Process News 2012 4 En

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process newsThe Magazine or the Process Industry

Number 4 | 2012 | siemens.com

A Changing MarketTrends in drive technology


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process news 4/2012 | Rubrikprocess news 4/2012 | Contents

Editorial

03 Higher Productivity, Higher Eiciency

Cover04 The Market Is Changing

Linde AG, Germany

Drive Technology

08 Standardized yet Individual

Sinamics G120

10 The Next Level

Geldersheim Sewage Treatment Plant, Germany

13 More Productive GrindingDrives or Vertical Mills

Cement

14 Solid Foundation

Building Materials Industry Company, Egypt

Packaging

16 Pack Smart

Meypack Verpackungssystemtechnik GmbH, Germany

Condition Monitoring18 Absolute Availability

Penig Gear Plant, Germany

Process Control Technology

20 Merging Systems

Switchgear Integration

22 No Access

Industrial Security

24 Virtual Commissioning

Simulation or the Process Industries

Plant Engineering

26 Perect Optimization

Zeppelin Systems GmbH, Germany

Pharmaceuticals

28 Clean and Integrated

Schlke & Mayr GmbH, Germany

Renewable Energy

30 Sustainable Power

North-Tec Maschinenbau GmbH, Germany

32 Complete Process Package

Arnold-Blume Bioenergie GmbH, Germany

Web Exclusive

34 Weighing Technology, Water Treatment, Sipart PS2

Dialogue

35 Preview

Focus on Drive TechnologyDrive technology is key to increasing energy eiciency

and productivity in the process industries. Many companies

are acing new challenges one example is the Linde

Engineering Division based in Munich. The cover photo

shows a urnace that is part o Lindes hydrogen

production plant in Burghausen, GermanyPhoto: The Linde Group


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Editorial | process news 4/2012

Higher Productivity,Higher Eiciency

Up to 70 percent o the power consumed in actories today is used or the

operation o drive systems and that is why drives can also make a

signiicant contribution to total energy savings. This is especially true or

an energy-intensive ield o production such as the process industry. Drive

technology is an important ac tor or optimizing plant liecycle costs, and

our customers are becoming increasingly aware o this issue, as Kurt Eder

rom Linde Engineering conirms in an interview on page 4.

As the leading industrial supplier o electrical drive solutions, Siemens

Drive Technologies has an obligation to both its customers and the

environment. We are committed to working together with partners and

customers to identiy potential or energy savings. We also demonstrate

this commitment in our own processes, where we strive or maximum

energy eiciency during the production o our motors and drives. Read

on page 18 how the Siemens gear production acility in Penig, near

Chemnitz, was able to improve productivity and reduce overall energy

consumption through plant monitoring and energy management.

When we talk about the next steps in the development o our automation

and drive portolio, IT integration is a key topic. Through tight integration

o control and drive components with IT systems, our customers can

improve their productivity in both engineering and operation. Our Simotics

motors are a major component o integrated drive systems and they are

part o our TIA product range, just like our converter solutions or the

process industry and high-per ormance drive concepts or mills. You can

read more about these and other topics concerning our products or the

process industry in this issue o process news.

Enjoy the read!

Ral-Michael Franke

CEO, Drive Technologies Division


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process news 4/2012 | Cover

Mr. Eder, as head o the electrical engineering

department in the Linde Engineering Division,

you are responsible or electrical equipment in

plants throughout the entire world. Why are you

so intensely involved in drive technology in this

context?

Kurt Eder: In these plants we are responsible or

practically everything that has a connection to a

power supply rom the medium-voltage cable to

even the telecommunications and access control sys-

tems, i the customer requires this. But, o course,

were involved with drives in particular because they

constitute maybe not in numbers but certainly interms o the power required the largest part o the

power consumers in a chemical plant.

But one would think that drive technology

is more a run-o-the-mill business as the

technology is very mature.

Eder: Youd think that at rst glance. But in act, the

technology is evolving and changing, so drives are a

market that is quite dynamic. One example is variable-

speed operation o drives, where inverters were in-

troduced very early into process applications. It took

a while or this new concept to catch on because it is

The basic technical principle has remained virtually unchanged or the lasthundred years, but electrical drives in the process industry are nevertheless an

area that is very dynamic and is evolving constantly. This changing market

provides some new challenges or the Linde Engineering Division, says Kurt Eder.

Linde AG, Germany

relatively complicated compared to a simple on/o

contactor. Today, the technology is considered estab-

lished, and we are equipping large drives with start-

ing inverters.

The next big challenge is increasing energy e-

ciency. At rst this was only discussed among special-

ists. Today our customers speciy energy-eciency

standards in their tender documents. In addition to

the capital expenditures o a plant, operational ex-

penditures are increasingly included in plant speci-

cations. We see this in the tender documents; oper-

ators are rethinking and changing their ocus in order

to reduce operating costs. And as they are large con-sumers o power, drives oer a correspondingly large

savings potential. The basic principle o an electrical

drive has indeed remained unchanged or well over

a hundred years but we are acing constantly evolv-

ing requirements in the application and process en-

vironment.

And does this have specic consequences

or your company and your partners?

Eder: Denitely. We have to nd innovative solutions

that are both cost-eective and resource-ecient in

a competitive and cost-driven market. So we need

The MarketIs Changing


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Cover | process news 4/2012

all-purpose drives in order to limit our engineering

expenses. And, as we are serving customers in many

regions o the world that allow us to have to comply

with dierent standards and meet dierent market

requirements, we need systems where we can reuse

the parts or components o a solution. That helps us

capitalize on the knowledge weve gained.

But we also need drives that are fexible. Ideally, we

want to be able to design or build a motor in such a

way that it has only the eatures that are really

needed or the given application. One customer may

include many eatures in the specications which

we are happy to provide, o course while anothercustomer asks us or a more streamlined and eco-

nomical version. It is thereore helpul to us when a

supplier can oer options like this with products that

meet our requirements in terms o price and peror-

mance. In Siemens, we have ound such a partner:

they can provide the required option packages and

collaborate with us in the bidding process.

What does this collaboration look like?

Eder: We create our requirements based on the ten-

der documents. What might happen next is that the

experts rom Siemens come back to us and ask

whether an alternative, oten more cost-eective

solution would be possible or a certain large drive

system. We really work together as a team in this pro-

cess, aligning requirements and solution in order to

nd the optimum solution or the customer. Just re-

cently, we won a contract exactly because o this

PublicisErlangen

We have to fnd

innovative solutions

that are both cost-

eective and efcient

in a cost-driven,

competitiveenvironment.

Kurt Eder, Manger o Electrical Technology,

Engineering Division, Linde AG


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other trend in the market is that chemical plants

and thus also the capacity o individual drives are

becoming larger and larger. Today, 60 MW motorsare more the rule, not the exception. Such huge mo-

tors will typically come with a starting inverter, not

to make them more energy-eicient but to limit the

start-up load or the power grid. So when we are

building a new plant, the growing scale means we

ace issue that used to be the domain o grid oper-

ators and power utilities.

A project that we worked on recently included the

power supply to a large air-separation plant via a 220

kV overhead power line. This type o power supply is

not what you would consider part o the classical

scope o a process engineering company. However,

team approach. In this case, Siemens could oer a

solution with a roller bearing that was considerably

more cost-eective than the planned solution withan oil unit, and that was ultimately the winning ac-

tor. Through working as a team, we could come up

with a more attractive oer and that is what we ex-

pect rom a drive technology partner. Large drives

are a business that requires a lot o consulting; o-

the-shel solutions just wont get you ar.

So partnership and expertise are important

even when you think you are dealing with an

established technology?

Eder: They are in act absolutely critical and not

just because o what we have just discussed. An-

process news 4/2012 | Cover

PublicisErlangen

10 MW

2002

2012

2014

40 MW70 MW

Larger and more powerul

Along with the scale o the plants they are used in, drives are

getting larger and larger. Ten years ago, a typical drive would

have a power o around 10 MW; today, engineers are designing

single drives with 70 MW. Such a drive will consume the powerequivalent o a well-sized city, which has engineering companies

acing completely new requirements.

17,000Homes

68,000Homes

119,000Homes


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INFO AND CONTACT

www.siemens.com/[email protected]

because the required power just cant be transmitted

at a lower voltage level, we are acing new chal-

lenges also because the grid operators themselves

have become very lean in their organizations and

they are telling us, You have to build this transormer

station according to our specications. For us, that

means we have to integrate our systems into the pub-

lic power grid. And the power utility would, o course,like this integration to be absolutely smooth.

Do you benet rom the collaboration with

Siemens in this area as well?

Eder: Absolutely. With such amounts o electrical

power, you really have to look closely at things like

power supply quality. However, our customers are

chemical companies, not power utilities. Thereore,

we have to work with the experts at Siemens to iden-

tiy ltering capabilities and solutions or the grid

connection that provide the greatest economic ben-

et. We then present the result to our customer in the

chemical industry, who, in turn, takes this solution to

the power utility.

Especially in the very dynamic markets in Asia, the

grid operator is oten planning the power supply

while we are already engineering the large-drive sys-

tems. We have to collaborate intensively in such an

environment so that in the end, the power utilit y will

accept our solution. That was one o our great suc-

cess stories that we had recently: we Linde, Siemens,

and the plant operator jointly developed a solution

that the customer presented and that was accepted

by the specialists at the Chinese utility. This proves

that you really can develop a good solution even in a

dicult environment when you team up with the

right experts.

A very rewarding project or you and also or

Siemens. So what do you think is next in the

area o drive technology?

Eder: The developments in the market denitely pres-

ent opportunities or innovation in the area o drive

technology. When we look at inverters or large drives,

we can see new options emerging in the design o the

process itsel or example, we can design the com-

pressor dierently, creating a wider range or partial

loads over the entire plant. And suddenly, requency

inverters in perormance classes up to several dozen

megawatts are really worth looking at.And the drives themselves will continue to get big-

ger. We have already designed a 70 MW machine or

a project. As electrical power is the most cost-eec-

tive source o energy in many cases, steam turbines

will be displaced to even higher perormance and

power ranges by electrical drives.

Another important area is power electronics,

where components are generally becoming more

cost-eective, which will have new implications and

allow new options or drive design. The inverters

themselves are also becoming smaller, more com-

pact, and less expensive. The use o requency invert-

ers will certainly trigger more changes in drive con-

cepts so drive technology really is a much more dy-

namic business than youd think.

Mr. Eder, thank you very much or speaking with us.

Cover | process news 4/2012

You can develop a

good solution even

in a difcult

environment when

you team up with the

right experts.

Kurt Eder, Manger o Electrical Technology,

Engineering Division, Linde AG

PublicisErlangen


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process news 4/2012 | Drive Technology

Sinamics G120

Standardized yetIndividualVariable-speed operation o motors or example, in pumps, ans, and

compressors has more benets than just saving energy. In the perormance

range between 0.37 kW and 250 kW, the Sinamics G120 modular inverter series

oers many possibilities or optimizing processes, perecting automation, and

perorming saety-related tasks.

The modular Sinamics G120

inverter system consists o

dierent unctional units a

control unit, a power module, and

an intelligent operator panel or,

optionally, a basic operator panel

Siem

ensAG


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Drive Technology | process news 4/2012

INFO AND CONTACT


The Sinamics G120 consists o a

power module, a control unit, and

either an intelligent operator panel

or a basic operator panel. The high

overload capability o this drive is espe-

cially suited or applications in the pro-

cess industry, as it helps prevent aults

due to jamming caused by particles or

when moving parts become stuck ater

extended downtimes.

Energy eciency due to recovery

The Sinamics drives support energy

eicient equipment operation in sev-

eral ways. The inverter can be kept in a

standby position with the hibernation

unction. When it is implemented in

a communication environment using

Pronet and the Proenergy protocol,

users can congure comprehensive sys-

tem solutions that can be completely

switched o during breaks in produc-

tion, thus decreasing power consump-

tion. The Sinamics G120 eatures the E-

cient Ineed Technology or regenera-

tive eedback into the line supply or

energy savings and users can convert

potential energy into power and thus

eliminate braking resistors. Even a power

choke is no longer required.

Modular and fexible

The trademark o the Sinamics G120 is

its modularity. The power module, con-

trol unit, and sotware unctions can beadapted to a wide range o tasks. Elec-

trical planners can select precisely the

components suitable or their applica-

tion and assemble the optimum re-

quency inverter.

Due to the completely customizable

coniguration o the power module,

controller assembly, and sotware, the

Sinamics G120 can be adapted to the

most diverse requirements. There is,

or example, a CU230P-2 control unit

especially or pumps, ans, and compres-

sors. Up to our proportional-integral-

derivative (PID) controllers depending

on the type o control unit can be

used to control process parameters,

which relieves some o the burden on

the plant control system. In addition, the

G120 also supports integrated saety

unctions and ail-sae communication

via Prosae. Altogether, the result is a

system suitable or many tasks.

Integrated unctions or saetyand rapid commissioning

O course, the inverter series also oers

integrated unctions or plant saety.

Five dierent objectives can be set

here rom sae torque shut-o to

completely stopping a drive. Due to the

shared-device unctionality, the saetytechnology is particularly easy to use.

Standard automation and saety tech-

nology can be planned separately. The

system engineers, or example, can use

a dedicated ail-sae programmable

logic controller (PLC) or saety technol-

ogy, or they can run standard process

automation and saety technology on

the same platorm. Users also benet

rom the unctionality o the Sinamics

devices during commissioning o the

drive system. Tools support the adapta-

tion and conguration o the motors.

Using the simulation mode, the motor

unction can be tested even without a

higher-level control and eedback to

the controller.

System solution orvariable-speed operation

With the Sinamics G120 model series,

users benet rom a ully customizable

drive series according to the speciic

requirements or hardware, sotware,

and unctional modules. This approach

acilitates creating an optimized drive

solution that is sae, energy-eicient,

reliable, powerul, and cost-eective.

The Sinamics G120 variable-speed drives

are not only an ideal solution or the

process industry but also or typicalmechanical engineering applications

or example, in conveyor technology;

in mixing and stirring plants; in centri-

uges, compactors, extruders, and ans;

or in packaging technology.

SiemensAG

A large number o

applications in or relating

to the process industry

beneit rom variable-

speed drives. The modular

Sinamics G120 can be

customized to it the

individual application


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Sewage treatment plants hold a special position

among municipal acilities. On the one hand,

they are large consumers o power and will typ-

ically rank even above schools and hospitals. On the

other hand, most sewage plants can also generate

power and heat. Anaerobic sludge decomposition

produces biogas, which ater purication can beused or power or heat generation with gas motors

or cogeneration units. Treating wastewater, however,

also requires a great deal o energy, and a dierent

type o energy as well, especially large quantities o

compressed air that is produced by rotary compres-

sors or turbocompressors, a process that is a major

consumer o electrical power. The process also re-

quires heat energy, or example, to control the tem-

perature in the decomposition and ermentation pro-

cesses. So energy optimization o a sewage plant in-

cludes both aspects: reducing energy consumption

and increasing energy eciency.

Basic and detail analysesare the keys to success

This was also the aim at the sewage treatment plant

in Geldersheim, where more than our million cubic

meters o wastewater are puried annually. As man-

ager Jrgen Seuert explains, in addition to upgrad-ing the Simatic controllers, the replacement o the

existing process control system was planned. In order

to successully implement these projects, Seuert

consulted specialists both the Nuremberg branch

o the H2Oce engineering rm, which specializes in

wastewater treatment plant optimization, and the

experts at the Siemens oce in Wrzburg to help

boost the acilitys eciency.

The optimization o energy use in wastewater treat-

ment usually starts with an energy audit. During the

basic analysis, a basic classication o the plant is per-

ormed and potential savings are identied. The de-

Energy consulting and technical modernization are perectly integrated

in the optimization measures implemented at the sewage treatment

plant in Geldersheim, Germany. The result is a system that is up-to-date

in terms o consumption and power production.

Geldersheim Sewage Treatment Plant, Germany

The Next Level


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INFO AND CONTACT



tail analysis then lists all the major electrical loads

with sucient data and compares specic consump-

tion gures and target or ideal values. Within this en-

ergy optimization study, the identied measures are

examined in terms o their technical and economic

easibility and placed on a timeline. The result is a

specic action guide or energy optimization.

Replacement o instrumentation and controls

In Geldersheim, it quickly became clear that in addi-

tion to process engineering expertise, the use o

modern technology was also required in order to

achieve the desired increase in eiciency. The

Simatic WinCC Supervisory Control and Data Acquisi-

tion (SCADA) system, initially installed to monitor the

exterior buildings, and the Acron logging tool estab-

lished the basis or the detailed analysis. Upgrading

the drives with variable-speed Sinamics requency

converters also played a role in ensuring energy-

ecient plant operation. The integration into the

SCADA system and the visualization o energy data

were easily accomplished. The automatic motor

speed control allows or the immediate adjustment

o power consumption in partial-load operation. Vir-

tually no energy is wasted, unlike with mechanical

systems.

Multiunctional measuring devices rom the

Sentron PAC series round out the technical equipmento the wastewater treatment plant. With these de-

vices, measured variables such as voltage, current, and

power supply values can be recorded precisely. These

data are then also made available to the higher-level

control system. Visualization o the newly captured

operating data in Simatic WinCC required an exten-

sion o the operating protocols. The experts rom

H2Oice and Siemens worked together to achieve

this. The engineering irm speciied which energy

data were to be incorporated into the calculation o

ratios and how the values recorded were to be eval-

uated and displayed. The Siemens specialists then

took on the appropriate programming and visualiza-

tion in the control system.

As part o the detailed analysis, the experts rom

H2Oce set up dynamic energy models or individ-

ual areas o the Geldersheim sewage treatment plant.

Secure remote access to the protocols then allowed

the simulation o pumping stations with all the actual

operating parameters. This enabled other operatingmodes and control behaviors, as well as their eects

on power consumption, to be examined without a-

ecting actual operation.

Energy generation was also to be increased in ad-

dition to energy savings. According to the general

analysis, it made sense to treat other organic waste

as well. In the detailed analysis, the result was con-

rmed by measurements indicating that gas produc-

tion could be increased by about 30 percent through

the co-ermentation o the grease separator contents,

enabling savings o more than 20,000 euros per year.

Positive balance

We are proud o the optimization measures we have

implemented, says plant manager Seuert, and the

next steps have already been identied. Among

other things, the team plans to introduce an energy

management system or the reduction o peak loads.

Both the theoretical and technical bases are nally

available, says Seuert. With Simatic WinCC and theknow-how o the two teams o experts, the opera-

tors are perectly prepared to implement urther en-

ergy optimization measures in Geldersheim.

We are proud o the optimization measures we

have implemented, and the next steps have already

been identifed. Among other things, we plan tointroduce an energy management system or the

reduction o peak loads.

Jrgen Seuert , Plant Manager, Geldersheim Sewage Treatment Plant


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Drive Technology | process news 4/2012

INFO AND CONTACT


The Flender EMPP is mechanically com-

patible with existing mill drives but has

been optimized in terms o power den-

sity and unction. The brushless per-

manent magnet motor is wear-ree,

and its cooling system is very eicient.

The entire drive is wear-ree due to the

use o sleeve bearings. Compared to a

system with a bevel gear and two plan-

etary gear stages, the drive system has

20 percent ewer moving parts. This re-

duces sources o aults. The size and

the weight have been reduced by ap-

proximately 25 percent through the in-

tegration o the motor into the gearbox.The inverter-controlled motor allows

active damping and optimum adjust-

ment o the grinding table speed, or

example, to dierent materials and

thereby enables the cement mills to

achieve higher eciency.

More and more, aster and aster

this is the trend everywhere, even

in the cement industry. For this

reason, larger and larger vertical

roller mills are being used. New

concepts optimize the power

transmission between drive and

mill, and productivity and

availability are increased.

Drives or Vertical Mills

The drive systems usually used or

vertical roller mills consist o a gear-

box and an asynchronous motor;

outputs o up to about 8 MW are possi-

ble. Larger cement mills, toward which

there is a clear trend, require ar higher

drive power. The demands on avail-

ability also increase with the mill size.

In order to allow at least partial-load

operation in case o malunctions, the

drive concepts must be modularly de-

signed and adequately redundant. I

the processes are then optimized using

more precise speed control, the grind

and productivity can be improved.

Innovative systems: FlenderMultipleDrive

Two new drive systems meet these re-

quirements. The central idea o the

Flender MultipleDrive concept is redun-

dancy. The input shats o up to six

small and compact helical bevel gear

units are each driven by a requency-

controlled asynchronous motor. Since

the gearbox, motor, drive coupling, and

oil supply system are arranged on a car-

rier, the replacement o a drive or in-

spection purposes is not a problem. Be-

cause o the redundancy, the operation

o the mill is also possible with a re-

duced number o actuators. The param-

eterization o the Flender MultipleDrive

requency converter ensures uniorm

load distribution while subjecting the

parallel drives to a low dynamic load.

The requency converter enables all the

required operating conditions as well as

precise control and regulation o the

mill speed. Outputs o up to 16.5 MW

are possible. The much lower height incomparison to conventional drives a-

vors more ecient mill construction.

and Flender EMPP

The Flender EMPP mill drive is based on

a new motor in the gearbox under the

planetary gear stages. The simple struc-

ture without a bevel gear stage opti-

mizes power transer. A very compact

unit is created rom the ve planetary

wheels in the main planetary gear stage.

MoreProductiveGrinding

New drive concepts such as the Flender MultipleDrive sustainably

enhance the productivity o vertical mills in the cement industry

S i e m e n s A G


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process news 4/2012 | Cement

Teamwork and partnership are the key to building

a cement works rom scratch in Upper Egypt.

Building Materials Industry Company, Egypt

When a major industrial production acility is to be

created on a greeneld site, many dierent organi-

zations must come together to ensure the success

o the project. Just such a situation occurred in Egypt in

2007 when the newly ounded Building Materials Industry

Company o Egypt (BMIC) acquired a license to build a new

Construction o the new cement mill began in 2010

Solid Foundation

cement plant in the Upper Egyptian governorate o

Assiut. When it is in ull production, the plant will produce

1.5 million tons o cement per year, making it a major pro-

duction acility by world standards. Modern cement plants

contain some o the largest rotating equipment in the world

and require motors with up to 12 MW o drive power.


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Cement | process news 4/2012

PLUS high-voltage motor with modular cooling, an N-compact

low-voltage three-phase motor, and Sinamics G150 and

GM150 drives. The DCS employed in Assiut is Cemat, based

on the Simatic PCS 7 platorm. The Cemat control system isan industry-speci ic sotware suite designed or the special

requirements o lime and cement works. It is the result o

over 35 years o close collaboration with manuacturers and

has been proven in use in the exceptionally tough environ-

mental conditions o cement works. ASEC AUTOMATION

handled all tasks related to the PCS 7 system implementation.

Smooth execution, planned start-up

The project has run smoothly and according to schedule thus

ar. Clinker production started in mid-2012, and cement pro-

duction will commence in early 2013.

Complete package

Construction o the plant began in 2010, and in March 2011,

ASEC AUTOMATION, the main contractor or the entirescope o electrical systems on a turnkey basis, awarded the

contract to provide all the large electric motors and drives

and the distributed control system (DCS) to Siemens Egypt.

Siemens won the contract against sti competition. A deci-

sive actor was Siemens ability to provide the technical sup-

port to develop a complete solution that met the specica-

tions o both the process provider and the electrical con-

tractor, optimizing the unction and costs and meeting the

complex specications in a tight time rame. Additionally,

Siemens provided technical support to the customer in se-

lecting some o the projects components (such as trans-

ormers and starters), which helped ASEC AUTOMATION stay

within budget.

Motors, drives, and DCS all rom a single source

The electric motors and drives solution or the main pro-

cess as well as the cooler, crusher, and conveyor systems

comprises an H-compact high-voltage motor, an H -compact

Cement plants contain extremely large

rotating equipment and require powerul drives

Siemens provided a comprehensive drive

and control solution or the plant

INFO AND CONTACT



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process news 4/2012 | Packaging

From rell packages or laundry detergent to con-

ventional instant ood bags to resealable bever-

age packaging, sealed-edge pouches or doypacks

are becoming more and more popular or consumer

goods. However, these bags provide challenges or

the manuacturers o machines that combine the in-

dividual packs into larger batches. The material used

or this purpose generally is very sot, so the bags

have no dened dimensions. However, as one o the

leading international manuacturers o special pack-

aging machines, Meypack has been an expert in such

applications or years. The latest innovations rom the

German company include a new generation o highly

fexible machines that perectly pack sealed-edge

pouches into wraparound cartons or trays.

In a new machine generation, the packaging specialist Meypack

relies on a comprehensive standardization concept rom Siemens

or the automation and drive technology. The new approach helps

achieve synergies that impress both the project managers and the

end customers.

Meypack Verpackungssystemtechnik GmbH, Germany

Pack Smart

Comprehensive standardization concept

The key eatures o the new generation o machines

are an innovative network topology and the use o

energy-ecient drive technology based on the com-

prehensive Optimized Packaging Line (OPL) standard-

ization concept. One o the rst packaging machines

using the new concept is the Meypack VP 453. The

machine packs sealed-edge pouches into display

trays with lids partially inserted on the long side o

the tray and secured against slipping with glue dots.

Beore the sealed-edge pouches are packed in the

trays, they pass through a vibrating conveyor. There

the content o the bags is precisely weighed and dis-

tributed as evenly as possible. Then the bags are

The way in which Siemens has achieved

savings through the optimization o

consumption and mains quality using

OPL is absolutely compelling and

constitutes a valuable sales argument or

our new packaging machines.

Klaus M. Vogel, Export Sales Manager, Meypack


17/36

17

INFO AND CONTACT


stacked horizontally and, ater reaching the desired

quantity, pushed to the tray section in such a way

that no bag can all over in the process. Ater being

packed, the display trays are conveyed out o the

packaging unit.

Increased energy savings potential

In order to perorm these highly motion-controlled

processes eiciently and with the lowest possible

plant liecycle costs, Meypack relies on the compre-

hensive OPL standardization concept or automation

and drive technology. Based on the hardware and

sotware topologies provided by Siemens or this

speciic case, Meypack decided to use the energy-

ecient and fexible Motox gear motors as well as the

matching regenerative and distributed Sinamics S120

drive technology. With this intelligent drive technol-

ogy, brake power can be used again and, i necessary,

ed back into the mains virtually without unwanted

eedback, thanks to the new active line module(ALM). Because the Meypack VP 453 also includes

Sentron PAC multiunctional measurement devices,

operators benet rom ull transparency in terms o

consumption, network quality, and demand peaks.

Potential energy savings o up to 40 percent result

rom the hardware conguration alone, representing

an enormous economic advantage, as energy costs

constitute up to 70 percent o the liecycle costs o a

machine. The technologies used have a positive e-

ect not only on power consumption but also on the

quality o the power grid, so that transormers and

network components can be better sized according

to actual requirements. Intelligent planning tools

such as Sizer have made it possible or the company

to eliminate overdimensioning during engineering,

which enables additional energy savings and cost re-

ductions. The way in which Siemens has generated

savings through the optimization o consumption

and mains quality using OPL is absolutely compelling

and constitutes a valuable sales argument or our

new packaging machines, says Klaus M. Vogel, ex-

port sales manager at Meypack.

Considerably reduced operating costs

The Meypack VP 453 is characterized by its standard-

ized drive technology, fexibility o processes, and in-

novative energy management. While perormance

remains the same, this ultramodern packaging ma-

chine helps minimize energy consumption and

thereby consistently reduce liecycle costs. In other

words, with the Meypack VP 453, those who look be-

yond just the initial investment costs o acquiring apackaging machine or sealed-edge pouches can

benet rom considerably lower operating costs over

the entire service lie o the machine.

The Meypack VP 453 packs sealed-edge pouches into display trays

MeypackVerpackungssystemtechnikGmbH


18/36

18

process news 4/2012 | Condition Monitoring

The production o gearwheelsthat transmit torque is a highly

energy-intensive process. To

reduce power consumption

while at the same time

increasing plant availability,

the Siemens gear-production

acility in Penig, Germany, uses

the ePS Network Services

condition monitoring system.

At its plant in Penig, Germany,

Siemens produces gears or in-

dustrial applications and rail

transmission systems. Siemens is one o

the worlds leading companies in this

eld. Its customer base includes OEMs

and industrial customers as well as all

the major railway vehicle manuactur-

ers in Europe and some in Asia. Railway

drives rom Penig are successully de-

ployed on every continent around the

Hardening the gearwheels is an energy-intensive process

Penig Gear Plant, Germany

Absolute Availability


19/36

19

Condition Monitoring | process news 4/2012

INFO AND CONTACT

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

globe. The component manuacturing

acility produces up to 600 torque-

transmission parts every day. To reduce

power consumption while at the same

time boosting productivity and plant

availability, the plant operators rely on

the ePS Network Services condition

monitoring system and the B.Data en-ergy management system.

Systematic plant monitoring

Approximately 300 employees work at

the Penig gear plant on approximately

130 machine tools. The e icient use o

the machines is an important key to

success, and service and regular moni-

toring o the production machines are

key prerequisites to achieving this e-

ciency. Preventive ault detection and

saeguarding availability and productiv-

ity are also becoming more and more

important.

At the Penig gear plant, systematic

plant monitoring takes place using the

ePS Network Services condition moni-

toring system. Axis tests are perormed

on the machine tools weekly, and indi-

vidual variables such as temperature,

vibration, and pressure are recorded.

These tests help detect trends and initi-

ate service measures in a timely man-

ner. Newly delivered machines are also

subject to mechanical as well as energy

ngerprinting, where values specied

by the OEM are recorded during initial

commissioning and the machines un-

dergo special tests.

The second comparative ngerprint is

taken ater installation in the machine

shop and used to detect signs o wear

and deects beore they can aect pro-

duction. This comprehensive approach

to machine monitoring helps sustain-

ably boost availability.

Maximum transparency

In addition to plant status monitoring,

the project managers wanted to reduce

power consumption. This was achieved

using the B.Data energy management

system. While the sotware itsel can-

not automatically reduce consumption,

it provides inormation to adjust the

processes or more energy-eicient

operation.

The hardening processes in Penig,

or example, are particularly energy-

intensive. The parts are carburized over

several hours in a thermochemical pro-

cess and then quenched in oil baths.

The timing is specied by a program,

but because loading the urnaces and

lowering the parts into the oil baths

must be done manually, the operators

still have a certain degree o reedom in

their decisions.

Due to extremely high power costs,

the goal is to optimize the plant opera-

tion based on exact power consump-

tion igures. B.Data provides the re-

quired data visibility by determining

precise consumption and enabling re-ductions in consumption without any

risk to the availability o the machines.

In such a process, even small adjust-

ments can result in considerable sav-

ings. B.Data can also record all other

orms o energy, including the con-

sumption o expensive compressed air.

As usually only about 4 percent o the

electrical power can be used as com-

pressed air power, monitoring air com-

pressor eciency is an important actor

or cost control.

Increases in machine availability

Ater the implementation o ePS Net-

work Services and B.Data, plant man-

agement at the Siemens gear plant in

Penig is very satised with the results.

In addition to the nancial benets, the

systems also motivate the employees.

The high level o transparency pro-

motes a sense o responsibilit y, and the

employees eel they have a direct eect

on the companys power consumption.

Condition monitoring has also in-

creased the availability and productiv-ity o the machine tools. Valuable inor-

mation on process optimization has

been derived rom the automatic cor-

relation o the operating state and the

power consumption o the machines.

allpictures:WolfgangGeyer

The gearwheels are

case-hardened at 930C

and then quenched at

840C in oil baths. Energy

consumption in this

process step is optimized

through an analysis o the

precise consumption data

by B.Data

At the Penig plant, energy

costs represent a large

share o production costs.

B.Data makes

nonproductive energy

consumption visible. At the

same time, ePS Network

Services support the userin detecting ailures early

and thereby optimizing

maintenance and

production


20/36

Operation and Monitoring IED

POWER

PROCESS

process news 4/2012 | Process Control Technology

Increased eort

Networking dierent systems results in numerous

drawbacks or the plant operator throughout the en-

tire liecycle o the system, starting with engineering

and commissioning. The integration o two indepen-

dent control systems requires an extensive coordina-

tion eort, which results in higher project risks. With

ongoing operation, in turn, the dierent user inter-

aces or operation and monitoring require separate

spheres o responsibility and sta with the appropri-

ate background knowledge. Service and repairs too

must be handled separately.

Generally, electrical switchgear and process automation systems are two separate

worlds that require custom coupling and interacing. Integrating the two system

environments produces signicant benets over the entire plant liecycle.

Switchgear Integration

Merging Systems

For controlling switchgear in process plants with

high power requirements, IEC 61850 is the glob-

ally recognized standard, and a wide array o

saety devices known as intelligent electrical de-

vices (IEDs) cover virtually every system automa-

tion task. These saety devices are generally con-

trolled via a control system that is operated and mon-

itored separately rom the plants distributed control

system (DCS). For ecient overall plant operation,

however, this system should be integrated into the

DCS preerably as smoothly as possible. In other

words, two dierent but technologically related sys-

tem environments must be interlinked.

20


21/36

PROCESS +POWER

21

INFO AND CONTACT

www.siemens.com/simatic-pcs7/[email protected]

Process Control Technology | process news 4/2012

Cost reduction through integration

With Simatic PCS 7 PowerControl, there is now a

solution or electrical switchgear with IEDs that is

based on the standard IEC 61850 protocol. Both the

electrical system and the process control systems are

integrated into Simatic PCS 7, creating a common sys-tem platorm or power and process control. This not

only reduces the eort expended or engineering and

commissioning but also lowers the plant liecycle

costs. Thus, switchgear and automation, or example,

will have a uniorm user interace, enabling uniorm

operation and monitoring o the system and minimiz-

ing the risk o operating errors.

The IEDs are operated and monitored with the

same operating philosophy that the user is already

amiliar with rom the motors, valves, and regulators.

Faceplates are available or typical components such

as branch circuits, motors and generators, transorm-

ers, synchronization devices, and busbars that corre-

spond to the electricians perspective and mind-set.

Engineering as usual

The standard controllers o the DCS are used to auto-

mate the switchgear systems. When there are only a

ew protective devices to address, the specic IEDs

are integrated as subsystems in the DCS controller. In

this way, process-dependent interconnections can be

congured easily in the control system. I stand-

alone station controllers are required, they too can

be integrated into the overall conguration.

During control system engineering, the individual

IEDs are simply integrated by importing the device

description les (IED capability descriptions, or ICDs)

and checking the input objects. Any data objects

that are still missing can be created with an instance

editor in order to expand the library on a project-

specic basis. The mass data project planning is car-

ried out via a database automation tool, with which

all the required instances o the IEC 61850 IEDs are

generated.

System benets with added value

The seamless integration o the switchgear control

systems into the process control system not only

lowers the liecycle costs o the plant; it also enables

eatures that are dicult to implement in traditional

solutions. An example is the automatic archiving o

process values and messages. Tasks such as alarm

management with time stamping and the sequence-

appropriate processing o the results can be handled

in a uniorm way through the entire process plant.

The system also provides or standardized user man-

agement as regards access rights. In addition, the

technological integration serves as the basis or com-

prehensive power management. The process data re-

quired or this are provided by the IEDs and can thus

be processed by the control system or the entire

plant.

The aceplates the screen shows an electrical saety device or a branch circuit

are identical or all saety devices and acilitate operation

Separate environments or process automation and switchgear systems, eachhaving its own domain, hinder uniorm and eicient system operation and increase

costs. A single system or the entire plant or the process and the power part

improves the level o integration, reduces the risk o operating errors, and results

in optimized system operation

SiemensAG


22/36

D.Obertreis

No AccessNo access, no harm. The systematic restriction o access rights is animportant barrier to prevent attacks rom inside and outside the

organization. In this context, it is just as important to consider the

users and operators as the hardware and sotware components.

Industrial Security


23/36

23

INFO AND CONTACT



The path to ecient industrial security is a multi-

layered deense-in-depth concept. It is com-

posed o dierent security measures that wrap

around the system, orming protective barriers and

giving potential attackers the smallest possible area

or an attack. Two o these measures are system

hardening and user management.

Ecient user management

Consistent user management is one o the most im-

portant security measures against attacks rom in-

side and outside the organization. The guiding prin-

ciple is that o least privilege. This means that users

and operators as well as devices and network and

sotware components are always given only those

rights that are really necessary to perorm their as-

signed tasks. This also means that users who log into

the system must identiy themselves correctly and in-

dividually. The rights should be assigned according

to a hierarchy that is closely aligned with the struc-

ture o the company and the relevant production

area. Security planners need to answer these critical

security questions: How are the areas o responsibil-

ity divided within production? What unctions do the

individual users and operators perorm? Which oper-

ational and access rights are required to do this?

Clearly dened rights

With Simatic Security Control, Siemens provides a

high-perormance tool or systematic system hard-

ening. During system installation, the tool ensures a

structured assignment o rights and the application-

specic hardening o computers within the local sub-

network. Simatic Security Control is a standard com-ponent o Simatic PCS 7 and Simatic WinCC. Simatic

Security Control ollows the established Microsot

recommendations or rights management. During

system installation, it supports dening the required

rights or each unction. For example, during the

installation o a Simatic sotware product, Simatic

Security Control conigures the local Windows ire-

wall to allow only Simatic-speciic communication

between the components. In addition, the required

Simatic user groups are created through the installa-

tion o the Simatic products. As a result, user ac-

counts with identical unctions can be combined in

the respective Simatic groups and will be granted

only the rights required or their specic unctions.

The use o Simatic Logon together with an active di-

rectory domain is the basis or the highly available

and ail-sae user authentication and log-in. For the

conguration and rights management o users and

user groups, local user accounts and groups in the

production domain are assigned to the user groups

in the Simatic environment based on their activities.

Systematic system hardening

Having a secure system also means that all devices,

network components, and sotware unctions are

granted only those access rights that are required or

their specic unctions. Thus, all nonessential ser-

vices and sotware components should be switched

o or uninstalled, and availability o services as well

as access rights should be limited. This applies to a

programmable logic controller (PLC) just the same as

it does to network components such as switches or

routers and, o course, PCs. Sotware components

not being used should be removed, especially rom

standard PCs. In the production area, this also in-

cludes media components and games.

Technical and human actors

Every automation system has its own characteristics

and very specic security requirements. Thereore,

Siemens oers comprehensive consulting services

ranging rom the evaluation o system security to the

design o appropriate solutions to system mainte-

nance. There are also special training courses ad-

dressing all security questions relating to process

plants. System hardening and user management areimportant components o a multilayered deense-in-

depth concept, but not every attack comes rom the

outside and not every attack is intentional. Thereore,

trained employees are also an important component

in a comprehensive industrial security concept.

Note on industrial security: Suitable protective measures (including industrial securit y, e.g., network segmentation) must be taken to

ensure the secure operation o the plant. Further inormation on industrial security can be ound at www.siemens.com/industrialsecurity


24/36

24

process news 4/2012 | Process Control Technology

Simulating in a virtual plant: Extensively test and validate automation

congurations, eectively train operators, and smoothly interace to

high-delity process simulators with Simit.

Simulation or the Process Industries

Virtual Commissioning

SiemensAG

Realize more projects with ewer

people in less time. Simulation is a

strategic lever that can be used to

attain these objectives and achieve a

high quality standard. The simulation

platorm Simit is an essential element

o integrated product and production

liecycles. Simulation maps real-world

installations into a virtual plant environ-

ment. A virtual plant supports engineers

throughout the entire plant liecycle.

Simulation enables high-quality engi-

neering through extensive conigura-

tion testing, which results in reduced

time to production, risk, and cost during

commissioning and plant start-up. Sim-

ulation also contributes to the achieve-

ment o operational excellence, includ-

ing workorce excellence and optimized

system and asset utilization. For engi-

neering test and operator training pur-

poses, generic plant models are either

generated directly in Simit or, in the

case o more rigorous process models,

through the use o highly specialized

process simulators. The simulation con-

cept is embedded in the complete lie-

cycle management concept to drive

down the plants total cost o owner-ship.

Simulation in a virtual plantenvironment

During plant design, the plant exists only

as a digital image in process descriptions,

piping diagrams, process charts, wiring

diagrams, and other engineering docu-

ments. Automation and electrical cong-

urations are based on these engineering

documents. During commissioning and


25/36

25

INFO AND CONTACT



SiemensAG

Functional scope:

Testing o engineering conguration in virtual plant

Operator Training System

Both hardware-in-the-loop and sotware-in-the-loop supported

Interace to third-party high-delity process simulators

Benets:

Higher engineering quality

Well trained plant operators

Lower commissioning eort Reduced time to production

Reduced total cost o ownership

Generic plant models enable

thorough testing o engineering

conigurations and eective

operator training

plant start-up, this digital world meets

reality. Data inconsistencies and bugs

in the automation conguration appear

too late to be easily corrected. Through

plant simulation, planning meets real-

ity sooner and necessary corrections

are identied in an early stage o the

project. The earlier a required change

to the conguration is recognized, the

less eort, cost, and resources are nec-

essary to implement the change.

Commissioning in a virtual plant

Simit increases quality in automation

engineering through virtual commis-

sioning, meaning early and extensive

testing in a vir tual plant environment.

Simit supports vir tual commissioning by

simulating signals, eld devices (actua-

tors and sensors), bus communications,

and processes. Simit takes advantage o

existing engineering data and gener-

ates the rst level o simulation, such as

the signal simulation, with only a ew

mouse clicks. For more rigorous, high-

delity process simulation requirements,

third-party process simulators can be

easily interaced with Simit. The automa-tion program is executed either hardware-

in-the-loop, meaning on real S7 control-

lers, or sotware-in-the- loop, meaning

on emulated virtual controllers. Simit is

optimized or Simatic PCS 7 or continu-

ous and batch processes and Simatic S7

or discrete processes. The test bed also

includes the ability to test the response

o the automation system to malunc-

tions and critical situations. In the early

phase o the project, the automation

engineering is thoroughly debugged,

resulting in increased reliability. The end

result is the seamless transer o a ault-

less automation coniguration to the

real-world plant. Actual commissioning

eorts and the total project duration as

well as time to production are signii-

cantly decreased.

Eective operator training

The Simit simulation platorm is also

designed or plant operator training.

While the primary requirement o engi-

neering tests is rapid coniguration o

the virtual test bed, operator training

systems require additional eatures to

challenge plant operators with import-

ant plant states. Simit provides the nec-

essary eatures to design and custom-

ize training schemes, including scenar-

ios and snapshots o various plant

states. Well-trained operators and

deeper plant knowledge enable excel-

lence in plant operation.

A leap orward

Simit enables a leap orward in engi-

neering eciency and operator excel-

lence. Project and plant managers ap-

preciate the reduced technical and i-

nancial risks to their investment.


26/36

26

process news 4/2012 | Plant Engineering

richshaen, Germany, is a world mar-

ket leader in engineering and building

silos and logistics centers that are tai-

lored to the individual requirements o

the customer. Through the implemen-

tation o a comprehensive plant engi-

neering system, Zeppelin Systems has

Improve plant processing quality, save time generating P&IDs, and optimize

global engineering these are just three o the numerous advantages achievableby using the innovative engineering sotware Comos at Zeppelin Systems GmbH.

Zeppelin Systems GmbH, Germany

Zeppelin Systems GmbH has a long

history stretching back over the

past century to when Gra von

Zeppelin irst developed his legendary

airships. Ater Zeppelin stopped pro-

ducing airships, the company went on

to ound numerous companies that

continue to be successul in various

markets in todays industry. These com-

panies include Zeppelin Systems GmbH,

a leading manuacturer o plants or

storing, conveying, dosing, weighing,

cleaning, and blending premium bulk

solids. The company, based in Fried-

ZeppelinSystems

Perect Optimization

Innovative bulk goods

technology or complete plants,

systems, and components


27/36

27

Plant Engineering | process news 4/2012

INFO AND CONTACT


succeeded in urther increasing its com-

petitive edge.

International collaborationin engineering

The project aimed at implementing more

ecient, consistent plant engineering. In

doing so, the processing and engineering

o plant construction, document manage-

ment, and data management were to be

improved in terms o quality and imple-

mented in a more cost-ecient manner.

Up to now, we have been working in Excel

and carrying out plant engineering using

a sotware tool that was no longer up-to-

date. Ater that we started using a bench-

mark o our renowned CAE products, re-

calls Mark Niestroj, head o engineering at

Zeppelin Systems. The rst step was to

speciy what exactly was required rom

the sotware solution. This included sot-

ware unctionalities such as the ERP (enter-

prise resource planning) system interace

and integration into current IT systems. Inparticular, great importance was attached

to global usability o the sotware, as en-

gineering collaborations across the globe

had become increasingly important and

branch oces around the world had con-

tinuously grown over the years.

High level o acceptanceamong colleagues

Ater carrying out exhaustive compara-

tive studies, the company selected the

Comos sotware solution. The quality

o plant engineering has signiicantly

improved since the sotware has been

introduced. Thanks to the integrateddatabase and the sotwares object-

oriented approach, the engineering

process now oers increased transpar-

ency. In turn, this has resulted in an

improved exchange o inormation be-

tween the individual technical depart-

ments. The error rate in plant process-

ing and engineering has been mini-

mized, while the development time

has been reduced, and costs have

been lowered. In addition, the open

sotware architecture guarantees easy

connection rom the engineering sot-

ware to the ERP system. The more ex-

perience the sta gain in using the

sotware, the better they can put the

integrated engineering sotwares po-

tential to use, Niestroj explains. Previ-

ous experience o customer-specic

sotware adjustments can be utilized

along with other data, resulting in con-tinual improvements. The level o ac-

ceptance or Comos is very high among

the teams, says Tobias Schlunski,

administrator or Comos at Zeppelin

Systems.

By now, the branch oces in China

and India are also working with Comos.

Access to the integrated data structure

has saved signicant amounts o time.

In addition to version control, the

multilingual support was another im-

portant actor. Flow diagrams and

specications were partly prepared in

Friedrichshaen and then nalized in

India according to local supply quotas.

Considerable boost in productivity

In the uture, Zeppelin Systems plans to

urther expand into the electrical engi-

neering sector. Here, the sotwares

integrated engineering approach

should also prove benecial in cabinet

engineering and automation. This ex-

pansion should enable the company to

oer its customers a wider range o en-

gineering solutions. Whats more, the

company also plans to connect the en-

gineering sotware to the SAP ERP sys-

tem. A urther increase in eciency is

expected, as the results achieved to

date have been perceived very posi-

tively by the management. All in all,

Comos has been a success story or us.

We were able to standardize and im-

prove our work processes, resulting in

a considerable increase in our plant en-gineering productivity. However, we

see even more scope or improvement

and we havent nished developing yet,

Niestroj concludes.

We were able to standardize and

improve our work processes, resulting

in a considerable increase in our plantengineering productivity.

Mark Niestroj, Engineering Manager, Zeppelin Systems

Niestroj (seated) and Tobias Schlunski, Comos administrator at Zeppelin Systems,

are responsible or the successul use o ComosZeppelinSystems


28/36

28

For on/o engineering, good prelim-

inary work in the design and engineer-

ing phase and close collaboration with

all the project participants were crucial

or the successul implementation o

the specication requirements. In this

process, documenting the sotware de-

sign was as high a priority as the engi-

Thanks to the Simatic PCS 7 process control system and the Simatic Batch sotware,

a new plant or disinectant production at Schlke & Mayr is running smoothly. The

managers are enthusiastic about the high degree o system integration and the

resulting improved ease o use.

Schlke & Mayr GmbH, Germany

Working under sterile conditions

would be impossible with-

out the use o disinectants.

Schlke & Mayr GmbH have long played

a major role in this eld, starting in

1913 with the introduction o Sagrotan,

the rst brand-name disinectant or

the consumer market.

The company, ounded in 1889 in

Norderstedt near Hamburg, Germany,

now produces 200 specialized products

in the elds o wound care, disinection,

and specialty chemistry. Until the re-

cent construction o a new plant, how-

ever, Schlke & Mayr had no plant or

the production and bottling o surace

disinectants.

Close collaboration

The contract or the automation o the

new plant was awarded to the Siemens

Solution Partner on/o engineering.

Prior to the project, we conducted sev-

eral intensive workshops to determinethe requirements, reports Lars Schulze,

project manager at Schlke & Mayr.

These requirements were recorded as

speciications or the engineering o

the process control system based on

Simatic PCS 7 with Simatic Batch. Cru-

cial or this project was that Simatic

Batch is in accordance with the require-

ments o the S88 standard, and we

would get a 21 CFR Part 11compliant

solution with PCS 7, Schulze explains.

Central challenges mastered

The qualication and validation o the

automation system represents a special

challenge in pharmaceutical plants.

Siemens supports the validation with

suitable products and guidelines that

make work easier or the project team.

process news 4/2012 | Pharmaceuticals

We beneft rom the integration

o the systems. Everything

runs automatically and that

saves us a lot o work.

Lars Schulze, Project Manager, Schlke & Mayr GmbH

allpictures:JrcoBoerner

Clean and Integrated


29/36

29

INFO AND CONTACT


Pharmaceuticals | process news 4/2012

neering itsel, as it ensured that the de-

tail design approved by Schlke & Mayr

was implemented into the correspond-

ing PCS 7 application sotware in aqualied manner and that the program

contains only dened and documented

states. It was also critical to dene

unctional processes and recipe struc-

tures with the electrical engineers, pro-

cess development engineers, and plant

design engineers in order to have a val-

idated plant at the end o the tests. Ac-

cording to the project managers at on/

o, this interdisciplinary teamwork is

the key to success in many projects.

Simplied operation

In collaboration with on/o engineer-

ing, the existing standard reporting was

tailored to the special needs o produc-

tion. The process control system is read-

ily equipped or possible uture produc-

tion expansions and the integration o

the SAP enterprise resource planning

(ERP) system already in use today.

Beore the PCS 7 system was delivered

to the site, Schlke & Mayr approved

the programs in a actory acceptance

test (FAT), together with the machine

manuacturer or some parts, on the

premises o on/o. Then the system was

installed on-site, tested, and accepted.

At Schlke & Mayr, the sta are sat-

ised with the progress and the results.

We worked together constructively and

successully, conirms Schulze. The

biggest advantage, in our opinion, lies

with the introduction o Simatic Batch.

The option to integrate the ERP system

later on and thus automate the job and

batch regeneration process is another

advantage. We benet rom the integra-

tion o the systems, Schulze concludes.No connection needs to be set up by

hand everything runs automatically

and that saves us a lot o work.

In Norderstedt

near Hamburg,

Schlke & Mayr

GmbH produces

over 200 specialty

products in the

areas o wound

care, disinection,

and specialized

chemistry.

Sterile surace

disinectants areproduced and

bottled at the

new plant

The plants

processes are

automated with

Simatic PCS 7

and SimaticBatch

on/o engineering gmbh was ounded as a product- and system-

independent engineering company or automation technology in

Hannover, Germany, in 1988. Since then, the company has developed into

a leading provider o process automation engineering services. Today,

more than 120 employees work at several branch oces in Germany andEurope. on/o supports its customers with customized solutions. The

companys services include the ollowing:

Process automation or the process industry

Control cabinet engineering and assembly

Manuacturing execution systems

24/7 service

IT inrastructure

Quality management consulting

Training Manuacturing industry automation


30/36

30

North-Tec Maschinenbau GmbH, Germany

Sustainable Power

As an innovation specialist, North-Tec

Maschinenbau GmbH in Bredstedt uses con-

cepts typical o modern industrial acilities or

equipping its biogas plants. In collaboration with

Siemens, North-Tec designs solutions that are char-

acterized by high availability and standardization.

Ral Breckling, managing director at North-Tec, re-

ports: Our business used to comprise just service

A comprehensive process automation solution at a biogas plant in Leckeng,

Germany, lays the oundation or continuous process monitoring while

ensuring highly ecient plant operation.

The Leckeng biogas plant in Schleswig-Holstein, northern Germany

and spare parts or biogas plants. And we realized

very quickly that the best investment or a plant op-

erator is in consistent, robust overall systems based

on rugged, fexible industry solutions. One illustra-

tion o this line o thought is a biogas plant in Leck-

eng near the Danish border that was built in mid-

2010. It consists o wet ermentation, a secondary

ermenter, and ermentation residue storage and


31/36

31

INFO AND CONTACT


supplies gas to two combined heat and power plants

(CHPs) with a power output o 400 kW each. Using

the discontinuous method, every hour new material

is introduced by a eed screw to keep the methane

production at a maximum.

Highest availability

An ecient, reliable, and fexible automation solution

based on Simatic WinCC and the Simatic ET 200S dis-

tributed I/O system with Pronet provides optimum

control and monitoring o the system. Mobile phones

are being increasingly used or remote control and

visualization. Detailed diagnosis has a high priority,

as a prolonged outage o the eed supply results in

signiicant inancial losses. A modem or remote

maintenance can be connected in order to enable the

astest possible 24/7 service. This allows the service

personnel to immediately give the plant operator

valuable inormation, such as where an alarm is com-

ing rom and how a ault can be remedied.

Plug and play

For the rst time, North-Tec has equipped the motor

and load eeders consisting o Sirius 3RT2 contac-tors and Sirius 3RV2 circuit breakers or motor protec-

tion with IO-Link. Sensors, control units, and actu-

ators can be uniormly connected to the control level

with convenient plug and play and standardized con-

nection components. This reduces the eort re-

quired in connecting the individual devices and wir-

ing the modules. Moreover, this approach provides

valuable diagnostic inormation on each motor con-

troller. These networked components and systems

can be easily integrated into the existing system.

They are also easy to maintain and can later be ex-

panded in a fexible manner. The connection o the

CHP satellite via Pronet illustrates this as well. The

second CHP plant, located 2 kilometers away, sup-

plies around 160 residential units with power and

heat. Breckling says, Through communication based

on TCP/IP and Pronet, such distributed solutions can

be as easily controlled as centralized acilities.

Ecient energy management

To allow the operators to always keep an eye on

power quality, power consumption, and system per-

ormance, the Leckeng acility is equipped with a

multiunctional PAC 3200 that can detect and pro-

vide over 50 dierent readings. With the inormation

rom the eld level, it is possible to determine at any

time whether, or example, a motor contactor has

started or whether voltage is present at all stages.

The system controller also ensures that energy-

intensive drive processes do not run simultaneously.

This is important or the eciency o the system be-

cause utility company contracts dene the peak load

at any given time. When these consumption limits are

exceeded, the result is high additional costs.

The transition to industrial automation solutions is

a logical step or cost-eective and sustainable power

production in biogas plants. Plant operators benetrom a consistent, transparent, and fexible system.

The intelligent combination o all diagnostic inorma-

tion makes it easier to service the system and helps

optimize operating costs. Automation plays a role in

achieving an excellent return on investment.

Biogas plants must

achieve the same high

level o availability as

industrial plants in order

to make energy produc-

tion cost-eective.

Volker Storm, Plant Operator, Leckeng Plant Storm

(let) and certied engineer Ral Breckling,

Managing Director, North-Tec

Renewable Energy | process news 4/2012

Photos:SiemensAG


32/36

32

process news 4/2012 | Renewable Energy

Integrated process instrumentation enables continuous

process monitoring and optimization at a biogas plant inRhinow, Germany, ensuring cost-eective plant operation.

The small town o Rhinow, with just over 2,000

residents, will soon be able to meet up to hal

its energy needs with a biogas plant. Currently,

560 kW o electrical power and 640 kW o heat are

being ed into the supply grid by two combined heat

and power plants (CHPs) designed or a total capac-

ity o 1,454 kW. For the automation o its rst biogas

plant, Arnold-Blume Bioenergie GmbH in Rhinow

decided to use a complete and comprehensive in-

strumentation package rom Siemens.

The plant in Rhinow is operated with corn and grass

silage as well as liquid manure. Biogas as a source o

energy is created through the ermentation o or-

ganic substrates into combustible methane, carbon di-

oxide, water, and trace gases such as hydrogen sulde,

ammonia, nitrogen, hydrogen, and oxygen.

Whether it is a small plant with the simplest mea-

surement equipment or a large plant with gas clean-

ing and a eed-in to the natural gas supply, a great

deal o inormation on temperature, fow, level, pres-

sure, and gas composition always needs to be col-

lected directly rom the process. When planning a bio-

gas plant, the ollowing questions must be asked in

advance: Which method is more reliable, radar or ul-

trasonic level measurement? And which is the most

cost-eective option in this case?

CompleteProcess Package

Arnold-Blume Bioenergie GmbH, Germany

The system operates largely autonomously

and is equipped with a complete process

instrumentation solution rom Siemens:

Sitrans P DSIII or gas pressure measurement

in the ermenter

Sitrans FM or fow measurement o the

liquid manure

Sitrans T or temperature measurement,

including in the ermenter

Sitrans Probe LU or contact-ree level

measurement in the mixing tank

Sitrans Probe LR or level measurement

in the ermenter

Multiranger or level measurement in the

ermentation residue silos

Pointek CLS or level detection in the

mixing tank


33/36

33

INFO AND CONTACT

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

Renewable Energy | process news 4/2012

Outside monitoring o the ermenter level with

a Sitrans LR radar level transmitter

The Arnold-Blume Bioenergie GmbH biogas plant

Biogas plants require level measurements at dier-

ent points that perorm many dierent tasks in a

wide range o physical and chemical conditions. Ac-

cordingly, ultrasonic, radar, capacitive, and hydro-

static measurement methods and devices are used.

As there is next to no gas in the mixing tank, or ex-

ample, a cost-eective ultrasonic device measures

the level here. A useul side eect is that the ultra-

sonic waves prevent caking on the sensor. In the er-

menter, in contrast, the level measurement is contact-

ree and takes place rom the outside through the

weather-protection and gas tarpaulin. This prevents

the ormation o deposits such as sulur.

An integrated solution improvescost-eectiveness

The experts in Rhinow all agree: the eciency and

cost-eectiveness o a biogas plant increases with a

greater degree o automation. The integrated pro-cess instrumentation allows the user to measure all

the processes securely and precisely, making them

transparent and optimizing perormance.

All process data at a glance

The gas quantity in the gas collector is measured

using a dierential pressure transmitter that is espe-

cially designed or very low pressures in the single-

digit millibar range. A magnetic-inductive fowmeter

records the liquid manure fow. Suitable sensors and

measurement transmitters were selected or tem-

perature monitoring. The ermenter, in particular, re-

quires exact temperature measurement. Continuous

stirring in the 15 m wide tank creates a high fow rate

and thereby riction on the edge o the container,

which, without special protection, would damage the

sensor.


34/36

34

process news 4/2012 | Web Exclusive

Sipart PS2

The Flexible All-Rounder

Weighing Technology

Unique Flexibility

Water Treatment

Motion Detection Means

Process Protection

The Seymour-Capilano Filtration Plant (SCFP) is the larg-

est o its kind in Canada. The plant uses process pro-tection devices rom Siemens that consist o a Milltron-

ics MFA 4p motion ailure alarm controller and a Milltronics

XPP-5 heavy-duty motion sensing probe. Since SCFP irst in-

stalled the Milltronics MFA 4p and the Milltronics XPP-5, op-

erators report that the devices have been working well.

They are an ideal it in the plants dewatering and disposal

system. This noncontacting technology also means reduced

maintenance requirements.

Read the complete article online:

www.siemens.com/processnews/412a

The Sipart PS2 positioner is multitalented. It is the

most-used position controller or push and swivel

drives in the widest range o processing industries,

and with good reason: with its unctionality, its robust-

ness, and its expandable modules and numerous avail-

able add-on sets, the Sipart PS2 positioner can be used

to control faps and valves even in demanding applica-tions with harsh ambient conditions, such as in metal and

mineral processing or in the paper industry.

Read the complete article online:

www.siemens.com/processnews/412b

Due to its diverse congura-

tion and scaling capabilities,the new Siwarex WP231

weighing module oers a very

high level o fexibility. The mod-

ule or the Simatic S7-1200 is pro -

grammable via the Totally Inte-

grated Automation (TIA) Portal

engineering platorm. In addition,

the excellent measuring capabili-

ties ensure reliable weighing. The

Siwarex WP231 is thereore the

ideal solution or industries with

high precision requirements

such as the ood, beverage, and

pharmaceutical industries.

www.siemens.com/siwarex

+++ www.siemens.com/processnews +++

+++WEBEXCLUSIVE+++WEB

EXCLUSIVE

+++


35/36

Dialogue | process news 4/2012

Browse through thought leadership ar-

ticles on what drives the process indus-

try today and what strategies can help

address key industry challenges. You

can access additional news, case stud-

ies, detailed technology articles,

and videos on key topics, plus read all

past issues o the print edition. Via RSS

eed, you will be instantly notied o

new publications on the site. Stay

ahead today!

www.siemens.com/processnews

Do you want to know more about the

systems and solutions or the process

industry rom Siemens? Simply visit our

inormation portal on the Internet at:

www.siemens.com/processautomation

Online

Info

process news 1/2013

Focus on Migration

While products and systems in process auto-

mation are ne-tuned or sturdiness and a

long service lie, at some point every sys-

tem operator is aced with this challenge: modern-

izing the existing process control system. What

makes this challenge even more complex: the indi-

vidual components in process automation have

very dierent liecycles. This is why we will ocus

on dierent aspects o system modernization in

the upcoming issue o process news. In our ocus

on migration, we will be addressing several press-

ing questions in system migration projects, such as

the ollowing:

How can companies standardize their

automation environments to save costs and

make production more eective?

How can a company gradually modernize an

existing system and thereby achieve an

optimum return on investment?

Which tools are available to migrate the

system sotware and where are the limits

o a tool-supported system migration today?

Additionally, as always, there will be numerous

other articles on technologies and applications

rom dierent industries. processnews 1/2013

will be published in April.

+++ PREVIEW +++ PREVIEW +++

Publisher: Siemens Aktiengesellschat,Gleiwitzer Str. 555, 90475 Nuremberg, Germanywww.siemens.com/automation

Drive Technologies DivisionIndustry Automation DivisionCustomer Services Division

Editorial Responsibility in Accordancewith the German Press Law:Ral Schmitt

Responsible or Technical Content:Cornelia Drreld

Editorial Committee:Ute Forstner, Petra Geiss, Michael Gilluck,Keirsten Henderson, Walter Huber, Ingo Kaiser,

Doina Pamlie, Elke Pilher, Stean Rausch,Matthias Wenning, Roland Wieser

Publishing House: Publicis Publishing,Postach 32 40, 91050 Erlangen, GermanyTel.: +49 (0) 91 31 91 92-5 [email protected] in chie: Kerstin PuruckerLayout: Nadine WachterCopy editing: Susanne WankeDTP: Mario Willms; TV Satzstudio GmbH

Printing: Wnsch, Neumarkt, GermanyCirculation: 32,500

Volume 17, process news is published quarterly

ISSN 1430-2284 (Print)IWI: TPOGOrder number: E20001-M6412-B100-X-7600

2012 by Siemens AktiengesellschatMunich and Berlin.All rights reserved by the publisher.

This edition was printed on environmentally riendlychlorine-ree paper. Printed in Germany

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