ii world wide pasta congress venezuela october 2000 page 1 totally integrated automation siemens in...
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II World Wide Pasta Congress Venezuela October 2000
PAGE 1
Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
the partner for theFlour Mill and Pasta Plants
SIEMENSSIEMENS
II World Wide Pasta Congress Venezuela October 2000
PAGE 2
Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
PRESENTATION PROGRAM
►Introduction►Concept►Requirements►Solution►Communications►Information management►Advantages►Conclusions
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
INTRODUCTION (1)
The automation of pasta plants had in these last years an important evolution.
The programmable controllers are able to integrate all the process control functions into a PLC and now into PC integrating through Profibus, peripherals as inputs/outputs, drives, intelligent devices and operator panels
The actual scenario is characterized by a Totally Integrated Automation Concept using a common hardware/software platform standard networking to satisfy the customers demand.
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
INTRODUCTION (2)
The Totally Integrated Automation Concept consists in integrating under a single automation system, three important areas which till now were automated separately as:
Semolina silos (upstream) Pasta production (mainstream)
Packaging and warehousing (downstream)
Totally Integrated Automation (T.I.A.) is performing process control, recipes handling, lots scheduling, products tracing, traceability, warehousing and web connectivity.
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
Raw Material
Wheat Receiving
Raw Material
Wheat Receiving
Milling
Semolina Silos
Mixing Silos
Milling
Semolina Silos
Mixing Silos
Press
Extrusion
Press
Extrusion
Drying
Cooling
Drying
Cooling
Packaging
Palletizing
Warehousing
Packaging
Palletizing
WarehousingUtilitiesUtilities
Ups
trea
mU
pstr
eam
Dow
nstreamD
ownstream
MainstreamMainstream
PLANT FLOW SCHEMATIC DIAGRAM
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
Wheat ReceivingWheat ReceivingMilling
Semolina
Silos
Milling
Semolina
SilosPress Extrus.Press Extrus. Drying Cool.Drying Cool. Packaging
Palletizing
Packaging
PalletizingUtilitiesUtilities
PLANTWIDE ISSUES
Distributed I/ODistributed I/O
ControllerController
HMIHMI
Drives / Field devicesDrives / Field devices
Co
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nica
tion
Co
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urin
g/P
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on
figu
ring
/Pro
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ing
PCSPCS
Data
ma
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gem
ent
Data
ma
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gem
ent
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
Handling,Packaging
Palletizing,Warehousing
Field Automation
Process Control System
Manufacturing Execution System
Enterprise Resource Planing
Semolina Silos
Extrusion,Drying,Cooling,Utilities
ARCHITECTURE STRUCTURE
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
► THE CONCEPT
T.I.A. means design the plant automation introducing a new concept that has to consider the factory in its entirety.
Production flexibility, costs control and total quality approach are successful key points for small and large companies.
The target is to change a production process from a critical factor to a qualifying factor.
To perform a complete control of all the different production phases starting from raw materials receiving and forwarding to the finished products.
TIA is given an important contribution in terms of costs reduction, for revamping and new pasta plants
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
PASTA PLANT WIDE ARCHITECTURE
Ethernet TCP/IP, 100 MBit
Engineeringstations
Short pasta line
ERP
Industial Ethernet TCP/IP, 100 MBit
Water treatment
Waste watertreatment
Compessedair
Cooling
Silos floor
Fieldbus system
PROFIBUSAS-Interface
MES
Boiler
Ground floor
Press Bridge
Press Foot
Cutter
Pre dryer
Dryer
Cooling/Storage
Grinding
Last floor silos
Press bridge
Flour silos
Long pasta line
Press Bridge
Press Foot
Spreader
Pre dryer
Dryer
Cooling
Storage
Packaging Palletizing
WinccClient
Grain Receiving
Milling
Sieving
WheighingSistem
Flour silos
Flour Silos
WinccServer
Milling Plant
WinccClient
WinccClient
WinccClient
Packaging
Handling Palletizing
Warehousing
WinccServer
WinccServer
WinccServer
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
► PLANT REQUIREMENTS
Real time monitoring of process variables through supervisory system, and relevant corrective actions in order to guarantee high quality.
Client/server technology to address information of concurrent process to Control Room and plant Information Room in order to maximize the sinergy.
Communication and interoperability of production areas (orizontal way) and other plant departments (vertical way)
Production data provided simply and clearly to the decision level
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
► AUTOMATION SOLUTION
SIMATIC S7 controllers with distributed ET200M, drives technology and field instruments linked through Profibus.
SIMATIC OP panel for distributed visualization and monitoring
Drives Technology
WINCC supervisory system based on client/server architecture with Industrial Ethernet networking
SIMATIC Industrial Software integrated through all Project Phases
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
SIMATIC Controllers
More than just PLC's
• S7 300 , S7 400 , S7 400H•I/O ET200M , ET200S•Operator Panels OP27 , OP37•Profibus and Ethernet Cards
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
DRIVES TECHNOLOGY
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
The Multi Client server architecture
A Multi Client provides a common view ofthe process data of distributed servers in one pictureall the measured value archives, e.g. in one curve windowall the message archivesthe pictures/picture windows of different servers
WINCC SUPERVISORY SYSTEM
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
WinCC Goes Web
Operation and monitoring of the plant via the Worldwide Web
WinCC WEB TECHNOLOGY
VENEZUELA H.Q.
USA Plant
INTERNET
MEXICO Plant
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
ENGINEERING STARTS WITH TOP-DOWN DESIGN OF YOUR SYSTEM
Plant / SystemPlant / System
Unit OperationUnit Operation
Equipment GroupEquipment Group
Device / LoopDevice / Loop
- Overall plant architectural structure - Control strategy- Operator visualization- Local operator panels- Peer communication- Field devices, including transmitter parameteriz.- 3rd Party PROFIBUS devices
THE SIMATIC MANAGER IS THE SINGLE TOOL
TO COORDINATE THE COMPLETE TIA SYSTEM CONFIGURATION
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
S7 400
AUTOMATION SYSTEM TOPOLOGY FOR LONG PASTA LINE
WIN CCINDUSTRIAL ETHERNET
PRESS DRYER/PREDRYER COOLING/STORAGE SPREADER
DOSING SYSTEM
MIXER
EXTRUSION SCREWUP TO 4
PRESS BRIDGE PRESS FOOT
REMOTE I/0ET200
REMOTE I/0ET200
REMOTE I/0ET200
PROFIBUS-DP
REMOTE I/0ET200
FAN
CHAINE MOTOR
REMOTE I/0ET200
OP OP
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
Distributed I/O systems save up to 20% of the wiring costs:
A family of distributed I/O systems provides the right I/O for the right application and reduces wiring costs
distributed motor starters and drives used in the pasta lines allow distributed wiring of the power bus
Savings in wiring costs
20%
Co
st f
or
wir
ing
REDUCED INVESTMENTS IN THE PASTA PLANT
DISTRIBUTED I/O SAVE WIRING COSTS
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
Each supervisory station can handle supervision functions of the entire plant in addition to graphic pages, recipes handling, data archiving real time/historical trending, alarming.
Comunication and interoperability are key factors for data flow from orizontal way to vertical way.
To achieve production flexibility , for successful growth, of small, medium and large companies
►COMMUNICATIONS (1)
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
With T.I.A. concept and relevant networking /communications we can assure data flow from process level to supervisory and management level, from incoming raw materials to the finished products.
It means :
- Right info
- To right people
- At right time
- At right place
In any kind of pasta plants
►COMMUNICATIONS (2)
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
TYPICAL SYSTEM TOPOLOGY FOR PASTA PLANT
WINCC
Multi Client
ETHERNET
WINCC SERVER
WINCC SERVER
PROFIBUS DP PROFIBUS DP PROFIBUS DP PROFIBUS DP
SHORT PASTA LINE
IND.ETHERNET
SHORT PASTA LINE LONG PASTA LINE LONG PASTA LINE
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
VERTICAL INTEGRATION– TCP/IP, @aGlance, ODBC, SQL, OPC,
Net DDE...– Web Browsers, intra / internet...– Gensym bridge...– SAP R/3 PP-PI…
HORIZONTAL INTEGRATION– Ethernet, PROFIBUS,, ASi-Bus
DATA MANAGEMENT STANDARD INTERFACING APPROACH
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
► INFORMATION MANAGEMENT
MES and ERP Connectivity in order to have plant information and management decision support
Process optimization and data analysis
Web connectivity for remote information and production control
Certified module for linking to SAP
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
MAIN FEATURES:
- process data acquisition
- data analysis
- process optimization
- certified module for linking to SAP
MAIN BENEFITS:
- improved production quality
- improved process diagnostic
OperationOperationManagementManagement
DraftDraft
Model
Intelligent Production Systems
Profound Process Knowledge
Integrated Software and Services
Platform Independence
PCS
Process Control Systems
Field Instrumentation & Operating Control
ERPCross-Company
Resource PlanningSupply Chain
Management & Business Systems
COMPLETE INFORMATION MANAGEMENT WITH INFOPLUS.21
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
► THE ADVANTAGES
It is able to satisfy adequately the requirements to operate and manage integrally the plant.
It trasforms the process control into plant production control with a single system solution.
It is garanted quality and HACCP certifications
It can begin from a minimum architecture of one to several lines, of a small to a large plant.
It reduces costs and spreads the investments according to plant growing, with an interesting pay back.
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
INCREASING EFFICIENCY IN THE PASTA PLANT
E.U. ADVANTAGES:
Central control room to control upstream, mainstream and downstream areas data production
Repetitive quality and relevant improvement
Fast trouble shouting (more lines availability)
Less Spare parts (maintenance costs reduction)
Energy saving
The Totally Integrated Automation advantages are the followings:
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
COSTS REDUCTION IN THE PASTA PLANT
ENERGY SAVING
OUTPUT QUALITY
LESS HUMAN RESOURCES
Due to optimization of motors control according to production needs (less power consumption using drives technology)
Repetitive quality and relevant improvment ,due to integrated process control and less reject during shape change
Fast trouble shouting ,less spare parts,resources optimization due to T.I.A. concept,central control room, diagnostic systems, intelligent allarms
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
► CONCLUSIONS
T.I.A. concept will give an important contribution in terms of costs control and cost reduction.
T.I.A. concept will increase the possibility to build up new plants in new geographical areas where there are new markets with less specific experience
The experience tipically of the Mediterranean countries is now available using T.I.A. concept in the ROW.
By using T.I.A. both the pasta lines manufacturer and pasta producer can achieve important market advantages.
II World Wide Pasta Congress Venezuela October 2000
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Totally Integrated Automation SIEMENSSIEMENS
in the Pasta Plants
Competence in Pasta Plant Automation
SIEMENSSIEMENS Thank for your attentionThank for your attention
Contact A&D Competence Center Food & Beverage - Mill &PastaAntonio Rossetti :phone +39 02 66762933
Massimiliano Andreoli :phone +39 02 66762889 fax +39 02 66762916E-mail to [email protected] [email protected]