic options, and perform preventive maintenance of the plant. In addition, the company receives system-generated support in its execution of the measures. The automa-tion system has optimized the plant to meet future re-quirements and therefore helps give RWE a competi-tive edge. p

T e c h n o l o g y o v e r v i e w

Simatic PCS 7 V6.1 with integrated 3asset management

Simatic Net OPC server 3

Simatic PDM process device manager 3

Profi bus and Profi bus PA 3

Simatic positioning drives, Sinamics 3frequency converters, Simocode drives, solenoid valves and heaters

Simatic ET 200 distributed I/O system 3

Scalance X Industrial Ethernet 3components

Simatic MP 370 operator panels 3

Sivacon switching system 3

Sitop power supply 3

Elpro GmbH implemented close-to-plant asset management using the asset management functions of Simatic PCS 7


G lobalization leads to a constant decrease in production costs in relation to total produc-tivity, but a continuous increase in logistics

costs. According to a study by the World Trade Orga-nization, the volume of international trade grew four times faster than the global gross product in 2007.

The main problem in the optimization of logistics processes is a lack of transparency. The large number of companies involved and the absence of data stan-dards makes it diffi cult to exchange information be-

tween the various parties. Radio-frequency identifi ca-tion (RFID), however, represents a potential solution. RFID is considered a key technology in bringing a con-sistently high level of visibility to logistics processes. RFID enables the movements of goods to be moni-tored continuously and automatically.

One of the emphases is on transport circuits with reusable containers such as skeleton transport boxes, barrels, or plastic crates, where great rationalization potential can be exploited by the use of RFID. Because

RFID p

Right on TrackRFID is emerging as a key technology

for asset management in logistics.



infocontact

www.siemens.com/rfi [email protected]

these transport containers complete the circuit from the producer to the end customer and back several times, the cost of the RFID transponders is less signif-icant than in open-loop goods fl ow – the return on in-vestment can be achieved sooner. This also allows the use of high-quality data media, which are better pro-tected against environmental infl uences and mechan-ical stress.

Asset tracking, tracking&tracing, supply chain management

By outfi tting containers with RFID tags, it is possible to perform three typical tasks: asset tracking for stock optimization of transport containers, tracking and tracing to ensure continuous traceability of products and raw materials, and supply chain management for automated goods traffi c.

Asset management aims to tie up as little capital as possible by optimally adapting the transport con-tainer stocks to the transport circuits. A prerequisite for this are robust transponders that accompany the containers for their entire lifecycle.

The data stored on the RFID chip are read out by sta-tionary or mobile readers that are linked to the com-pany’s manufacturing execution system (MES) or lo-gistics execution system (LES) by RFID edgeware. If the EPCglobal standard is used, it is even possible to implement company-wide logistics processes.

RFID chips can not only be read out but also pro-grammed as required. This makes it possible to iden-tify the contents of the transport container and to track them continuously – a technology that is partic-ularly interesting for the food, chemical, and pharma-ceutical industries, for example, in which comprehen-sive documentation of all production and logistics steps is required by law.

It is just one small step from company-wide RFID in-frastructure to comprehensive supply chain optimi-zation. For example, the automotive industry, which has already been using RFID for more than 20 years, is keen to use this technology for supply logistics as well in the future. The basis for this will be a standard-ization of the RFID data based on EPCglobal as it is currently being developed by the European Automo-bile Industry Association.

Some like it hot

The transponders can also be used in particularly de-manding and harsh environments, as one example from aluminum processing demonstrates. Incoming materials are processed into aluminum alloy castings that are delivered partially melted in pots for further processing. Temperatures on the outer walls of the containers reach 130 degrees Celsius, despite the ex-tensive insulation.

Specially developed transponders with UHF-RFID technology in accordance with the EPCglobal stan-dard have recently been developed for this applica-tion. A sophisticated design of several insulating lay-

ers with ambient air circulating in between now makes the Simatic RF620T transponder suitable for this application as well.

The increased transparency allows for more effi -cient use of the pots. The pots previously needed to be cleaned cyclically by heating to avoid contamina-tion. Cleaning can now be dispensed with if a pot is to be refi lled with an alloy of the same type. It is also clear at all times where any given pot is located, so production is better organized. The pot profi le serves at the same time as automatically generated proof of the product and delivery quality for the outgoing goods.

An economic opportunity

RFID technology offers promising opportunities for further automation of industrial logistics. Even though some obstacles to standardization remain, completed projects confi rm that the technology has proven itself in practice, especially in terms of cost-effectiveness. p

W e l l - o r g a n i z e d t o o l b o x e s

Siemens Power Generation in Berlin produces turbines for power stations. For machining, the turbine blades are fi xed in special jigs that must have extremely high dimensional stability and therefore must be checked and measured regularly for this purpose.

With more than 3,500 different tools, it is a challenge to ensure that every jig has the necessary dimensional accuracy. Siemens now achieves this by means of RFID transponders placed directly on every device as well as readers at all entries to the production area. Every use of a jig can then be recorded automatically, and

the tool deployment system can detect when a jig is due for a

routine inspection.

Phot

os:

W.

Gey

er


Car

sten

Mey

er,

Foto

lia

Siem

ens

AG

Jim

Par

kin

, Fo

tolia

Telecontrol p

Reach Far, Know More

Countless applications demand the linking of distant substations to a central automation system by so-called remote terminal units

(RTUs). Typical examples are pump or line valve sta-tions in oil or gas pipelines, as well as collection or pump stations in the water industry. Typically, these RTUs usually have a relatively low degree of automa-tion and are distributed over a wide area.

To allow the RTUs to be operated and monitored in the facility’s central control room, they are integrated into the central control system by telecontrol systems. Several different media are available for communica-tion, such as dedicated lines, dial-up connections, and radio systems. Since the RTUs normally only transmit small volumes of data to the control center, the com-paratively low bandwidth of such connections suffi ces. However, communication problems are more frequent with these connections than with industrial commu-

Simatic PCS 7 TeleControl enables the fl exible integration

of distant substations into a uniform and seamlessly

integrated automation solution.

nication networks. This means the telecontrol system must be able to buffer information when the connec-tion to the central control station is down and to pri-oritize data so that important information such as op-erating faults is transmitted as quickly as possible.

Since the data are often transmitted with a delay, they must be clearly identifi ed by a time stamp. And it is best to keep the total volume of data transmitted low, for example, by only transmitting measured val-ues and data from process devices when they have changed.

Distant substations smoothly integrated

With Simatic PCS 7 TeleControl, users now have a tele-control system based on the proven components of the Simatic automation line that integrates smoothly into the Simatic PCS 7 process control system in all

T e c h n o l o g y P r o c e s s C o n t r o l


infocontact


I n t e g r a t i o n o p t i o n sDifferent types of RTUs can be installed in the distant substation, depending on the existing automation with Simatic PCS 7 TeleControl:

Siplus RIC (Remote Interface Control) 3with Modbus/IEC interface, extended temperature range, low current consumption, up to approx. 30 I/O signals

Simatic S7-300/S7-300F with Sinaut TIM 3(TeleControl Interface Module), Modbus/IEC interface, also in fail-safe version, extremely fl exible confi guration, up to approx. 100 I/O signals

Simatic S7-400/S7-400F, with Sinaut 3TIM, Modbus/IEC interface, also in fail-safe version, for higher I/O numbers

Siem

ens

AG

respects – with regard to both the user interfaces and system confi guration and the automation hardware. The standardized platform reduces the error sources and simplifi es confi guration, commissioning, and op-eration.

Simatic PCS 7 TeleControl supports a wide range of communication standards: dedicated lines, dialed connections, or radio systems, but also increasingly TCP/IP-based techniques such as DSL or GPRS, as well as the Sinaut ST7 and Modbus protocols; other proto-col standards, such as IEC 870 and DNP V3, are under development.

The Sinaut ST7 telecontrol protocol provides func-tions for time stamping and synchronization of the RTUs. The telecontrol modules of Simatic PCS 7 Tele-

Control buffer the data in the RTU so that no data are lost even if the communication fails. Existing RTU sys-tems and RTUs of other manufacturers can also be in-tegrated into Simatic PCS 7 TeleControl via Modbus.

Wherever a very high level of operating reliability is necessary, either for reasons of plant safety or be-cause the distant substations are very hard to reach, Simatic PCS 7 TeleControl allows redundant solutions on all system levels. This guarantees that the distant substation operates absolutely reliably.

Safer, more reliable, and more economical

With Simatic TeleControl, the user benefi ts from a telecontrol system that can be individually adapted to the requirements of the relevant systems yet still co-operates with the master control system without sys-tem breakdowns.

Thanks to the standardized HMI level, the operator constantly has an overview of the entire system and can respond in a quick and targeted manner to faults and messages, and the uniform visualization consid-erably reduces the danger of operator errors. Ex-penses for training staff also decrease because a sin-gle system is used both for the telecontrol technology and for the actual process control technology. The costs for installation, commissioning, and mainte-nance are considerably reduced as well. p

H i g h l i g h t s S i m a t i c P C S 7 T e l e C o n t r o l :

Higher degree of system integration 3

uUniform hardware platform

uLocal time stamping in the RTULow risk of operator errors 3

uUniform user interface(identical visualization and operation)

Minimized engineering and maintenance 3effort

uUniform software platform

uMinimum hardware requirementsFlexible selection of communication media 3(radio, WLAN, LAN, phone, etc.)


R u b r i k U n t e r r u b r i k

Especially in more complex processes, APC means process control that considerably re-duces the use of energy and resources, enables

constant compliance with high quality standards, and contributes to more fl exible production. The control concepts common in the process industry to-day are based almost exclusively on proportional-integral-derivative (PID) controllers. These are sim-ple to use and can be easily integrated into control systems and are therefore widely used. However, in certain processes such controllers may not be able to optimally hold the specifi ed operating points. Therefore, operators must frequently resort to man-ual operation to control the process by hand.

APC functionality integrated into the control system

Thanks to further development of controllers, im-proved programming systems, and the increasing ef-fi ciency of modern process control systems, now even complex process-parameter relations can be described mathematically and used for automatic and fl exible system operation. The APC methods applied here in-clude, above all, control processes that go far beyond the capabilities of PID controllers and standard pro-

cess controllers, such as fuzzy control, neural net-works, or model predictive multivariable control.

Numerous specialist providers offer standardized APC tools for specific jobs that are usually linked to the control system as a programming system via an OPC (OLE for Process Control) interface. With its Simatic PCS 7 process control system, Siemens pursues a wider solution. One approach, of course, is the link-ing of standardized APC tools via OPC. The other ap-proach uses an integrated concept: numerous ad-vanced control methods are already part of Simatic PCS 7, in the form of both components and functional sample plans of measuring point types. In addition, add-on products that have been jointly developed with well-known partners and that are integrated tightly into PCS 7 are available to the user for spe-cial requirements – for example, an operator train-ing simulator, a module for fuzzy control, or soft sen-sor methods.

The decisive advantage for the user is that he or she can simply choose the suitable measuring point type for the control job from a library and assign the ap-propriate parameters to it. The openness, the ordered structure, and the documentation of the existing, standardized APC measuring points also allow trou-ble-free adaptation to individual requirements.

Advanced Process Control p

APC Made EasyFor many years, Advanced Process Control (APC) had the reputation of being

expensive, complex, and for experts only. The APC features of Simatic PCS 7

Version 7.0 now enable simple, cost-effective implementation of APC applications.

T e c h n o l o g y P r o c e s s C o n t r o l


Complex control in four steps

A typical example is the model predictive controller. It processes up to four manipulated and controlled variables and a measurable disturbance variable in a standard function module. The confi guration re-quires only four steps. First, the system component is simply dragged and dropped from the library into the continuous function chart (CFC) plan for imple-mentation, whereupon the operating component and all messages are generated automatically by the control system. Second, the controller learns the dy-namic response of the system automatically in the so-called step test. For this test, a standard step to a set point is initiated, and the process lag time is pro-cessed by with the help of a mathematical model in order to determine the process dynamic behavior. Third, a model is mapped mathematically to the re-sulting curve. The hierarchy of the control and ma-nipulated variables can then be quickly established for modeling purposes, before simply generating the SCL source by pressing a button. The last step is to load the modeled component into the running sys-tem and test it. Then a functional model predictive controller is available that can be operated via an au-tomatically generated faceplate.

Intelligent process optimization

With these advanced control functions from the stan-dard components library, effi cient APC methods can be implemented with Simatic PCS 7 on small and me-dium-sized systems too. No additional investments are necessary, and the confi guration can be com-pleted without outside help.

Typical areas of application include optimum con-trol of start-up, load, and product change processes, and control of reactors, distillation stacks, and cou-pled systems. Advanced control functions not only minimize fl uctuations in critical process variables and the use of raw materials and energy; they also contribute to an increase in throughput and consid-erably lessen the operator’s workload. p

A P C : I n t e g r a t e d i n S i m a t i c P C S 7

Numerous APC methods are already incorporated into the standard PCS 7 V7.0 and are available to the user without additional investment:

Split-range control 3Ratio control 3Cascade loop control 3Lead-lag feed forward control 3Override control 3Gain scheduling 3PID tuner 3Control performance monitoring 3Smith predictor 3Model predictive control 3

infocontact


Pub

licis


Veolia/SIDEM, Bahrain p

Steady Flow

Aset of desert islands surrounded by saltwater, the Kingdom of Bahrain (population 718,300) has immense water needs. Less than 3 per-

cent of the land is naturally arable, so irrigation is a must. To satisfy the great need for water, Bahrain’s de-salination plant was recently expanded, more than doubling its capacity, to become the world’s largest thermal multiple-effect distillation (MED) plant, pro-ducing 400,000 cubic meters of fresh water each day. The expansion project was implemented by SIDEM (Sté Internationale de Dessalement), a subsidiary of Veolia Water Solutions and Technologies, headquar-

Siemens and Solution Partner Cira-Concept jointly provided

and implemented control technology for the world’s largest

MED seawater desalination plant, in Bahrain.

tered in Paris. SIDEM is the global market leader for the MED method, with more than 370 units installed to date.

Ten additional units

To help with the control aspects of the expansion, SIDEM chose the Simatic PCS 7 process control system and entrusted Siemens and Cira-Concept, a Siemens Solution Partner and PCS 7 specialist, with the imple-mentation. The expansion project, which cost about 275 million euros, consists of 10 desalination units,

I n d u s t r y W a t e r

SID

EM


infocontact


which evaporate and condense seawater within a number of vacuum chambers, separating the water from the salt. Low-pressure steam is brought in from the Al Hidd heating power station to supply the desal-ination units with heat.

Also in use are a cleaning unit, a hypochlorination unit, a carbon dioxide unit, three boilers, a seawater pump system, and a metering system. These combine to produce an additional 273,000 cubic meters of wa-ter each day.

Multiple benefi ts

SIDEM chose the Simatic PCS 7 process control system for a variety of reasons. It provides time stamping for all digital inputs with an accuracy of 5 milliseconds. It can be integrated redundantly into external sys-tems – via Profi bus to the boiler management system (BMS); via Modbus transmission control protocol (TCP) to the metering systems for electricity, water, and gas; and via secure OPC-DA data access to the plant accounting system, which monitors plant con-sumption for fi nancing purposes.

The PCS 7 asset management system was attractive because it provides troubleshooting diagnostic sup-port through visualization of materials over the PCS 7 network. PCS 7’s control architecture and the SFC can be used in a variety of ways and are compatible with the SIDEM automation standard. “Lastly, another as-pect in favor of PCS 7 was the fact that Cira-Concept as a system integrator had profound expertise with this system. We had already worked with Cira-Con-cept, so this offered additional effi ciency in the imple-mentation,” say Yannick Le Goff, head of control tech-nology at SIDEM, and Manuel Manjon, DCS project manager for SIDEM.

Desalination expertise

Cira-Concept, headquartered in Lyon, France, is a systems integrator specializing in processes for con-trol systems, power supplies, instrumentation, and general installation. Cira-Concept was an excellent

choice to partner with Siemens on this project, as it already had proven experience in seawater desalina-tion projects.

The expansion project was technically demanding, and to enable on-time completion, SIDEM chose a 100 percent redundant PCS 7 system. The PCS 7 solution consists of nine automation systems, each of the PCS 7 417H CPU type, with a redundant optical network and redundant Siclock clocks.

In addition to providing its renowned process man-agement functions, the PCS 7 system manages the in-terconnection of the external metering systems for electricity, gas, and water, and the central consump-tion accounting system for the plant.

Siemens and Cira-Concept worked together to de-liver all the control materials, including switch cabi-nets, four kilometers of fi ber-optic cable for the net-work, and the control room equipment. They ran elec-trical and network studies, confi gured the PCS 7 system and factory acceptance test, documented the project, performed local commissioning, and trained the op-erators and maintenance personnel.

On time and on budget

Thanks to the close collaboration between Siemens’ PCS 7 engineers, the staff of the system integrator Cira-Concept, and the Control Technology Depart-ment at SIDEM, the expansion progressed smoothly and on schedule. The project began in June 2006, the fi rst control units were dispatched in January 2007, the fi rst desalination units went into operation in May 2007, and the project was fi nished on time and within budget at the beginning of 2008. p

» The SIDEM, Siemens, and Cira-Concept teams have done an excellent job of combining their competencies to achieve on-time commissioning of a powerful and easy-to-maintain plant. We were able to complete this project on schedule and within the budget. «

Denis Bouteille, Project Manager, Cira-Concept

P r o j e c t k e y f i g u r e s

Approximately 7,000 I/O 3devices10,000 hours of planning 3and executionTotal project time: 31.5 yearsCommissioning and training 3in 6 months


Evonik Industries is a modern industrial group based in Germany, with business activities all over the world. In its three business areas of

chemicals, energy, and real estate, Evonik occupies leading market positions. Evonik concentrates on steadily improving its market and customer focus as well as on operational excellence, establishing an even stronger presence in attractive growth regions, and focusing on the impetus generated by innovations.

At its production site in Antwerp, Evonik runs two facilities for the synthesis of hydrogen peroxide. Hy-drogen peroxide is an environmentally friendly chem-ical that is used for various oxidation reactions, waste-water treatment, waste gas scrubbing, and disinfect-ing applications. Both synthesis facilities are supplied with hydrogen by pipelines; the hydrogen is then turned into hydrogen peroxide in a multistage process. The plant facility also includes two tank farms for in-termediate storage of the hydrogen peroxide in differ-ent concentrations, as well as a dispatch department.

Targeted change to fi eldbus architecture

At the Antwerp site, Evonik is in the process of grad-ually changing over the communication at the process level to fi eldbus technology. Fieldbuses are becoming increasingly established in the chemical industry be-

Evonik Industries, Belgium p

Full CircleIn Antwerp, Evonik recently

successfully tested the ring topology

for Profi bus and Profi bus PA, which is

available with the new Version 7 of

Simatic PCS 7.

I n d u s t r y C h e m i c a l s

Evo

nik

Ind

ust

ries

R e d u n d a n c y i n P r o f i b u s P A

With the new Version 7 of Simatic PCS 7, a redundant Profi bus PA network can be set up, thanks to a newly developed concept that consists of couplers and intelligent fi eld distributors as hardware. Active fi eld distributors (AFDs) integrate Profi bus PA fi eld devices via four short-circuit-proof spur line connections in a Profi bus PA ring with automatic bus termination. Hot swapping of an AFD is possible, and correct functioning of the Profi bus PA devices on the AFDs is not infl uenced by this. The Profi bus PA ring is connected to two FDC 157-0 DP/PA couplers of a DP/PA router, which can be operated on a single or redundant Profi bus network.

Advantages of ring architecture:Maximum availability 3Transparent redundancy management of the intelligent DP/PA couplers for the host system 3Active bus terminators for automatic bus termination in the DP/PA couplers and the AFDs, permitting: 3

3 Automatic, bumpless isolation of faulty subsegments in the event of a short circuit or line break 3 Modifi cation of ring confi guration and instrumentation during operation; addition or removal of ring segments

Safety-related and fault-tolerant applications with low device and cabling overheads 3


infocontact


cause of the time and cost savings due to lower instal-lation expenses, lower hardware costs, and extended diagnostic possibilities. Fieldbus systems such as Profi -bus also enable generally higher performance than classic alternatives such as Hart communication.

The unrestricted availability of the process control system and the related communication infrastructure is top priority in the hydrogen peroxide production plant. That is why Evonik modernized the process control technology with Simatic PCS 7 in the course of changing over to the fieldbus system and imple-mented the new version of PCS 7, which supports a ring topology for both Profi bus and Profi bus PA. This produces consistently redundant wiring at the fi eld-bus level, contributing signifi cantly to plant availabil-ity. A line break in the fiber-optic cables laid in the area of the production plant no longer leads automat-ically to a partial or total breakdown in fi eldbus com-munication.

This redundancy concept is relatively new and plugs a previous gap in fi eldbus communication for process automation. The fi eldbus is set up with coupler and media redundancy, whereby the connection between the PA network to which the individual fi eld devices are connected and the master Profi bus infrastructure is made via DP/PA couplers. These couplers have an integrated diagnostic-slave function and therefore

support standardized fieldbus diagnosis from the control center.

Evonik also tried out a new connection technique at the process level. Evonik previously used PA fi eld dis-tributors with M12 connectors and had the problem of short circuits and electrolysis effects caused by pene-tration of the connectors by water, which kept causing equipment failures. The cable screw connections of the Simatic AFD active fi eld distributors for connect-ing the main cable and the stub cables, in contrast, have proven to be ideal for use in harsh environments. There has not been a single fault caused by water pen-etration since their commissioning nine months ago.

Pilot project completed successfully

For Evonik, this fi rst use of a Profi bus PA ring was more or less a fi eld trial under production conditions, and the experience to date is all positive. The entire system operates robustly and without any signifi cant prob-lems. The complete project execution, up to commis-sioning, was a time- and cost-saving enterprise. p

Siem

ens

AG


Granarolo is Italy’s fourth-ranked food group. The group is structured into two separate and synergic structures: a milk producers so-

ciety (Granlatte) that operates the farming sector and gathers raw materials, and a joint-stock company (Granarolo Spa) that commercializes the products.

In the company’s Gioia del Colle and Bologna plants, Granarolo wanted to implement an internal traceabil-ity system to monitor the quality of the products dis-tributed to the market, especially high-quality pas-teurized milk. In particular, the customer needed to precisely identify every product lot. Thus, it was es-

Granarolo, Italy p

Fresh with TechnologySimatic IT enables a major Italian food group to achieve quality end products

while meeting strict regulatory requirements.

I n d u s t r y F o o d & B e v e r a g e


infocontact


Foto

lia,

Tom

Den

ham

sential to identify and manage the fl ow of raw mate-rials entering the plant, the intermediates, and the fi -nal products leaving the plant. Together with solution partner Atos Origin, Siemens implemented Simatic IT with a manufacturing execution system (MES) solu-tion that now records the backward genealogy of ev-ery individual product lot and computes all necessary key performance indicators (KPIs).

Intelligent package for traceability

The Simatic IT package with the Production Suite, His-torian, and Report Manager modules fulfi lled the cus-tomer’s requirements as well as regulatory require-ments. Specifi cally, Simatic IT Historian builds gene-alogy records in order to provide reports for backward and forward genealogy for each individual package. The genealogy records include the raw and intermedi-ate materials used to produce the products as well as the packaging materials that are physically in contact with the products. The genealogy focuses on detecting possible cross-contamination during the entire man-ufacturing cycle. The Production Suite automatically defi nes all the routings among the various pieces of equipment involved in the production process. Addi-tionally, the suite continuously monitors and updates the contents of all individual units, such as tanks and silos. The Report Manager allows access to genealogy reports from various locations and provides availabil-ity in real time. In order to associate personnel infor-mation with the traceability records, the genealogy function takes into account the operators who are cur-rently logged on to the workstations.

Simatic IT was integrated with the existing enter-prise resource planning (ERP) system and warehouse management system (WMS) to enable the download-ing of material master data and production orders as well as allowing for timely upgrades with performance feedback. Upon receiving a Simatic IT message, the ERP system prints the shipping documents for the product lot delivered. Over 30 different product types are handled by Simatic IT in the Gioia del Colle and Bo-logna plants. Simatic IT is part of the Totally Integrated

Automation (TIA) concept, the Siemens solution for managing plant operation from the shop fl oor to the top fl oor.

Shorter response times, better monitoring

To provide consistent genealogy records for each in-dividual product lot along the entire manufacturing cycle, the customer had to associate with each prod-uct lot the data and information such as KPIs and quality data produced by in-process tests. These tests are performed during manufacturing operations. Furthermore, the inbound and outbound inventories as well as the intermediate warehouses had to be taken into account.

The Simatic IT solution has allowed Granarolo to re-spond quickly to product quality issues, enabled bet-ter management of quality certifi cation, and facili-tated more detailed monitoring of plant effi ciency. “The implementation of Simatic IT brought us a lot of advantages. So we can now, for example, rapidly and fl exibly react to a customer complaint, and we are able to quickly respond to internal quality audits,” says Ro-berto Poli, information and communication technol-ogy (ICT) manager at Granarolo. Additionally, the fl exibility of Simatic IT has enabled Granarolo to ex-plore new possibilities for improving the entire man-ufacturing process. p

T h e s o l u t i o n a t G r a n a r o l o

Key challenges:Response to stringent regulatory requirements 3Brand image reinforcement by improving 3product quality Plant effi ciency improvement 3Genealogy of each product lot in real time 3

Solution:Simatic IT Production Suite 3Simatic IT Historian 3Simatic IT Report Manager 3

Key benefi ts:Timely response to product quality issues 3Fast and focused recall procedures 3Better management of quality certifi cation 3Detailed monitoring of plant effi ciency 3Real-time answers to customer requests 3Common platform for various plants 3

Partner:Atos Origin Italia: www.atosorigin.com

» The implementation of Simatic IT brought us a lot of advantages. So we can now, for example, rapidly and fl exibly react to a customer complaint, and we are able to quickly respond to internal quality audits. «

Roberto Poli, ICT Manager, Granarolo


Phot

os:

CSL

Beh

rin

g

CSL Behring is one of the world’s leading man-ufacturers of plasma products. The company’s product portfolio includes numerous prod-

ucts that are used, for example, for blood coagulation disorders and immune defects, in wound healing, and in intensive care. The company, founded in 1904 by Emil von Behring, is today part of the Australian bio-

pharmaceutical manufacturer CSL Limited and em-ploys about 6,000 people worldwide. The Marburg site is one of numerous production locations, plasma col-lection centers, and research and development divi-sions in Europe and the United States. For the Factor IX and Factor I/XIII production sections in Görzhausen near Marburg, the company upgraded the process

CSL Behring GmbH, Germany p

Qualifi ed Upgrade

The HMI level of two existing process control systems at CSL Behring

was migrated to Simatic PCS 7 in a mere six weeks – including the site

acceptance test (SAT), qualifi cation, and training of the technical and

operating personnel.

I n d u s t r y P h a r m a


infocontact


control system and migrated the HMI level of two ex-isting Unix-based process control systems (using Simatic PCS Version 3.1.2a) to PCS 7/505 OS Version 6.1. The sensors, actuators, and measuring technol-ogy, as well as the entire control level based on Simatic 505 controllers, were to be retained.

A logical decision

CSL Behring’s decision to continue its existing rela-tionship with Siemens was a logical one. Siemens had already performed a similar migration for two other process control systems for CSL and had extensive ex-pertise in this area as well as the necessary knowledge to make GMP-compliant changes to a validated pro-duction plant. Siemens was also able to offer rapid service with short response times due to its strong lo-cal presence.

Siemens was responsible for the entire project man-agement and for coordinating all units as well as the partner companies contracted for the installation and engineering. The project was carried out according to the PM@Siemens project management guidelines and the standards specifi ed by the customer, which made an important contribution to completing the entire project within an extremely tight time frame and in-cluding additional services that became necessary as the project progressed.

Old and new go hand in hand

The project phases that required a shutdown of the production plant had to be carried out within an ex-ceptionally tight time frame. Assembly and installa-tion of all components, the SAT, and training of the technical and operating personnel were completed in just six weeks, thanks to an extremely strict schedule. The existing Unix-based Simatic PCS 3.1.2a process control system was replaced by PCS 7/505 OS V6.1 in the course of the migration. This ensures that the new system can communicate with the existing Simatic 505 controllers. A uniform user interface with the look and feel of PCS 7 was implemented using a spe-cially developed library. Redundantly designed indus-trial computers of the Simatic IL43 type are used as process control system computers.

All process computers are located in a central server cabinet and are controlled by an operating channel extension. The changes are read into the system by a central engineering station. The two PCS 7 servers are operated redundantly. Two clean-room operator sta-tions were also installed. The completely new termi-nal bus was installed as a redundant system and com-missioned. Moreover, a clocking system based on Si-clock was implemented in the course of the project. It receives the trigger signal via GPS and sends the time to the two redundant domain controllers, which are used as a time master for a total of four process con-

trol systems. Simatic IT Historian V6.1 is used for long-term data archiving, and the existing redundant domain controllers are used for user and rights man-agement – for central user management for the other process control systems in the production building. This has the advantage that all user management can be confi gured and maintained from one place. Batch logging with PMQuality was integrated for the Factor I/XIII production line, and this was linked with WinCC ReportManager for the Factor IX distributed control system (DCS).

Targeted preparation for qualifi cation

The key to implementing the project within the tight time schedule was the integrated qualifi cation solu-tion, that is, a process was already defi ned in advance, backed up by a risk analysis, that enabled direct uti-lization of the test documents generated there for qualifi cation during the factory acceptance test (FAT) and later during the SAT. This process, however, re-quired strict deviation management with all the re-sulting consequences (tracking, strict version man-

agement, and documentation, including evaluation of all deviations from tests already conducted). The pro-grammers had to plan the project in advance, create the documentation, and then implement it in the sys-tem so that only a minimum of modifi cations was nec-essary.

At the end of the migration, Siemens staff assisted the production team in restarting the system on-site, and later Siemens provided support in the form of standby service. These measures ensured that any technical faults could be remedied with minimum ef-fect on production. The new system has now been working for almost a year without any problems, and CSL Behring is reaping the advantages of a modern HMI solution. p

» The test documentation was prepared with the aim of being able to complete the required qualifi cation of the automation system in the shortest possible time. «

Mathias Kuhl, Project Manager, CSL Behring


Sasc

ha

Burk

ard

, Fo

tolia

Energy Effi ciency p

Less Is More

Heating, ventilation, and air-

conditioning make up the lion’s

share of the energy costs and

emissions of the pharmaceutical

industry. Targeted measures allow

sustainable savings in this area.

I n d u s t r y P h a r m a

More than 80 percent of the total energy ex-penses of the pharmaceutical industry go into buildings, and 65 percent of the en-

ergy is used for heating, ventilation, and air-condi-tioning (HVAC) technology.

This is due mainly to the fact that air-conditioning and ventilation not only ensure comfortable working conditions but are also necessary for the very high air-change rates required in these buildings for per-sonnel and product protection. In some cases, the room air is entirely exchanged more than 100 times per hour to reduce particle concentration.

The circulated air provides an important barrier – for example, preventing room contamination or the introduction of particles from outside into produc-tion areas. In addition, air temperature and humidity have a direct infl uence on the product quality in many processes.

A challenge in terms of responsible care (that is, the sustained protection of health and the environment) is to fi nd new ways of utilizing energy more effi ciently – without making any compromises in personnel and product safety – to achieve the same effect with less resources.


infocontact


With Energy Monitoring and Controlling (EMC), Siemens supports the pharmaceutical industry in its efforts to achieve more effi cient utilization of energy. The basis for the energy optimization is a detailed overview of the current consumption situation. To provide this overview, the EMC system picks up the data for electrical and thermal energy either automat-ically or by heat meters, for example, or they are en-tered manually. The automatic evaluation and pro-cessing of the data enables a source-related allocation of the costs to cost centers, the automatic calculation of carbon dioxide emissions, and the comparison of different buildings and users.

Integrated thinking

In the pharmaceutical industry especially, the effi -cient use of energy cannot be considered in isolation but requires extensive knowledge of the production processes and strict offi cial specifi cations. Siemens runs one of the largest application laboratories in Eu-rope in Zug, Switzerland, which is concerned exclu-sively with HVAC issues. Here, the expertise of vari-ous fi elds of technology is combined in new solutions for different industries. For instance, Siemens is able to support the pharmaceutical industry in the long-term reduction of its energy consumption and at the same time guarantee high quality standards in pro-duction, as countless examples demonstrate.

A well-known research center in the United States, for example, realized the importance of cold genera-tion for reducing energy consumption and performed extensive optimization measures. The pump sequences were specifi cally adapted, the temperature control modernized, and the sequencing of the cold machines and the use of return cooling units modifi ed. The nec-essary investment of 390,000 US dollars generated an-nual savings of 186,000 US dollars and a reduction in carbon dioxide emissions of more than 450 tons per year. In a pharmaceutical laboratory in Switzerland, the laboratory extractors were converted from con-stant to variable volumetric fl ow. Together with opti-mized room pressure control, this resulted in a sus-tained 50 percent reduction in the volume of condi-tioned air. Another example is a toxicological research center in Germany. Here, 36 fans were converted to variable-speed control, and the entire building auto-mation and lighting systems were modernized. The investment amounted to approximately 2.7 million euros and led to an annual energy cost savings of 670,000 euros in addition to the reduction in carbon dioxide emissions of more than 5,300 tons per year.

Investments in a “green” future

These examples show that investments in more effi -cient utilization of energy quickly pay off even under the special conditions that prevail in the pharmaceu-tical industry. The pharmaceutical industry can there-fore make an important contribution to sustainable energy utilization and help reduce emissions. p

Source: Energy Efficiency Improvement and Cost Saving Opportunities for Pharmaceutical Industry. Ernest Orlando Lawrence Berkeley National Laboratory, Sept. 2005

M e a s u r e s f o r g r e a t e r e f f i c i e n c y

Numerous factors affect the optimization of heating, ventilation, and air-conditioning technology:

Adaptation of air change rates to different 3operating modesVariable volumetric fl ows due to time- 3dependent switching programsMonitoring of clean-room conditions by 3continuous particle measurementOptimization of cold and heat generation 3Integrated networking of generation, 3distribution, and consumersTransparent visualization, alarming, and 3optimization by building control technology

Hamburg-based Conergy AG is Europe’s lead-ing solar enterprise and also a leading inter-national supplier in the fi eld of solar systems

integration. On its Frankfurt (Oder) premises, the company turned a former chip fab into one of the world’s most advanced solar power plants. The plant began operating in the summer of 2007 and will reach its full capacity in 2009. The target is a production ca-pacity of 250 megawatts per year.

Tight timeline

The equipment for the new plant had to be delivered and installed in a challenging setting. First, the solu-tions for integrating the various systems in the facil-ity were quite complex from a technical point of view.

And second, the project had to be completed within a very tight time frame: just seven months from order to completion. This also included the integration of multiple units via interfaces of considerable complex-ity. However, this task proved only a small challenge for the project team of M+W Zander, Siemens, and Conergy’s technical project leads.

M+W Zander contracted Siemens to deliver the auto-mation technology for the entire process infrastruc-ture. This package also included process cooling units, air-conditioning systems, vacuum systems, systems for heating and distributing hot water, and chemical supply. Siemens was able to convincingly demonstrate its industry expertise during this project.

Moreover, the integrated Simatic technology, which is based on proven industry standards, offers several


Conergy AG, Germany p

Sunny Side UpConergy’s new solar plant in Frankfurt (Oder) serves as a benchmark

for the solar industry by integrating all production steps – from wafer

to fi nished photovoltaic module – into a seamless concept.

I n d u s t r y S o l a r

A “ s i n g l e r o o f ” f a c i l i t y

The Conergy solar power plant in Frankfurt (Oder) 3incorporates a fully integrated wafer, cell, and module production plant.Conergy invested around 250 million euros. 3This state-of-the-art facility supports highly effi cient mass 3production of photovoltaic systems and will help Conergy maintain its competitive edge. By exploiting synergies through the close integration of 3production and R&D activities, Conergy is also pursuing ambitious goals for innovation – for example, raising the effi ciency of monocrystalline solar modules to more than 17 percent.Aligning internal production design with production units 3decreases distances for transport.The high degree of automation in the facility helps reduce 3breakage in handling the sensitive cells. The machinery that is employed offers options for further 3improvements in operational effi ciency and silicon consumption. Currently, production uses cells with a thickness of 3200 micrometers, but plans aim at reducing the cell thickness to 160 micrometers and even lower.


Integrated solution

This integrated and uniform system for engineering, process visualization, and operation is an absolute fi rst for the photovoltaic industry. Effective and straightforward engineering is supported by an easy-to-use tool set, and a uniform software library based on the semiconductor library of the Simatic PCS 7 Version 7 process control system enables uniform and integrated engineering. Operator symbols are the same on every operator station, so all user screens have the same look and feel, an aspect that also sig-nifi cantly facilitates staff training. A solution that was implemented especially for the solar manufacturing plant in Frankfurt (Oder) is the PCS 7 CAS central ar-chive server, which delivers long-term archiving ca-pability for all relevant system messages and mea-sured values.

Photovoltaics enjoys a sunny outlook

Looking back on the project, all parties are extremely satisfi ed with the results and the team performance. The systems in the plant are currently being fi ne-tuned. With analysts predicting continuing growth in photovoltaics, Conergy expects future expansions of the facility over the next few years – and this might also mean that the proven collaboration with M+W Zander and Siemens will be continued as well. p

infocontact


benefits for such an application. The Simatic S7 con-troller family covers a set of components that are well accepted in the market and meet the different require-ments in the various plant units. The integrated com-munication concept (Profi bus for process-level com-munication and Industrial Ethernet as the backbone) enables easy integration of the controllers in the pro-cess units, such as cooling systems, vacuum pumps, and chemical cabinets.

The Simatic PCS 7 process control system in a re-dundant confi guration handles all higher-level con-trol tasks. It controls plant operation, handles alarms, and manages all data analysis and archiving. A dedi-cated process bus system in a fi ber-optic ring confi g-uration was installed for fast communication between the automation systems and the servers for the opera-tor stations. This ring is equipped with active Scalance components. The process level is connected to the con-trol system via Profi bus. Several Modbus devices are also connected via a Modbus/DP link module. The en-terprise resource planning (ERP) system, the offi ce ap-plications, an alarm system with a radio server, and a system for paging functionality are linked to the con-trol system via standard interfaces.

Another part of the electrical installation, the switch-gear systems for medium and low voltage, are also in-tegrated into the control system via Profi bus. Conse-quently, Conergy can benefi t from comprehensive power monitoring and excellent system visibility from all the operator stations of the control systems. The same principle was also applied in the units for chem-ical supply and water treatment, where all operational conditions can be monitored both locally on operator terminals and in the central control room.

Phot

os:

Co

ner

gy

AG


Aguas de la Cuenca del Segura S.A., Spain p

Fresh Water Technology

The desalination of seawater is a significant component of the effort to ensure a clean drinking-water supply. Within the framework

of the Spanish Environment Ministry’s AGUA pro-gram, which deals with measures for water manage-ment and more effi cient use of water, the state-owned company Aguas de la Cuenca del Segura S.A. built Europe’s largest seawater desalination plant in Val-delentisco, Spain. Its pressure fi lters use a reverse os-mosis process to desalinate up to 200,000 cubic me-ters of water daily for the drinking water supply and for agricultural irrigation. The plant, which also serves research purposes, uses fewer chemicals in the pretreatment of the seawater, reduces the necessary reversal per produced cubic hectometer, and requires less space compared to other plants.

Avoiding expensive downtime

A joint venture between two companies, Ferrovial and Cadagua, built the turnkey plant and put it into oper-ation in January 2008. The production process was au-tomated with the Simatic PCS 7 process control sys-tem, which features high availability thanks to the full redundancy of all control parts.

Redundant Profi bus DP fi ber-optic technology links remote I/O systems as well as several process devices. The digital process devices are linked by the Hart communication system and Profibus PA. Frequency converters are used to control the pumps as well as the instruments that measure pH value, redox, and conductivity, which communicate with the control system via Profibus. The network analyzers and pro-tective relays for the medium-voltage cells are linked via Modbus.

The installation and networking of the measuring instruments can be optimized because both the cabi-nets with the I/O cards and the devices for direct con-nection to the bus can be installed remotely at the lo-cation in the plant where the actual process takes place. The process instruments are also connected to the control system by a bus cable, which is separated into several physical segments.

Simatic PCS 7 ensures reliable and effi cient processes in the largest

seawater desalination plant in Europe.

I n d u s t r y W a t e r


infocontact


Siem

ens

AG

Industrial Ethernet is used as a system bus to link the process control with the engineering stations (ESs) and operator stations (OSs). Redundant switches not only ensure high availability for communication between the process control and the work stations but also fi lter and optimize the communication.

Sophisticated concept

To ensure comprehensive process monitoring, a cli-ent/server architecture was installed in the central control room that consists of two fully redundant OS servers and two OS clients for the visualization and operation of the plant. A Web server application is in-stalled on one of the clients, and all plant data can be accessed via the Internet from any PC that is confi g-ured as a Web client of PCS 7. An ES is additionally available for the centralized confi guration of all ele-ments for the plant control. The confi guration of all fi eld devices from the ES is done using the Simatic PDM process device manager.

Two fully redundant AS417-4H automation systems are used for each of the two production lines of the plant. The physical pretreatment of the seawater in the collection tank takes place before the suction pro-

cess by the supply pumps, so no solids larger than 16 millimeters in diameter can penetrate. The pretreated water is then fed back to the sand pressure fi lters by underwater pumps. Then it passes through a number of fi ner fi lters, which fi lter out even the smallest par-ticles. A sewage pipe feeds the residue back to the sea through a diffuser system. The fi ltered, salty water is sucked into the reverse osmosis housings by high-pressure pumps that are controlled from the operat-ing rooms.

A fi fth process controller, used by both production lines, regulates the posttreatment of the desalinated water before it is distributed to two tanks, for irriga-tion and the drinking water supply. Water that will en-ter the drinking water supply is disinfected later in a device adjacent to the system; it then meets all re-quirements for purity. p

T e c h n o l o g y a t a g l a n c e

Cable signals via distributed I/O cards: 33840ED, 1680SD, and 366EA, of which 60 have analog instrumentation, communicating via Hart protocol71 network analyzers, 34 motor protection 3relays, and 9 uninterruptible power supplies communicating via Modbus24 electromagnetic fl owmeters, 4 differential 3pressure transmitters, 36 pressure transmitters, 8 level-measuring instruments, and 8 temperature sensors, distributed over 12 Profi bus DP/PA segments11 measuring instruments for pH value, 6 for 3redox, and 25 for conductivity; 14 Sinamics G 150 frequency converters; and 30 Micromaster MM 440, communicating via Profi bus


Phot

os:

Sie

men

s A

G

I n d u s t r y I n f r a s t r u c t u r e

Valorec Services, Switzerland p

Sinamics Steams It UpValorec Services AG recently modernized a large steam-generating system

with Simatic PCS 7 – including new burners, new pipes, a new control system,

and new ventilation systems that are controlled by modern, effi cient

Sinamics G150 converters.

As high as an apartment building: The standby furnace serves to

avoid steam bottlenecks


info

contact

www.siemens.com/sinamicswww.siemens.com/[email protected]

The city of Basel needs a lot of steam. Novartis, Ciba, Syngenta, SF-Chem, and Clariant use it for various chemical processes and to heat their

production and offi ce facilities. To ensure there is al-ways a suffi cient supply of steam, Valorec Services in Basel operates a power station for producing steam that is piped directly to the neighboring chemical plants. In normal operation the steam is generated by two power plants that use waste and solvents as fuel. An oil boiler serves as a standby system so that the system always feeds enough steam into the distribu-tion network – for example, during the summer, when the waste and solvent incineration plants undergo maintenance, and during the winter heating period.

Incineration plants 1 and 2 together generate 60 tons of steam per hour. The standby system can supply an-other 45 tons per hour. The boiler of this system is fi red by extra-light heating oil. The burners can be switched on individually or together, depending on the volume of steam required. If all three are fired together, the steam plant can be run up from hot standby (150 degrees Celsius) to full operating tem-perature within just half an hour.

Modern environment for proven technology

The boiler was recently fi tted with new burners, new pipes, new fans, and a new control system in a four-month total refurbishment. Getinge Alfa AG in Rhein-felden was responsible for the overall concept and the entire conversion.

Getinge Alfa used Simatic PCS 7 as the process con-trol system – one of the reasons being that the Teleperm M process control system was already used in the facility. The two waste and solvent incineration plants and the standby boiler are controlled from a central control room. The waste and solvent incinera-tion plants still run with Teleperm M, but the visual-ization has already been migrated to WinCC through-out. “The possibility of operating part of the system in parallel under Teleperm was critical for the change-over to PCS 7,” explains Beat Tonazzi, head of I&O Ser-vices at Valorec. “That was a good test because we will have to decide what to do with Teleperm in the next few years.” Although this was his first configuration

of the PCS 7 process control system, Stephan Kaiser from Getinge Alfa was very pleased. “Everything went smoothly,” he concluded.

Central system control

The system is controlled from the central control room. An additional local container operator station is available if necessary. The Simatic PCS 7 process control system uses Simatic WinCC for visualization on all operator stations and is therefore smoothly in-tegrated into the operating concept of the steam plant. The control room of the steam plant is connected by an Industrial Ethernet link. The three Saacke burners are integrated into the control system via one distrib-uted Simatic ET 200M I/O system each (for the motor starter and analog signals such as temperature and pressure) as well as two ET 200S systems. The sensors and actuators for the ignition gas valves and the igni-tion transformer, for example, are also linked by Simatic ET 200 devices. A fi ring manager is used for the control of fresh air, recirculation air, and heating oil. It also manages the fail-safe tasks for the burner, such as monitoring the ignition and pre-venting time of the boiler.

Another new feature in the upgraded system is the use of Sinamics G150 frequency converters for con-trolling the ventilation systems in the steam plant. A 160-kilowatt fan feeds large amounts of air into the system for targeted combustion. Another 110-kilo-watt fan recirculates some of the exhaust gases and helps optimize the combustion process.

The Sinamics converters can be connected easily to the existing 500-volt company network. Although this was a fairly new product, the confi guration was straightforward, according to Kaiser: “Just connect to the power supply, connect Profi bus, and the converter is up and running.” p

V a l o r e c S e r v i c e s A G , B a s e l

Valorec AG runs two key businesses: waste and special waste disposal, and energy provision. The company was founded in 1998 as a subsidiary of Novartis AG, which resulted from the merger of Ciba-Geigy and Sandoz in 1996. In 2001, the company was taken over by the French company Veolia Environnement, one of the world’s leading providers of environment services, as Valorec Services AG.

Both fans – for fresh and recirculation air – are controlled by Sinamics G150 frequency converters


I n B r i e f

Siem

ens

AG

fuel21 GmbH produces bioethanol with Siemens technology

Bioethanol from Sugar Beets

Sitrans LR260 radar level transmitter

Solids Expert

The new Sitrans LR260 two-wire radar continuous level transmitter with Pro-cess Intelligence echo processing and 25 gigahertz pulse technology is par-ticularly suitable for level measurement of virtually any solid medium, in-cluding cement powder, fly ash, coal, gypsum, flour, grain, aggregates, and plastics. The new transmitter reliably measures up to a distance of 30 meters even in environments with extreme dust load and high temperatures up to 200 degrees Celsius.

With the built-in Easy Aimer feature, the transmitter is simple to install. The multilingual Quick Start Wizard guides the user through the programming of the transmitter and has Sitrans LR260 measuring in minutes.

The transmitter can be pro-grammed via the intrinsically safe infrared handheld program-mer or remotely using Simatic PDM via Hart or Profibus PA. Sitrans LR260 includes self-diag-nostics that communicate to the local display and across the milli-ampere loop or network. p

www.siemens.com/level

New Sitrans LG200 guided wave radar level transmitters

Good Guidance

The two-wire, loop-powered Sitrans LG200 Hart level transmitter can measure materials with a dielectric range of 1.4 and higher, tempera-tures up to 427 degrees Celsius, and pressures up to 431 bar. It offers re-liable level and interface measure-ment in liquids with corrosive va-pors, foam, steam, high viscosity, surface agitation, high fi ll/empty rates, low level, and varying dielec-tric number or density.

The new product line of 15 models includes coaxial, single and twin rod, and cable probes. All models are available with Intrinsically Safe, Ex-plosion Proof, or Non-Incendive ap-

provals. With its compact design and range of threaded and fl ange pro-cess connections, Sitrans LG200 is easy to install. Setup is simple with three programming buttons on the instrument or via a Hart handheld programmer. The user can also pro-gram the device from a remote loca-tion with the Simatic PDM process device manager via Hart. p

www.siemens.com/lg200

The two-wire, loop-powered Hart level transmitter Sitrans LG200 can measure materials with a dielectric range of 1.4 and higher, temperatures up to 427 degrees Celsius, and pressures up to 431 bar

Siem

ens

AG

After a project duration of only about 12 months, the fi rst bioethanol plant of the Nordzucker subsidiary fuel21 in Klein Wanzleben near Magdeburg went into operation at the beginning of 2008 and will produce 130,000 m3 bioethanol per year

Siemens received the complete contract for the engineering, delivery, and installa-tion of the energy supply, the drive and automation technology, and the fi eld in-strumentation for the fi rst bioethanol plant of Nordzucker AG in Klein Wanzleben, Germany. The order included 70 Sivacon panels with Simocode consumer outlets, the Simatic PCS 7 process control system, the drive technology for approximately 250 drives, the process instrumentation for about 1,500 measuring positions, integra-tion of the boiler from the sugar factory, and integration of the existing Teleperm M system. The Siemens Automation Solu-tion Partner on / off was responsible for the services part. The plant has since been fi n-ished and was successfully accepted to the satisfaction of Nordzucker AG / fuel21 in March 2008. p

www.siemens.com/biofuels

Siem

ens

AG


D i a l o g u e

process news 3-2008PublisherSiemens Aktiengesellschaft,Gleiwitzer Str. 555, 90475 Nuremberg, Germanywww.siemens.com/automation

Drive Technologies DivisionCEO Klaus Helmrich

Industry Automation DivisionCEO Anton S. Huber

Responsible for ContentPeter Miodek

Responsible for Technical ContentCornelia Dürrfeld

ConceptChristian Leifels

EditorCornelia Dürrfeld, Siemens AG, A&D CC P MC Siemensallee 84, 76187 Karlsruhe, GermanyTel.: +49 (0) 7 21 5 95-25 91Fax: +49 (0) 7 21 5 95-63 [email protected]

Editorial CommitteeAlexandre Bouriant, Sigrun Ebert-Heffels, Michael Gilluck, Birgit Gottsauner, Walter Huber, Ivonne Luthardt, Corinna Nunneri, Rüdiger Selig, Todd Stauffer, Roland Wieser

Publishing HousePublicis KommunikationsAgentur GmbH, GWACorporate Publishing Medien 1 P.O. Box 3240, 91050 Erlangen, GermanyTel.: +49 (0) 91 31 91 92-5 01Fax: +49 (0) 91 31 91 92-5 [email protected]

Editor in chief: Kerstin PuruckerLayout: Jürgen Streitenberger, Bettina RauneckerCopy editing: Irmgard Wagner

DTP: der Döss für Kommunikation, NurembergPrinting: Hofmann-Infocom, Nuremberg

process news is published quarterly.

Cover photo: Fotolia

Circulation: 30.000Job number: 002800 12198

© 2008 by Siemens Aktiengesellschaft Munich and Berlin, Germany.

All rights reserved by the publisher. This edition was printed on environmentally friendly chlorine-free paper.

ISSN 1430-2292 (Print)

The following products are registered trademarks of Siemens AG:ET 200, MICROMASTER, PCS 7, S7-400, SCALANCE, SICLOCK, SIMATIC, SIMATIC IT, SIMOCODE, SIMOVERT, SINAMICS, SINAUT, SIPAT, SITOP, SITRANS, SIVACON, SIWAREX, WinCC

If trademarks, trade names, technical solutions, or similar are not listed above, this does not imply that they are not registered.

The information provided in this magazine contains merely general descriptions or characteristics of performance, which in the case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteris-tics shall exist only if expressly agreed in the terms of contract.

IWI: TPOGOrder number: E20001-M6308-B100-X-7600Printed in Germany

onlineOn the Internet at

www.siemens.com/processnewsyou can download the current issue and past issues of process news as PDF fi les, or search directly for articles about specifi c topics, technologies, and systems in the Reference Center.

projectsSimatic PCS 7 selected for the new CNPC/PetroChina refi nery

Strategic Success

Siemens recently won the contract to serve as main automation vendor for the new CNPC refi nery beacon project in Fushun. Fushun Petrochemical will be the biggest integrated refi ning and petrochemical base in northeastern China. PetroChina decided in 2006 to in-vest 2.4 billion euros to build a refi ning and petro-chemical complex in Fushun in the Liaoning Province of China, which will be run by PetroChina Fushun Pet-rochemical Company. All plants are due to be opera-tional in 2010.

CNPC PetroChina, the world’s third biggest listed energy company by market value, is fully convinced of the benefits of the integration of distributed con-trol system and safety integrated system based on the Totally Integrated Automation concept. PCS 7 has been successfully qualified and accepted due to the superiority of this concept and its unique fea-tures.

The plant installation will be executed by Siemens Industrial Automation Ltd. Shanghai (SIAS). SIAS has 12 years of experience in large-scale project ex-ecution and has just successfully finished the imple-mentation and start-up of the Qingdao refinery proj-ect, also implementing PCS 7. p

www.siemens.com/chemicals

info Do you want to know more about the systems and solutions for the process industry from Siemens Automation and Drives? Simply visit our information portal on the Internet at

www.siemens.com/processautomation

Solution PartnersIn automation top-notch quality is the decisive factor of success in every sector of industry. The Siemens Solution Partners are selected system integrators who act as worldwide solution providers of the Siemens range of products and services and meet global qualification standards. They demonstrate their specialist knowledge and technical expertise in automation, power distribution and product lifecycle management. The global acceptance of our program underscores the standard of quality that our partners implement worldwide. You can recognize this standard by our logo – the assurance of quality. More information: www.siemens.com/true-quality

Answers for industry.

Summa cum laude ...

... summa cum quality.

Download - process news - Siemens · 35 Dialogue. process news | 3-2008 3 Editorial ... intelligent Sipart PS2 positioner, or with an add-on product for the Simatic S7-400FH safety system, allow

Top Related