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SIMATIC PCS 7 In Pulp and Paper

The high-performance Process Control System from SIEMENS

Horizontal integration of all process areas with DCS

TMP

Power distribution Process controlsystem

Quality controlsystem

Sectional drives Single-motor drives

Industrial ETHERNET

Reel transport,packaging, shipping

Sheetcutter

Reel cutterRewinderPaper machineHeadboxStock preparation

Engineering Central human-machine interface systems

Grinding

Wood

Waste paper

LocaloperationTMP

M MM MM M MM MM M

Profibus DP

Power generation

Calander

Pulp

Challenges in the Pulp & Paper industry

The decisive factors for economic production with the enduring price pressures in the P & P industry are:

Production with highest availability and robustness

Increasing complexity of plants

Reducing operating cost by efficient use of resources

Minimizing life-cycle costs, maintenance cost

Increasing productivity

Complying with regulations for environmental protection

Improved flow of information across the entire value chain

Integrated drives

Where DCS can be used in Pulp & Paper?

Complete Pulp & Paper Plants Pulp Plants

Woodyard/Mechanical Pulp/De-inked Pulp/Chemical Pulp

Paper Plants‾ Stock preparation‾ Refiner control‾ Machine control‾ Winder Control‾ Finishing – converting/packaging/etc.

Millwide DCS‾ MIMS/MES

Power & Steam Distribution (Utilities)‾ Boiler control and monitoring‾ Energy management and monitoring

Water & Wastewater Treatment Warehouse Management

Trends in the Pulp and Paper IndustrySiemens faces the customer

TRENDSTRENDS REQUIREMENTSREQUIREMENTSSIEMENS’ ADDED

VALUE

Mergers & acquisitions of companies and their production locations

Globalization of market activities

Increased competition - shorter product lifetime - higher risks

Higher flexibility of production Reduction of quality

management costs

Complete vertical and horizontal integration(from ERP to production floor - from receiving to shipping)

One supplier for all components of all automation levels

Automation with globally available HW, reusable SW and local support

Increased automation of quality management

Siemens’ global presence Openness of SIMATIC TIA provides complete

integration on a single HW and SW platform

ERP, MES, production automation and logistic solutions

Field instrumentation and electrical equipment thru’one-stop shopping

Engineering, project mgmt & execution

Large Bandwidth of Scalability (1:1000)

Pilot plant

ScalableFrom a laboratory system (~100 E/A)...

Productionplant

Interconnected plants at a production location

...to the distributed system in client/server architecture (~ 100.000 E/A)

Customized solutions for PULP AND PAPER

Siemens understand the 7 key challenges for process industry Achieve important competitive advantages with – SIMATIC PCS 7 V8.1

There are many aspects to process industry.Only those who manage them all can leverage the entire potential and take a key step toward the future of manufacturing:

SIMATIC PCS 7 V8.1 =

Innovation based on Experience AND creates new added values for our Customers

• Increase throughput and product quality• Make best use of all resources• Act faster and more powerful in the market

1. Boost productivity2. Protect plants3. Safeguard production4. Increase flexibility5. Enhance operational efficiency6. Cut energy cost7. Speed up time-to-market

SIMATIC PCS 7 Overview – Technologies

IntegratedTelecontrol

MaterialTransports

BatchAutomation

IntegratedField devices

APC Optimization

SafetyIntegrated

PCS 7 in theIndustries

Plant AssetManagement

Scalability

Life Cycle & Remote Services

DCS vsHMI / PLC

IntegratedEngineering

IntegratedSwitchgear

e

Openness

IntegrationPackage Units

EnergyManagement

Information Management

PCS 7 Upgrades &Migration

IndustrialSecurity

24 / 7 / 365

e

SimulationFAT / OTS

System architecture SIMATIC PCS 7

Mobile Client Web Client- OS- Maintenance

Data Monitor ERP

OS/Batch/Route Control/Maintenance Clients

Ethernet, Office LAN

Industrial Ethernet, terminal bus

Industrial Ethernet, plant bus

EngineeringStations

Web Server/OpenPCS 7

Route Control server

Batchserver

Maintenance server

PCS 7 BOX OS Single Station

IndustrialWireless LAN

Wireless HART

Weighing systems

Integrated power management

AS-Interface

Integrated drives

PROFIBUS DP

Modbus, serial connection

PCS 7 AS RTX

Standard automation systems

ET 200pro

PA/FF link

PA link

AFD

PROFIBUS PA

ET 200M,Ex-I/O, HART

AFDiS

PA/FF

ET 200M

Fault-tolerant automation systems

Safety-related automation systems

Zone 2 Zone 1

PROFIBUS

DP-iS

ET 200M

Y-Link

Gas analysis

AFDiS

PA/FF link

AFD

ET 200M, standard andF modules

ET 200M,F modules

PA link

PROFIBUS PA

OSserver

MES/MIS Plant Lifecycle Man.

Archive serverPH / IS

FrontFirewall

BackFirewall

Zone 1ET 200iSP

ET 200iSP

Zone 2 Zone 1

ET 200M

Autom.systemswith PN

Comos

MTA

~

Controller & IOs

Motors and Drives

Pressure Transmitters

TemperatureTransmitters

Flow Metering

Level MeasurementGas

Analyzers Weight Measurement

High- and medium voltage

Safety Products

MotorControl Centers

Operator StationsAdvanced Process Control

Low voltage switch gears, motor starters

Inhouse Production and

R&D of all components

Siemens and the Pulp and Paper IndustryProducts, Services and Solutions

PM-6 : Machine Capacity :280 TPDPaper Type: W&PProject Year :2009-2010

A customer from Andhra Pradesh

Total Scope:

HT PCC, MCC Sectional AC/DC Drive system Drive control automation with PCS7 Automation for Paper Machine MCS Commissioning & supervision of operation

S5 I/Os for Wet End & Dry End

I/Os for MCCs and different process sections

I/O Field for Head Box and Wire

PROFIBUS NETWORK

PCS7 CONTROLLERCPU 414

Speed Sizer I/Os and DVT waste water Plant I/Os DRIVE SYSTEM

QCS

OS3 OS4OS1 OS2

AREA # 3 ( WET END ) AREA # 4 ( DRY END )

PR1 PR2PR3 PR4

Server Monitor

ES ( ENGG. PC )

Fiber Optics Ring Topology

Fiber Optics Ring TopologyREDUNDANT SERVER

A customer from Andhra PradeshSystem Configuration

Green Field Project Machine Capacity: 120TPD, Machine speed : 250mpm, Paper Type: Kraft , Deckle : 4.5 m. Project Schedule : 2009-2011

A paper customer from Tamilnadu

Total Scope:

Engineering, Supply, Installation & commissioning of

11KV Switchyard HT PCC, LT PMCC Distribution Transformer LT Motors Sectional & Standalone Drives S7 based Automation for Drive Control DCS system for Pulp Mill & Machine control HT/LT Cables Plant lighting, Earthing 5 years Maintenance Contract

A paper customer from TamilnaduSystem Configuration

OS1

PRINTER

PMCC-1 SIMOCODE RELAYPAPER MACHINE

PMCC-2 SIMOCODE RELAYPULP MILL

PAPER MACHINEDRIVE CONTROLLER-1

ES

OS2

I/O Field & INST.PAPAER MACHINE & PULP MILL

PROFIBUS

PULP MILL CONTROL ROOMPAPER MACHINE CONTROL ROOM

ETHERNET

SERVER

ETHERNET

CONTROLLER

STANDALONE DRIVES

A customer from Andhra Pradesh

Total Scope:

Engineering, Supply, Installation & commissioning of

DCS for Waste Recovery Boiler 12TPH including Digester, Evaporator, Caustisizer

Supply & Commissioning of PCS7 based HOT STANDBY controller, remote IO stations for 1800 I/Os

6 nos. of Operator Stations and Field Instrumentation Project Schedule: 2005-2006.

A customer from Andhra PradeshSystem Configuration

CPU 417-4H HOT STANDBY CONTROLER

Power Boiler

ET 200MI/O Station1

Printer

Evaporator Area

OS1 OS2Recovery Boiler

ES/OS3 OS4

Digester AreaOS5 OS6

ET 200MI/O Station2

ET 200MI/O Station3

First Unit : Project TG4 (Expansion of PM-5) (2003-2004)Pulp Mill Expansion (2006-2007)

Second Unit : Project TG (18MW TG) (2004-2005)Board Machine-1 (2006-2007)Machine Capacity: 300TPD

A paper customer from Telangana

Siemens Scope:

First Unit (Turbine Generator) Turnkey contract for Entire Power Distribution & Plant Electrics 11KV Panels, LT Panels, Cables, Motors & Distribution Transformer Bhadrachalam Unit (Pulp Mill Expansion) Turnkey contract for Entire Power Distribution & Plant Electrics 11KV Panels, LT Panels, Motors & Illumination, Earthing & Lighting Kovai Unit (TG) Turnkey contract for Entire Power Distribution & Plant Electrics 11KV Panels, LT Panels , Cables & Distribution Transformer

Second Unit (Board Machine) Revamping of Existing DC Drive to AC Drive, standalone Drives Automation

Our vision – setting the pace!Pulp Mill

Our vision – setting the pace!Pulp Mill

Our vision – setting the pace!Paper Machine

Our vision – setting the pace!One screen for all Drives parameters…

Mechanical pulpMechanical pulp

TissueTissue

GraphicGraphic

Siemens Pulp & Paper activities in the internetwww.siemens.com/paper

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