Systems and Solutions for the Process Industry
processnews
10th edition December 4|2005
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Looking at the Bigger PictureSolutions and strategies for the process industry in the Americas
Process Safety:
Safety Matrix Toolset for Simatic S7-400F/FH
Joint Offer:
Siemens equipswafer fab at Siltronic
Process Safety:
Safety Matrix Toolset for Simatic S7-400F/FH
Joint Offer:
Siemens equipswafer fab at Siltronic
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Focus on the Americas: The processautomation market in North and CentralAmerica is highly competitive. The reasons forthis can be found in the process industryitself, especially in the US – companies areexposed to strong market pressures
The in situ laser diode spectrometer LDS 6 is an accurate, and fast-reactingmeasuring solution, even fordemandung tasks such as trace moisture monitoring in clorine gas
With an automation project for a new nitrogen fertilizerplant of Uhde in Turkmenistan,Siemens proved that SimaticPCS 7 also offers solid benefitsin fertilizer production
CONTENT2
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3 EDITORIAL
4 NEWS
Entertainment and Technology
Compact Replacement
Size Matters
Sugar Experts
Cast Off!
FOCUSThe Americas
6 Raising the BarSimatic PCS7 control system key for plantupgrade at Air Products
8 Looking at the Bigger PictureSiemens aims at maintaining competi-tiveness for its customers in the U.S.
10 Partnering in SpecializationCRB Consulting Engineers and Siemens
11 Less Waste, More GainTyson Foods delivers MES business case with Simatic IT in poultry processing plant
12 Smooth FlowSitrans F M 911/E magnetic flowmeteroptimizes dredge pump control
13 Operating at a High LevelPeterborough water treatment plantbenefits from innovative levelmonitoring technology
14 Keeping the Pots HotSimatic PCS7 at the controls of the largestaluminum smelter in the Americas
16 Clean Air ActionSiemens develops process analysis solution foremission control in Texas
17 Settling the DustSitrans radar technology solves levelmeasurement challenges for cement producer
TECHNOLOGYProcess Safety
18 Enter the MatrixThe Safety Matrix cause-and-effect matrix toolsetfor Simatic process safety systems
Process Control20 Heads Up
Alarm management capabilities of Simatic PCS7help leverage industry best practices
Process Analytics21 Fast and Accurate
In situ moisture analysis of chlorine gas with LDS 6
Modular Automation32 The Key to Success
Modular automation pays off
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Industrial Plants atHouston, TexasPicture: stockyard.com
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Dear Readers!The past year presented the process automationindustry with tremendous challenges: theincreasingly competitive global economy, thecommoditization of products, the rising cost offuel and the natural disasters affecting everyonearound the globe.
This is also true of our customers in theAmericas, an economic region where fiercecompetition and pricing pressures place thehighest demands on systems and solutionssuppliers such as Siemens. In the United States,successful companies are using innovation andtechnology to improve product quality,productivity, and time to market to overcomethese challenges. Many newly industrializedcountries offer lower labor costs, and it isdifficult for U.S. manufacturers to compete solelyat that level.
That's why Siemens is committed to providinginnovative product and service solutions to helpour customers recognize efficiencies and toremain competitive. We are addressing the needfor productivity gains with our Totally IntegratedAutomation program to provide our customerswith a single-source for their industrialautomation and infrastructure needs.
This edition of Process News will provide youwith insights into some of our solutions forcustomers from Canada, Mexico, and the UnitedStates. I invite you to explore these solutions andto learn how companies are relying on Siemensinnovative automation solutions to help drivecompetitiveness. Further, we'll present newtechnologies in the fields of process automationand process safety as well as machine buildingthat will help you maintain your competitiveedge. Finally, we'll feature an exciting projectfrom the heart of the German silicon industry,where Siemens was able to demonstrate thebenefits of a joint project approach.
I hope you enjoy the read!
Best regards,
Joint offer: Together with the generalcontractor M+W Zander, Siemens developedan integrated automation, buildingtechnology, and power supply solution at anew wafer fab for Siltronic
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CASE STUDIESBreweries
22 Successful UpgradeBraumat enables tracking and tracing in Mexican brewery
Chemical Industry24 Engine for Growth
Simatic PCS reference project in Turkmenistan
Semiconductor26 Consistently Successful
New wafer factory benefits from a high degree of standardization and an experienced projectmanagement team
Semiconductor29 The joint work of specialists
M+W Zander sets up an entire factory in just two years
Specialty Chemicals30 Modern Platform
Operating system migration from Teleperm M to Simatic PCS7 at Bayer
Water34 Controlling the Flow
Greater transparency and economy at the Mannheim waterworks
35 DIALOGUE
EDITORIAL
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Aubert MartinPresident and CEOSiemens Energy and Automation, Inc.
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4 NEWS
Largest Sitrans magnetic flowmetersold to customer in California
Size Matters
B ranom Instruments is the current recordholder for the largest Sitrans magnetic
flowmeters sold in the United States: Amajor municipality in northern California is the proud owner of two Sitrans MAGFLO3100 flowmeters with a diameter of 72 inch – roughly 183 centimeters. Themammoth meters are being used on theraw water influent stream of the plant andare lined with composite hard elastomersuitable for use in water and wastewaterapplication.
In addition to these large flowmeters,the customer also ordered a quantity of
smaller Sitrans flowmeters from Branom.The entire package is worth over 175,000US dollars. The decisive argument in favorof the Sitrans devices was the Verificatortechnology to verify long-term accuracy ofthe devices. Branom used the Verificator tocertify all flowmeters on the project beforestart-up.
Branom and Siemens have maintained agreat working relationship with the con-tractor through the project, so that Siemensis the front-runner for Phase 2 of the project,which includes another 72-inch unit. �
Find out more:www.siemens.com/waterE-mail: [email protected]
MicroSAM scores at Shell Germany
Compact Replacement
During a replacement project, Shell Ger-many was looking for a new process
analytical solution for its liquid gas plant atthe Harburg refinery in Hamburg, Germany.The systems in use there were becomingdated and scheduled for replacement.
While trying to find a cost-effective andsimple solution, Siemens gave a presen-tation at Shell that helped to convincethem of the benefits of the compactprocess gas chromatograph MicroSAM.Consequently, shell ordered four devicesfor the Hamburg plant. Decisive argu-ments in favor of MicroSAM were a high-
The Walt Disney Com-pany and Siemens re-
cently announced a 12-year strategic alliance,bringing together theworld’s leading familyentertainment companywith a premier globaltechnology and infra-structure company. WhileDisney already uses arange of Siemens tech-nologies, the agreementexpands the relationshipand paves the way forthe two companies tobroaden their techno-logical collaboration across several plat-forms.
“Embracing new technology is a keystrategic priority at Disney, because it sup-ports our commitment to creating an out-standing guest experience and drivesgrowth for the entire company,” said BobIger, president and CEO, The Walt DisneyCompany. “Our extended and strengthenedrelationship with Siemens is a perfect fit aswe implement new forms of technology.”
The agreement includes marketing andpromotional rights, attraction sponsorships,and a promotional presence that featuresSiemens products and services at Walt Dis-
The flow meter is large enough for anadult person
ney World Resort and Disneyland Resort inCalifornia. In addition, the companies willwork together to develop and further applynew technologies across a range of plat-forms, as well as explore ways to integratesome of Siemens’ technologies into Disney’scurrent attractions and at its resorts. Also,Siemens will build on its existing relation-ship with Disney Media Network’s and ESPNby sponsoring ABC’s video board at TimesSquare in New York City. �
ly competitive price as well as the low in-stallation and maintenance costs.
The refinery is situated on the banks ofthe Elbe river and processes 5.1 million tonsof crude oil per year, focusing on gasolineand other fuels. The liquid gas plant pro-duces propane, butane, and pentane in adistillation process. These gases have to bemonitored for various concentration levelsat several locations in the plant. �
Find out more:www.siemens.com/processanalyticsE-mail: [email protected]
Find out more:www.sea.siemens.comE-mail: [email protected]
Siemens and The Walt Disney Company announce strategic alliance
Entertainment and Technology
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S iemens has been able to secure an order by the Jos. L. Meyer GmbHshipyard for equipping two new club cruise ships of the AIDA Cruis-
es shipping company. The order, worth 25 million euros, comprises thediesel-electric motors, power supply, and automation technology formonitoring and control tasks of all onboard functions.
The decisive argument in favor of Siemens was the fact that Siemenspresented an offering that was designed to meet the customer re-quirements down to the smallest detail. Siemens will supply a com-prehensive solution for the AIDA project: systems that are specificallytuned to marine propulsion, including all drives, motors, generators,the Simatic PCS 7 process control system, middle-voltage switchgearwith NXAIR technology, and the air conditioning automation.
The AIDA club cruise ships are each 249 meters long and 32,2 me-ters wide and will be cruising the Mediterranean, North Sea, and BalticSea as well as the Caribbean and Central American waters. Four dieselengines in each ship will deliver a power of 36 megawatt or 50,000horsepowers. The ships can reach a speed of more than 21 knots or40 kilometers per hour. Since the motors operate at minimum noiseand vibration levels, passengers enjoy maximum comfort during thejourney. �
Find out more:www.siemens.com/pcs7E-mail: [email protected]
Sugar refineries in Bangladesh and Iran benefit from Siemens technology
Sugar Experts
S iemens recently received an order tosupply instrumentation and automation
equipment for a complete new sugar refin-ery in Bangladesh. The contract consists of
process control equipment based on theSimatic PCS 7 process control system, in-cluding Simatic ET 200 I/O terminals as wellas process instruments for temperature, lev-
el, and pressure. Training andcommissioning services are alsopart of the contract. With thisproject, Siemens will be able tocomplete a reference plant forthe Asian sugar industry andstrengthen its position in thisgrowing market.
Moreover, Siemens has suc-cessfully commissioned twonew sugar plants in the Khuzes-tan province in Iran. The SugarCane & By Products Co. Ltd isbuilding a total of seven newcane sugar plants there, includ-ing utilities and infrastructuresuch as irrigation systems and
roads. Two paper mills and a chipboard fac-tory are also planned for processing sugarcane by-products.
The first three plants, commissioned afew years back, were automated using con-ventional technology. The recently commis-sioned plants four and five were equippedwith an integrated solution for instrumen-tation, field devices, and automation bySiemens. Commissioning was performedsuccessfully and finished after three weekson site with the fine-tuning of the crystal-lization technology. The customer is highlysatisfied with the results. The final two plantsare currently being equipped with SimaticPCS 7 process control technology and will becommissioned in 2006 and 2007. �
Find out more:www.siemens.com/sugarE-mail: [email protected]
Comprehensive solution for AIDA cruise ships
Cast Off! One of the new clubcruise ships in
dry dock
In Iran, Siemens has successfully commissioned twonew sugar plants
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T he first phase focused on South Plant,a hydrogen reaction facility special-izing in polyurethane curing agents
and additives sold to chemical, coatings,paint, and foam companies. Dependingon customer orders, the plant normallyproduces 35 different products, but hasthe capability of manufacturing up to 250products.
The project team was given only 21 daysto complete the installation that would con-trol the 75 unit vessels and 50 equipmentmodules at the South Plant before coldweather set in. During the outage the teaminstalled the new PCS 7 system, made suremore than 2,500 I/O points were transi-tioned, and tested the Simatic Batch soft-ware configuration for product productionsequencing.
In addition, all wiring from existingfield devices up to the terminals was re-tained and undisturbed. Air Products keptthe existing field terminal assembly (FTA)cabinets, but replaced the FTA boards,one by one, with Siemens FTA boards. Noadditional cabinet space was required.
Eighteen days after taking the processdown for migration, the plant was up andrunning – three days ahead of schedule.
“The start-up went very well,” plantmanager Ramon Lopez says. “We hadaround-the-clock coverage from a crossfunctional team. Any issues were quicklyresolved during the Site Acceptance Test-ing, and nothing delayed the critical timingof the start-up.”
Simatic PCS 7 control system key for plant upgrade at Air Products
Raising the BarDuring the recently completed first of two phases toupgrade plant operations, the Air Products andChemicals, Inc. site in Wichita, Kansas, U.S.A. chose tomigrate from a 20-year-old continuous process controlsystem to the Simatic PCS 7 process control systemwith Simatic Batch for batch control. A wise choice inmany respects, as it turns out: whether in terms ofcost reductions, increased quality and efficiency,minimizing downtime, or improving the bottom line.
Air Products' Wichita, Kansas facility producespolyurethane curing agents and additives sold tochemical, coatings, paint, and foam companies
Air Products offersenvironmentally superiorproducts for both high-solids and waterbornepolyurethane coatings
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Lopez stresses the time devoted to thestartup was greatly accelerated becauseSimit simulation software was used duringthe FAT at Spring House as well as to trainthe operators.
The Simit simulation software, whichmakes use of the existing controller con-figuration to generate the simulation pro-gram, allowed simulation of values of allthe I/O points without modifying the actualsystem configuration. In addition, opera-tors were able to practice with the graphicsand batch manager software before startup.Today, operators receive on-the-job train-ing because of the intuitive and easy-to-use qualities of the PCS 7 system.
The PCS 7 control system installation in-cluded four AS 400 automation systems, aredundant pair of Simatic process safetyHF systems, a redundant pair of operatorsystem servers, six operator system multi-clients, one engineering system server, anda stand-alone operator system archive. TheSafety Matrix engineering tool was alsoused to help simplify the configuration ofthe safety system.
Batch software helps production
Lopez also expects to increase the capac-ity of the plant and to improve visibility ofthe process with the new software.
“We now have a more precise way ofmaking our chemicals, and it will be con-sistent shift after shift, hour after hour,”Lopez explains. “That reduces raw materialcosts. Being able to operate the equipmentconsistently all of the time will also reducethe maintenance of that equipment. Re-ducing downtime by five percent is a bigimprovement.”
The control system and S88 reportingfeatures of the Simatic Batch software sim-plify troubleshooting at the plant. In thepast, operators read some of the plant in-formation directly off of panel mountedcontrollers. The information was availableat that moment, but there was no way to au-tomatically log the information for futurereference.
Today, all information is reported auto-matically to the control room through thePCS 7 system and logged into electronichistory.
Profibus pays off
As part of the automation upgrade at theplant’s drumming and blending facility, AirProducts installed a Simatic PCS 7 process
control system using Profibus as the field-bus for field device integration. The controlsystem and Profibus accommodate equip-ment from multiple vendors. Embedded di-agnostics, enabling preventative and pre-dictive maintenance, help keep operatingcosts low.
“Implementing Profibus has set us upfor a leap in technology and engineering,”Lopez explains. “We also get better com-missioning and long-term maintenance.”
At the beginning of the project, Air Prod-ucts worked closely with Siemens engi-neers and a consulting firm specializing inthe design and implementation of fieldbussystems to develop the technical layout. Atraditional star topology was chosen to ac-commodate anticipated future expansionsand retrofits.
The results have been impressive. Mate-rial, labor, and field installation costs havebeen reduced by approximately 30 percentafter one year of operation.
Eighty smart devices from multiple ven-dors at the drumming and blending facilitycommunicate with the Simatic PCS 7 pro-cess control system via Profibus.
The devices include mass flow meters,transmitters, Simocode motor control andprotection devices, Mettler-Toledo weighscales, and third-party devices.
The fieldbus system includes both Profi-bus DP and PA layers to accommodate com-mon devices, including transmitters andvalve positioners, as well as smart motorprotection and control devices. PCS 7 oper-ator stations are located in Class 1 Division2 process areas in appropriate enclosures.If necessary, the field devices can be all ac-cessed from a central location for mainte-nance purposes, or to make configurationchanges.
“Siemens support was very good,” Lopezsaid. “We worked as a team and nothing de-layed the timing of any of our activities.Our expectations to reduce costs, increasequality, and reduce downtime are fully re-alized.” �
Find out more:www.siemens.com/pcs7E-mail: [email protected]
Air Products is one of the leadingcompanies in the development andproduction of innovative additivessuch as the Surfynol moleculardefoamer
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Siemens aims at maintaining competitiveness for its customers in the US
Looking at the Bigger PictureAs Siemens builds a stronger presence in the US market, Process News sat downwith Reiner Pallmann, Vice President of Siemens Energy & Automation’s ProcessSolution Division and Tom Kopanski, Vice President of the company’s Automationand Motion Division, who are both determined to build closer relationships to theircustomers to strengthen their customers’ competitive positions.
What are some of the biggest challengesfaced by your process customers in theUnited States today?
Tom Kopanski: The challenges in the USare very similar to those around the world.Companies are looking to find better ways tomanufacture products safely and consis-tently. Some industries face very specificchallenges resulting from government reg-ulations, especially the food & beverage,pharmaceutical, and life sciences indus-tries. Others are simply looking for ways tocurtail production costs to remain compet-itive. It’s all about profitability, getting goodreturn on your assets.
Reiner Pallmann: That’s true. Many com-panies we work with are looking to upgradeolder systems to bring more consistency andquality to their product. They want to achievemore production with the same number ofpeople. We think Siemens industry knowledgecombined with some of the most advancedmanufacturing technologies in the market-place can give our customers a competitiveedge, in a way that no other company can.
How exactly can Siemens improve thecustomers competitive edge?
Tom Kopanski: The answer lies in ourapproach to the customer’s problem: Welook at every situation from the customer’spoint of view. We dive into what’s critical totheir success: whether that is a quick start-
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Find out more:www.siemens.com/automationE-mail: [email protected]
up, or making sure that they are investingin the system that will give them a solidpayback, or simply minimizing their risk.Some of our organizational structures havechanged as a result of listening to andlearning from their feedback. In somecases, such as in the increased customersupport we provide, these changes are eas-ily visible. In others, such as changing ourinternal processes to clear a path for them,they are not.
Reiner Pallmann: Over the past few years,we have also supported our customersthrough the economic downturn. Invest-ment slowed, and some companies sufferedbecause their suppliers and partners strug-gled as well. We didn’t reduce our presenceand, since 2000, we have more than doubledour systems business in the process indus-tries. Our customers responded very favor-ably to the effort we made to support them.
We hear a lot about high labor costs inthe US. What do you see as the future ofmanufacturing in the US?
Reiner Pallmann: We absolutely believein the viability of manufacturing in the US.To remain competitive, companies canleverage our automation and energy costmanagement solutions, as well as our abil-ity to work with businesses to optimizetheir processes. It’s the technology coupledwith the industry knowledge that allowscompanies in the U.S. to compete withregions that have lower labor costs.
Tom Kopanski: Our customer focusenables a real dialog that’s more than asales call. We work with customers to thinkthrough the whole process, not just thelabor costs. The answer isn’t just outsourc-ing. By really understanding a company,Siemens can help someone stay focused onthe business issues.
You have both talked about helpingcustomers improve their processes. But isn’t changing a process a difficult thingfor a company?
Reiner Pallmann: Sometimes it seems asif people don’t want to change. But themanagers we work with know that theright change at the right time brings valueto the business. You must have your busi-ness goals in mind and work with part-ners who can help you to manage thechange properly.
Tom Kopanski: Whenever customershave to change or upgrade their processcontrol system, they view that as a potentialrisk. It is our job to show those customersthat we will not only help them managethat risk, but that we will give them a bet-ter solution and return on investment thanthey previously had. We do this by bringingour industry expertise, strong technicalskills, and clear focus to the task. We havedemonstrated this in cooperative effortswith various customers – for example, withAir Products, where Simatic PCS 7 is help-ing to improve process control. We realizethat we must understand customers’ needsto take them to where they want to go as abusiness.
What about the payback? That plays a big role doesn’t it?
Reiner Pallmann: Payback is an importantelement of any project. It doesn’t matter ifit’s a brownfield retrofit that pays back ina year or a multi-million dollar tissue milllike the one we just completed. If ROI canbe demonstrated, it makes sense to makethe change. Of course, trust is anotheraspect: Our global-local support helps tobuild stronger relationships. Our nationalcenter of competence for service, whetherit is automation or energy, makes sure thatour customers have the support they needfrom experts in the US.
“We look at every situation from the customer’s pointof view.”
Tom Kopanski, Vice President automation and motion division
“Our center of com-petence for servicemakes sure ourcustomers have thesupport they need.”
Reiner Pallmann, Vice President process solutions division
Tom Kopanski: I need to say somethingabout focus here, because I think it’s animportant element to any discussion aboutour customer commitment. Even Siemensdoesn’t have unlimited resources. So we’vemade efforts in certain industries todevelop the knowledge we need to take ourcustomers to the next level. Ethanol is oneinstance. We’re involved in nearly three-quarters of all new ethanol processingplants being built in the US. We have Cen-ters of Competence for the food & beverage,chemical, glass, and pharmaceutical indus-tries.
Reiner Pallmann: Not to mention ourteams that support oil & gas, metals, paperand water. We’ve developed our competen-cies so that when a customer has a vision,our focus allows us to understand their lan-guage and their needs. This focus on cer-tain industries enables us to gain the in-depth knowledge to be a true partner, andthat strength allows our customers to moveinto the future more securely, and oftentimes even faster.
Thank you for talking with us.
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Mr. Pflantz, where do you see thegreatest challenges for your company inthe pharmaceutical and biotechnologymarkets today?
Steve Pflantz: Through the increasinglevel of sophistication in both markets withrespect to product quality and productionflexibility, there is great demand for theengineering support our company pro-vides. These market opportunities, how-ever, come with high customer expecta-tions. Apart from in-depth industry knowl-edge and experience, customers ask forefficient, reliable solutions that will netthem predictable outcomes.
Why does CRB rely on Siemensproducts in its designs?
Steve Pflantz: Few vendors provide therange of products that Siemens offers,whether motor controls, drives, DCSs, PLCs,OITs, instrumentation, BMS, you name it.Global product availability is excellent, as isthe service that goes with them. In additionto good brand recognition, the size of thecompany also ensures that spare parts willbe around for a while.
And what about technological aspects?
Steve Pflantz: We’re very satisfied with theSiemens products, as are our customers.Let me give you one example: Our designsfor the pharmaceutical and biotechnologyindustry utilized remote mounted sole-
noids to keep the high volume and highpressure air discharge of the valve actu-ators from discharging into clean spaces.Manifold solenoid systems that are con-trolled via fieldbus such as Profibus saveinstallation time and cost. However, notall devices have fieldbus capability. Con-ventional I/O signals are still required.Simatic ET 200S has met all of our require-ments for accuracy on analog signals as
well as available signal types for I/O – andboth installers and integrators have giventhe ET 200S high marks for quality, func-tionality, and ease of use.
So this solution has already proven to be beneficial in projects?
Steve Pflantz: Of course. Take, for example,a new biotechnology production facility inthe midwest. Siemens products were used
for the entire building power distribu-tion, from the main switchboard downto the final circuit panels, includingprocess control with Simatic PCS7, net-working with Profibus DP, and SimaticET 200 as a remote I/O system. This inte-
grated approach resulted in considerablelabor, time, and material savings, not tomention more efficient and attractive use ofspace, and a much simpler integration. Solu-tions such as Profibus and the ASI bus camewith a higher price tag, but looking at thebottom line, are worth every penny.
Thank you for taking the time to speakwith us.
CRB Consulting Engineers and Siemens
Partnering inSpecializationCRB Consulting Engineers, headquarteredin Kansas City, Missouri, USA, is an inter-national design firm specializing in facilityand process configurations for high tech-nology industries. CRB utilizes Siemensproducts in numerous pharmaceutical andbiotechnology facility designs. Process Newsspoke with Steven W. Pflantz, instrumentand controls engineer at CRB, about thecooperation between CRB and Siemens.
Find out more:www.siemens.com/automationwww.crbusa.comE-mail: [email protected]
“Market opportunities come with high customer expectations.”
Steve Pflantz, CRB Consulting EngineersC
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CRB Consulting Engineers, Inc. is an international design firm specializingin facility and process design for high technology industries such as thepharmaceutical and biotech industries
MES business case with Simatic IT in poultry processing plant
Less Waste, More GainIt took only one pilot project on a single production line to convince executive management at a US-based food and beverage company to give the green light to a multi-plant corporate rollout of the Simatic IT manufacturing execution system (MES).
eliminating the waste. It then identifiedevery process step where Simatic IT coulddeliver more information faster, and quan-tified the return-on-investment associatedwith that opportunity.
Substantial gains on many levels
Simatic IT’s flexible framework architectureand workflow technology was used to tailor,extend, and add to the production opera-tion functionality provided in the system’sprocess-step library. That way, the numberof traceable documents could be reducedby 59 percent, and people tied to docu-ments by 15 percent. Moreover, 63 percentof all non value-adding steps and all wastedsteps were eliminated. As a result of theSimatic IT implementation, the overallnumber of steps went down to one third.Process velocity powered by Simatic IT –the time it takes to put information in thehands of a decision maker – also sped dra-matically.
The challenge now is how fast Simatic ITcan be rolled out to multiple plants. Butsince the process has been analyzed andthe corresponding libraries that were de-veloped for the trial production line arereusable, the company can exploit the al-ready established best practices. Addition-ally, both Simatic IT and the SAP systemembrace the ISA 95 approach, which en-ables the communication between the twosystems. �
The company wanted to justify thebusiness case for the envisioned cor-porate-wide Simatic IT MES to be run
in parallel with the SAP enterprise system.The goal was to align all business processes– from financials, to human resources,manufacturing, and transportation – to oneend: executing the “perfect order” from thecustomer’s perspective, delivering thehighest-quality product at the lowest price.To do that, critical production informationhad to be available whenever decisions af-fecting efficiency and profitability weremade. These parameters in turn hadtremendous impact on quality and price.
Eliminating waste
For this purpose, a single production linewas chosen to as a mirror for the entire en-terprise. The project’s first step was to doc-ument every task and activity – from thefront office to the back dock – that impactedthe one line. That encompassed 19 processflows with more than 100,000 steps perweek. The project team looked at every-
thing in the process where the companywas losing yield or having problems. Theyexamined if and where more informationcould be obtained faster. For each step, thecompany identified whether it was value-adding, or non value-adding, and started
Find out more:www..siemens.com/simatic-itE-mail: [email protected]
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11FOCUSThe Americas
Business benefitsachieved withSimatic IT
B Real-time information went fromzero to nearly 38 percent
B Minute information went from lessthan 4 percent to nearly 16 percent
B Hourly information went from almost57 percent to almost 40 percent
B Daily information went from almost 40 percent to about 7 percent
B Weekly bucketed information wentfrom 2 percent to 0.2 percent.
ZEFA
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CTE Sand & Gravel, a subsidiary of Kuhl-man Corporation, supplies sand andstone to ready-mixed concrete pro-
ducers, concrete block plants, road builders,landscapers, landfills, excavators, and publicagencies throughout Southeast Michiganand Northwest Ohio. CTE uses a 25-centime-ter dredge to pump less than 12-centimetersand and gravel particles from its sand mine.The slurry is then discharged into a velocitybox. From there, the material is screened,graded, and distributed to storage piles.
Improving monitoring reliability and accuracy
To maximize production, it is particularlyimportant to effectively control the pump-
ing operation of the dredge. Steve Wag-ner, General Manager at CTE, tested fivedifferent flowmeters, strap-on, and Doppler,from three different suppliers – with littlesuccess.
Flow measurement reliability remainedpoor, and there was no linearity or accu-racy. Occasionally, the signal would errat-ically move higher or lower without rea-son. It was critical that the flowmeterremain reliable in a very harsh environ-ment, where up to 12-centimeter gravelparticles travel at about 5.5 meters persecond.
In early 2005, Steve Wagner decided toautomate the entire dredge process, andmet with Sheldon Shepherd of Siemens to
discuss the application. Siemens engineersrecommended the Sitrans F M 911/E mag-netic flowmeter with the Transmag IItransmitter. This flowmeter was devel-oped to measure pulsating media andmedia of low conductivity and/or with ahigh proportion of solids. The 911E flowtube was supplied with a thick rubber linerand protection ring to guard against abra-sion, and was installed near the dischargeof the dredge pipe. Now, the velocity meas-urement from the 911E Flowmeter is trans-mitted to the dredge a quarter of a mile awayvia wireless Ethernet, where it is used tocontrol the speed of the dredge pump.
Problems have disappeared
Since installing the Sitrans F M flowmeterat the beginning of this season, the unithas been working non-stop and without aproblem. The previous linearity and accu-racy problems have all but disappeared.As Steve Wagner points out, “I have hadno complaints. The unit has been workinggreat.” ■
Find out more:www.siemens.com/processinstrumentationE-mail: [email protected]
After severalunsuccessfulattempts withother techno-logies, CTEfound the rightsolution to achallengingflow monitoringproblem withthe Sitrans F Mflowmeter
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Sitrans F M 911/E magnetic flowmeter optimizes dredge pump control
Smooth FlowTo ensure trouble-free operation in its sand mine, CTE Sand & Gravel sought areliable and accurate flow monitoring solution for its dredge pumping. Severalsystems from various suppliers had failed at the task. Finally, CTE found theright solution in the Sitrans F M 911/E flowmeter.
our interior tanks developed a leak, the lev-el monitor immediately gave us an alarm sowe could take action before it became a se-rious problem. Also, constant monitoringof the river rate of change is critical. Theequipment's fast and accurate responsekeeps us on top of this at all times.”
Walking around the scrupulously cleanand modern plant, you can see some of thelevel instruments are older models. “That'sbecause they are reliable and don't breakdown,” says Gary Stevenson. “We almostnever have to replace them, and that helpskeep our maintenance costs low.”
Using the latest technology and thelatest in water management techniques, Pe-terborough remains proactive in its effortsto deliver quality water efficiently to cityresidents. “Our water quality is excellentand we want to ensure we continue to ex-ceed drinking water standards,” says GaryStevenson. ■
flocculation tanks, sedimentation basins,settled water trough, filter beds, finishedwater storage reservoirs, chemical tanks,and other applications. An ultrasonic de-vice monitors the floor as a safeguard to de-tect any spillage from a leak or rupturedpipe. At the city's various stations, reser-voirs, and elevated water tanks, there areanother 20 points of level being constantlymonitored. Signals from remote sites aretransmitted by radio link to the plant con-trol center.
“Every one to two years, we have testedsomething here,” says Gary Stevenson,plant superintendent at Peterborough anda 25-year veteran of the water industry. “Wewere part of the testing of the originalProbe device and we encouraged develop-ment of the one-piece transmitter ap-proach.”
Accurate and fast response
“The equipment is accurate and respondsvery quickly to any change,” says GaryStevenson. “Detecting rate of change is re-ally important. As an example, when one of
Peterborough water treatment plant benefits frominnovative level monitoring technology
Operating at a High LevelThe Peterborough water treatment plant, serving a city of 74,000 near Toronto,Canada, has been an early adopter of new technology for many years. Throughits partnership with Siemens, the plant has often served as a test site for newlevel measurement technology used by the water and wastewater industryworldwide. This technological edge helps the plant deliver quality water thatexceeds drinking water standards.
process news 4/2005
13FOCUS
The Peterborough plant brings waterfrom the Otonabee River, cleans andtreats it, then distributes it to resi-
dents. The system has about 400 kilometersof water mains, and pumps an average of 45million liters of water a day. The Peterbor-ough plant faces the same challenges asother water plants today. A steadily growingpopulation has increased demand for fresh,high quality water. Pressure to control costsrequires striving to improve efficiency,while new regulations require enhancedsafety, training, and environmental protec-tion.
Integrated solution
For any water plant, one of the most criti-cal automation needs is level monitoring.Starting in 1994, all process points at thePeterborough plant have been fully inte-grated into a central SCADA system for con-tinuous monitoring and control.
Peterborough has Siemens level instru-ments at more than 40 points in the mainplant. They monitor the river level, gate po-sition in the river, as well as level in the
The Americas
Find out more:www.siemens.com/processinstrumentationE-mail: [email protected]
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Gary Stevenson, Superintendent of thePeterborough Water Plant, and his teamhave taken a progressive approach inadopting new technologies andtechniques to create a proud qualityrecord
process news 4/2005
14The Americas
FOCUS
22,000 I/O that the Phase 1 system features.Some 60 engineers from SLH and fourengineers from Siemens spent nearly200,000 hours integrating and applying thePCS7 to the existing database.
According to Alouette maintenance andtechnical services manager Richard Lapierre,the excellent technical support providedby Siemens made the transition from the
old to the new system much easier. “Thesmelter was up and running by the thirdweek of January, as planned. We’re con-vinced that we’ve achieved substantial gainsfor the future,” says Richard Lapierre. Headded that the link with the old system hasproven very efficient and, above all, muchless costly than the distributed system.As for the advantages of PCS7, Lapierre is
The Alouette plantis currently thelargest smelter inthe Americas
During the project, thefacilities were expandedwithout interfering withproduction
Simatic PCS7 at the controls of the largest aluminum smelter in the Americas
Keeping the pots hotSince its first pot in 1992, Pointe-Noire Aluminerie Alouette,
located in SeptÎles, Québec, has gained world renown for its expertise and ultramodern facilities. To further consolidate its leading market position, the company began construction
on Phase 2 of its smelter in October 2002. To automate the new phase of the smelter, Alouette selected the new
Simatic PCS 7 Version 6.0, whose innovative features offerseveral substantial advantages.
T he estimated $1.4 billion expansion,scheduled to be fully operationalby September 2005, increases the
annual production capacity from 245,000to 550,000 metric tons, in the process cre-ating 340 new permanent jobs and makingit the largest aluminum smelter in theAmericas.
Growth without missing a beat
Phase 2 at Alouette, which consisted ofexpanding the facilities without interferingwith current operations, represented amajor challenge for the SNC-Lavalin/Hatch(SLH) consortium hired by Alouette to man-age the project.
In order to ensure that production andconstruction could go on side by side, SLHturned to the expertise of Siemens and itsSimatic PCS 7 Version 6.0 process controlsystem. For Alouette, the collaboration withSiemens was perfectly natural, because thecompany was already using Simatic PLCs tooperate Phase 1 of its smelter built in 1990.
The challenge lay in replacing the exist-ing PLC with the new PCS7 AS417 system.This new phase will enable more than30,000 I/O to be added to the approximately
process news 4/2005
15
praising the new Siemens technology. “Tobegin with, PCS 7 combines the speed ofautomation with the integration of a dis-tributed system. Thus, the process of coordi-nating two systems was wonderfully smooth.It spared us a substantial amount of timeand money,” as he explained. “ PCS7 servesas a real shared center platform, which sim-plifies integrating control and supervisiontechnologies.” He also stresses that, giventhe magnitude of the project, Alouette ben-efited from a preferential price for PCS 7installation, noting that the substantialgains achieved for the smelter furtherstrengthened business relations betweenAlouette and Siemens.
Access to expertise
Alouette President and Chief ExecutiveOfficer Joe Lombard is more than pleasedwith the partnership formed with Siemensin Phase 2 construction. “I’ve been closelyinvolved in many similar projects over thecourse of my career, and I can positivelysay that this project was the easiest I’ve evercome across.“
“Normally, changing over from one sys-tem to another takes months because of
computer problems. With Siemens, the op-eration simply involved pressing a button.In addition to complying with all of ourspecifications, Siemens technology enabledus to keep our operations up and runningto meet the needs of our customers,” saidJoe Lombard. “We’re very proud of that.”
One of the main objectives of the part-nership with Siemens concerned upgrad-ing and securing the plant without inter-fering with operations. Not only did theproduct meet the full approval of Alouettemanagement, the customer service thatcame with it also surpassed expectations.“The Siemens approach goes beyondinstalling the equipment. We benefitedfrom unlimited access to Siemens’ expert-ise worldwide. That’s very assuring whenyou’re managing a project of this size,” saidJoe Lombard.
“The Siemens people gave us all the tech-nical support we needed to successfully com-plete the project, even though we insistedon having our own engineers install theprogram,” he added. “It’s very pleasant towork under conditions such as those.”
The company head is so satisfied withPCS 7’s reliability and flexibility. He plans
to convert all of the company’s equipmentto the new Siemens technology. Siemens’contribution to the project did not stop withPCS7. In addition to supervising the totalintegration of the various layers of prod-ucts, such as the variable frequency drivesand instrumentation, Siemens also assumedresponsibility for the power supply and dis-tribution, specifically for the 25 Kilovoltand 5 Kilovolt equipment, the 600 Voltloop, and the engine control centers.
Positive outlook
After the sucess of this project, Joe Lom-bard is very optimistic about the future.The addition of 330 pots will make Alouettethe largest smelter in the Americas with anannual production of 550,000 metric tonsand close to 900 employees. �
Find out more:www.siemens.com/metalswww.siemens.com/pcs7E-mail: [email protected]
PCS 7 serves asa real sharedcenter platform,simplifying theintegration ofcontrol andsupervision
The new facilities prior to
project completion in 2005
All
pict
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s: A
lou
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16The Americas
FOCUS
When the State of Texas mandatedthe monitoring and measurement ofemissions of flare and cooling towersin the Houston area, Siemens AppliedAutomation immediately respondedto the legislative changes. No soonerhad the “first draft” regulationsbecome available when Siemensbrought in comprehensive analyticalresources to educate customers andto provide measurement and systemsolutions.
Nowhere else in the United States isthere a higher concentration of in-dustrial and petrochemical plants
than in the Houston/Galveston area. Theindustrial plants account for additionalemissions of highly reactive volatile or-ganic compounds (HRVOC) that can pro-mote Ozone formation. Consequently, aspart of a wider concerted effort, the TexasCommission on Environmental Quality(TCEQ) decided to do something aboutozone-forming air pollution in Spring2002, focusing on flare and cooling toweremissions. The anticipated regulationsfrom the TCEQ had industries looking foraffordable, cost effective solutions.
Proactive cooperation
Siemens learned of the TCEQ plans at anearly stage and set up a dedicated teamaround Ulrich Gokeler, the HRVOC prod-uct manager based in Houston, whoworked closely with the TCEQ. To get in-dustry feedback on the first draft of theregulation released by the TCEQ, Ulrich
Gokeler contacted his customers: “It be-came apparent that the way the rules andregulations were written was not very re-alistic,” Ulrich Gokeler said. “So our cus-tomers asked us to talk with the regulato-ry agency to educate them more abouton-line measurement capabilities. Theyalso asked us to standardize the solutionto lower the costs and to increase opera-tional efficiency.” The TCEQ invited Gokel-
er to come to Austin to present recom-mendations for analytical and system op-eration and, after extensive discussions,a more technologically and economicallyfeasible regulation was adopted. UlrichGokeler also worked closely with theTCEQ to simplify the calibration process.The original requirement forced plantsto provide more than 30 reference gascylinders for the calibration – a figurethat was reduced to three in many cases,following the Siemens proposal, and onewhich lead to considerable savings.
Orders following initiative
The Siemens solution focuses on the pro-cess gas chromatograph Maxum Edition
II, which automatically collects HRVOCsamples from the flares and cooling tow-ers every 7.5 minutes – more frequentlythan the 15 minute intervals required bythe environmental agency. In addition,the Maxum gas chromatograph can vali-date between the actual analyses be-cause of the shorter cycle time. Thus,operators can be assured of accuratemeasurements at all times.
Siemens was able to secure orders formore than 70 percent of all of the gaschromatograph analyzers installed in theHouston/Galveston area. Currently, Siemenstraining and field service teams are busyworking with customers in preparationfor the new regulations, requiring moni-toring of emissions, beginning January 1,2006. �
Siemens develops process analysis solutionfor emission control in Texas
Clean Air Action
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Siemens was able to secure more than
70 percent of allorders for
emission monitoringsystems based on
its Maxum process gas chromatograph
solution
Find out more:www.siemens.com/processanalyticsE-mail: [email protected]
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ard.
com
Sitrans radar technology solves level measurementchallenges for cement producer
Settling the DustLike other companies in the industry, a leading Mexican producer ofcement and ready-mix products had trouble measuring level in dustyapplications. Installing a Sitrans LR 400 radar device solved the problem.
process news 4/2005
17FOCUS
A t one site, the company sought a lev-el measurement solution for its pe-troleum coke silo. Petroleum coke,
or pet coke, is a petroleum industry by-product that is often used as a cost-effectivefuel by the cement industry. The pet coke isconveyed from a train-unloading stationand pneumatically fed into a storage silothat is 18 meters high. Pet coke is a finesticky powder, and despite extensive ef-forts, the installed level monitoring systemcould not produce reliable readings. Dur-ing filling, where a lot of dust is created, thepersonnel had to rely on manual measure-ments. Operators were very frustrated withthis situation.
The radar solution to dust
In order to solve the problem, the compa-ny decided to test a Sitrans LR 400 radar in-strument. It easily fit onto the existing noz-zle, requiring no custom fittings or silomodifications. After programming the firsteight “Auto Setup” parameters, the SitransLR 400 immediately displayed the right lev-el. It was fully operational just 15 minutesafter installation. Operators can now mon-itor how much material is available to main-tain the kiln process, and also how much in-ventory is available for local deliveries. Fol-lowing this successful trial, they tried theradar instrument on another tough and ex-tremely dusty application: the cement ho-mogenization silo.
Another challenge
During homogenization, silos are continu-ously filled and emptied, and the component
The Americas
materials are constantly aeratedto ensure good mixing. This cre-ates a tremendous amount ofdust that makes it difficult to ob-tain reliable readings with tra-ditional non-contacting meas-urement devices.
The operators installed aSitrans LR 400 device on the 40meter high homogenizationsilo and monitored measuringperformance for two months.The radar instrument main-tained a signal output at alltimes, even during filling – un-like other technologies, whichcan usually only conduct meas-urements during static condi-tions.
Preferred solution
As a result of these successful tests, opera-tors can now base their production deci-sions on accurate readings. Also, operatorsno longer have to climb the silo, savingvaluable staff time and enhancing plantsafety. Following these first trials, thecompany has already installed additionalSitrans LR 400 instruments, and the tech-nical manager at the main plant has pro-posed Sitrans LR 400 as the preferred levelmeasurement solution for these applica-tions. �
Find out more:www.siemens.com/processinstrumentationE-mail: [email protected]
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The new Sitrans radar devicedelivered correct readings onlyminutes after installation
Clear benefits: Simatic Safety Matrix� Automatic creation of safety logic� Minimization of programming mistakes� Automatic generation of documentation after safety reviews� Shortened configuration times, since no special programming
knowledge is required� Automatic user-friendly display of the safety matrix on the
operator interface of Simatic PCS7� Automatic management of project versions� Easy tracking of changes � Straightforward online changes to safety functions and easy
adaptation of logic in test mode, as well as maintenancefunctions such as bypass, reset, and override
process news 4/2005
18Process Safety
TECHNOLOGY
A cause-and-effect matrix is a designand analysis tool used in many dis-ciplines to organize large amounts
of related information. The cause-and-ef-fect matrix graphically shows the relation-ship between initiating events (causes) andthe actions taken (effects). The matrix for-mat prompts the designer of the cause-and-effect diagram to consider and documentthe relationship between each cause andeach effect.
The cause-and-effect matrix has longbeen used in the design of emergency shut-
down (ESD) systems as a tool to graphical-ly and comprehensively analyze and docu-ment the relationship between process in-puts and the actions they should trigger.Because the cause-and-effect matrix is astraightforward graphical representationof the operation of the system, it allows allof those involved in the design and imple-mentation of a safety system – from theprocess engineer and the control engi-neer to the maintenance engineer – tospeak a common language. Consequent-ly, it has been an important tool in the de-
sign of safety systems for years. However,its effectiveness was always limited be-cause safety PLCs were programmed in adifferent language. With Simatic Safety Ma-trix, Siemens has developed a tool that willhelp bridge this gap.
The safety life cycle
Both as a tool and as a method, the SafetyMatrix ties into all aspects of the safety lifecycle. The safety life cycle is a practicalmethodology that defines the steps nec-essary to ensure overall plant safety for
The Safety Matrix cause-and-effect matrixtoolset for Simatic process safety systems
Enter the MatrixThe Safety Matrix for the Simatic S7-400F/FH process safetysystem, developed as both a development tool and amethodology, is easy to use and can help reduce configu-ration time, testing, and maintenance by up to 50 percent.
The SimaticSafety Matrixoffers an easy-to-useconfigurationtoolset forprocess safetyapplications
Simatic safety systems recommended by DuPont
DuPont Sourcing and Engineering has selected Siemens Simatic safety systems to beone of two approved global supplier platforms. The scalable Simatic safety systems willallow DuPont Sourcing and Engineering to provide the highest levels of protectionwhile finding the most cost-effective architectures for its processes.
“We are pleased that the Simatic safety systems have been globally selected byDuPont Sourcing and Engineering,” said Robert James, manager of process safetysystems for Siemens automation systems. “This agreement allows DuPont Sourcing andEngineering to cost-effectively address its safety concerns, and gives Siemens helpfulinput from an industry leader, as we strive to meet the needs of this changing market.”
Simatic safety systems are TUV certified to IEC 61508 for applications up to SIL 3,regardless of the system architecture. The Simatic safety system helps manufacturerssuch as DuPont comply with the new IEC 61511 standard for safety instrumentedsystems in the process industries. “The modular Simatic safety system gives us a greatdeal of flexibility to reduce costs,” says DuPont engineer Richard Dunn. “We can nowcustomize the system architecture to the specific availability requirements of theapplication. The safety system also interfaces with all of our existing control systems. In addition, the unique Simatic Safety Matrix cause-and-effect tool reduces engineering,commissioning, and maintenance costs.”
process news 4/2005
19
process plants. By defining a sequence ofphases and the deliverables from each phase,the safety life cycle helps prevent the fail-ures that have been identified as the rootcause of many industrial accidents. Thesafety life cycle can be divided into threemain phases: the analysis phase, the real-ization phase, and the operation phase.
In the analysis phase, the Simatic SafetyMatrix functions primarily as a require-ments documentation tool. While othertools are used to perform functions such ashazard analysis, layer-of-protection analy-sis, and SIL selection, the Safety Matrix isthe ideal place to document the safety in-strumented functions, and the cause-and-effect matrices themselves become an im-portant part of the safety requirementsspecification.
The Safety Matrix Viewer is the onlinegraphical interface that is fully integratedinto the control system HMI. It allows op-erations and maintenance personnel tomonitor the Safety Matrix with live data.Best of all, the Viewer incorporates a se-quence-of-events recorder for automatictime and date stamping and logging. Thisprovides an invaluable tool for start-up,day-to-day operations, maintenance, andperiodic functional testing.
Substantial savings
The Safety Matrix plays a crucial role in therealization phase, because it automaticallycreates the safety PLC program from thesafety requirements specification. End usershave reported that this feature alone canreduce their detailed design efforts by 50percent. Moreover, the online monitoring,event logging, and other maintenancefeatures of the Safety Matrix make it anideal commissioning tool. Here again,users have reported that the Safety Matrixhas saved them up to 60 percent in theirsystem commissioning efforts. And sincethe Safety Matrix is a complete operations,maintenance, troubleshooting, and man-agement-of-change tool, additional bene-fits can be achieved in the operations phaseof the processing plant or unit. �
Du
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Safety is a key concern also in DuPont products: For example, glass laminatedwith DuPont’s Butacite can offer protection even after the glass if broken,because glass fragments adhere to the interlayer
Find out more:www.siemens.com/process-safetyE-mail: [email protected]: [email protected]
process news 4/2005
20Process Control
TECHNOLOGY
A recent study found that in the U.S.alone, over 20 billion dollars arelost annually due to unplanned
downtime, with approximately 40 percentof this figure being the result of preventa-ble human error. One of the key factorscausing human errors is the proliferationof alarms and the operator’s ability torespond quickly, efficiently, and correctlyduring upset conditions.
The good news is that there are manyexcellent references which document indus-try best practices with respect to alarmmanagement. The PCS7 alarm subsystempossesses many capabilities to help endusers implement alarm management bestpractices such as EEMUA pub. 191.
Focus, information, and action
One of the most important features of PCS7is the ability to focus the operator’s atten-tion on the most critical alarms. Built-inalarm horn capability, the option of assign-ing priority levels to individual alarm mes-sages, and a structured incoming alarm listhelp to identify the most important alarms,even during high traffic times.
Equally important, PCS7 provides clearand understandable information in alarmmessages, and is also able to recommendcorrective actions by allowing operationsbest practices to be captured and docu-mented within the system.
Coping with meaningless alarms
In order to cut down on the number ofmeaningless alarms, the operators can use
the alarm “locking” or suppression capa-bility of PCS 7: All alarms of an individ-ual device or of an entire process area canbe suppressed by touching the “lock” but-ton – for example, to remove alarms fromequipment which has been taken out ofservice, or from process areas which arenon-operational.
To prevent important alarms from re-maining out-of-service, PCS7 can display alist of all devices which are currently sup-pressed in the “lock” list. Thus, operationspersonnel can get an up-to-date list of all ofthe locked alarms in their system to deter-mine whether it is safe to start up or use theequipment.
Analyzing alarm system performance
Finally, effective alarm management is adynamic process which requires continu-ous attention. PCS7 has several out-of-the-box tools that provide alarm-related keyperformance indicators (KPI) which engi-neers and operations personnel can use tocontinuously evaluate and improve the per-formance of the system and the operator.Consequently, plant operators can ensurethat their alarm management consistentlycontributes to overall plant efficiency. �
Alarm management capabilities of Simatic PCS7 help leverage industry best practices
Heads UpIn today’s competitive global economy, the issue of alarmmanagement in process automation systems has neverbeen more important. Simatic PCS7 offers a range offunctions and features for effective alarm management.
Managing alarmseffectivelyWith Simatic PCS7, plant operators canexploit the system’s features to improvetheir alarm management by:
B Focusing operator attention onimportant alarms
B Providing clear and understandablealarm messages
B Providing information on therecommended corrective action
B Suppressing all alarms of a device orof a process area
B Analyzing alarm system performancemetrics to identify nuisance alarms orareas requiring additional training
Theincomingalarm listprovides
options forsorting
andfiltering all
alarmmessages
in thesystem
Find out more:www.siemens.com/pcs7E-mail: [email protected]
21TECHNOLOGYProcessanalytics
on the corrosion behavior of the gas. Tomeasure the traces of moisture in the chlo-rine, phosphorous pentoxide sensors were
previously used. The extractive technologyapplied here, however, had high mainte-nance requirements and limited reliability.The relatively long signal response timealso posed problems, as corrosive gas couldcause significant damage before an alarmwas triggered.
In situ monitoring
An attractive alternative is offered by theLDS 6 in situ laser diode spectrometer. Thisenables infrared active gas componentssuch as water to be determined directlywithin the process in quantities of less thanone part per million. The values are meas-ured in real time and are free of spectralsuperpositions, thereby enabling the mon-itoring and control even of dynamic pro-cesses.
The device consists of a central analyzerto which up to three measuring head pairscan be connected. Since the measuringunits are connected by fiber-optic cables,the analyzer can be installed in a separateroom and, therefore, outside of hazardousareas. The analyzer can be purged with drynitrogen. The moisture content of thepurging gas can be monitored to enableexact calculations of the measure tracemoisture value. For this, the purging nitro-gen is fed into a reference cell, where itstrace moisture is measured. This technol-ogy leads to highly precise measuringresults, regardless of the ambient condi-tions.
Operation requires no recalibration inthe field, and no maintenance is necessaryfor cleaning or reassigning the measuringcells. The highly resistant measuring headsare hermetically sealed and designed formeasurements in extremely corrosivemedia.
Representative data
The precision, speed, and reliability of theLSD 6 laser gas analyzer opens up manynew possibilities for efficient control ofchlorine gas drying. Moreover, it offers animpressive example of a truly representa-tive measuring method: previously, only afew liters of measuring gas were measuredper hour, whereas now the laser technologycan monitor several thousands of liters ofchlorine gas directly in the gas stream. �
In situ moisture analysis of chlorine gas with LDS 6
Fast and AccurateThe moisture content of chlorine gas is an important variable inchlorine chemistry. Until now, these moisture traces could only bemeasured with phosphorus pentoxide sensors with numerousdisadvantages. The technology used in this monitoring method hashigh maintenance requirements and long signal response times. Now,the LDS 6 laser gas analyzer is available as a low-maintenance,accurate, and fast-reacting alternative.
D rying is an important step in the pro-duction of chlorine gas, because themoisture content has a direct effect
Find out more:www.siemens.com/processanalyticsE-mail: [email protected]
The LDS 6 laser diode spectrometer is a reliable and high-precision alternative toestablished measuring methods in determining the trace moisture in chlorine gas
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process news 4/2005
G rupo Modelo S.A. currently ranksseventh on the list of the world’slargest breweries. The reasons for
this success are good positioning in thedomestic and the US markets, along with aunique product and the company’s bigseller worldwide: Corona Extra. With thisparagon of Mexican beers as well as widevariety of special beers and products madeunder license, the producer successfullymarkets its beverages in more than 150countries. In order to comply with all of theregulations currently in force in the variousregions and countries in which it operates,the company bases its production on themost stringent requirements placed onprocess visibility and quality: the specifica-
tions of the FDA and the EU directive 178/2002. Since such high process visibility ispossible only by employing modern pro-cess control technology throughout, GrupoModelo decided to successively modernizeits brewing sites beginning in fall 2003.
Satisfactory pilot project
In the search for a new partner for the firstmodernization project in Mexico, the Obre-gon brewery, Grupo Modelo chose the Zie-mann brewery, based in Ludwigsburg, Ger-many, as supplier. Ziemann has been suc-cessfully working with Siemens for a verylong time, and has more than 20 years ofexperience with Braumat. The companytherefore decided to use Braumat at Obre-
The upgrade took place over the courseof a single weekend
Braumat enables tracking and tracing in Mexican brewery
Successful UpgradeOver the course of just one weekend, the complete software system for theprocess control technology of a large brewery was upgraded two versions,including the entire periphery – without interfering with ongoing production.With this state-of-the-art technology, the company can produce beer not onlyfor customers in Mexico, but also for the United States and the entire world.
Breweries
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In Torreon, Grupo Modelo S.A., theseventh largest beer brewer in theworld, produces a total of 2.85 millionhectoliters of beer per year in twobrewing lines
CASE STUDY
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gon, too – with great success. In the courseof the pilot project, the process control tech-nology of one brewing line was upgradedfrom Braumat NT 2.13 to Braumat V5.3, andthe available CPUs of the Simatic Controllerwere replaced by the latest CPUs of theSimatic S7-400 series – all in the period ofjust two weekends, without interfering withnormal production.
Francisco Gomez, head of electrical engi-neering and automation at Grupo Modelo,was understandably pleased with the Zie-mann and Siemens team after the comple-tion of the pilot project: “After the success-ful implementation at Obregon, and due tothe new Braumat functions, we also wantedto install the same flexible and modernprocess control technology at Torreon.”
The team did not have to wait long forthe order to modernize the brewing site atTorreon. And the schedule was even tighterthis time: only a single weekend was avail-able for the entire conversion of the processcontrol technology – from 5 p.m. Friday to6 a.m. Tuesday, at which time the plant hadto be up and running again at 100 percentproduction capacity.
Meticulously prepared transition
During a thorough analysis, all of the sys-tems to be replaced were first identified
and their functions examined. At the sametime, all actuators and controllers thatcould still be used were registered. Zie-mann in Ludwigsburg simulated the entireTorreon plant based on this knowledge. Thecore of this simulation was the componentsof the process control system that was actu-ally used later: the two S7-400 CPUs, theredundant IOS servers (complete withclients), and the Industrial Ethernet wiring.In this way, not only could all of the plantcomponents be optimally configured inLudwigsburg, but the software could beadapted there as well, including the devel-opment and integration of the processimages – more than 7,500 miles away fromTorreon in central Mexico. The requiredfactory acceptance test (FAT) was also per-formed in Ludwigsburg.
Thanks to this thorough preparationand the modular structure of all of the Brau-mat components used, the strict schedulewas met. After dismantling the mosaic cir-cuit diagram, which included changing thewiring and PLC as well as installing the newIOS servers with clients, the system wasready for trials on Monday morning. Withinthe scope of this controlled run-up, theplant was tested step by step according to apredefined plan and ramped up to 100 per-cent performance capacity, at which point
all of the recipes saved in the system couldbe executed.
Transparent and future-safe system
Since the commissioning of the new sys-tem, Grupo Modelo now benefits from theadvantages of the new Braumat version atTorreon as well. The availability and relia-bility of the brew house have been greatlyimproved, and the intuitive IOS user inter-face reduces sources of error as well astraining costs. The use of Braumat-basedrecipe-controlled methods not only increasesthe flexibility of production, but also con-siderably simplifies the introduction of newproducts. Finally, the long-term systemdevelopment planning based on commonindustrial standards contributes to a highlevel of investment security. In view ofthese advantages, chances look good thatGrupo Modelo, Ziemann, and Siemens willwork together on other projects. �
Find out more:www.siemens.com/breweriesE-mail: [email protected]
Ziemann andSiemensThe Torreon project is very significant for
Ziemann and Siemens, as it is the first
joint project since the signing of a
partnership agreement. The aim of the
contract, signed at the beginning of
February 2005, is to deepen the
strategic cooperation between the two
companies, and to further develop and
market innovative brewing technology
based on the latest Braumat systems. In
conjunction with this partnership, the
Ziemann Group in Ludwigsburg opened
a completely new test brewery – with
Braumat PCS 7 as the process control
solution – at the beginning of July 2005.
The new Braumat control center
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process news 4/2005
ergy-saving ammonia synthesis principledeveloped by Uhde. The plant can produce600 tons of ammonia per day. At anotherplant, urea is produced from ammonia byadding carbon dioxide, which is then usedas a fertilizer. The urea synthesis uses thepool reactor method under license fromthe Dutch company Stamicarbon. The ureais then granulated and filled into sacks fortransport or delivered directly by truck andrail.
Integration as a technologicaladvantage
At the end of 2002, Siemens received theorder from Uhde to supply the completeprocess control technology for the fertil-
izer production facility in Tejen. The goodprice/performance ratio of the Simatic PCS7process control system, along with the suc-cessful cooperation between Siemens andUhde on earlier projects (PCS 7 had alreadyproven its reliability at another Uhde plantin China), contributed to this decision.
The Siemens project team took on theengineering and construction of the con-trol system in Tejen – covering everythingfrom the compilation of the specificationsto the hardware and software engineering,and from the building of the switch cabi-nets and system testing to the delivery of afully functional control system. The sys-tem’s great integration capability onceagain proved to be a major advantage in
Simatic PCS reference project in Turkmenistan
Engine for GrowthNitrogen fertilizer is indispensable for modern intensiveagriculture. A new fertilizer plant in Turkmenistan will help thiscountry in the heart of Asia remain one of the largest cottonproducers in the world. In this plant, the Simatic PCS 7 processcontrol system is being used for the first time in fertilizerproduction.
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N itrogen is considered an “engine” forplant growth. It is indispensable forthe metabolism of amino acids.
Some plants can take in nitrogen from theair with the help of bacteria, but the major-ity of crops rely on mineral-bound nitrogenin the form of nitrate, which, until the be-ginning of the 20th century, could only beintroduced into the ground by naturallyfound nitrogen salts or organic fertilizers.
It was not until the development of large-scale ammonia synthesis based on theHaber-Bosch principle that slow-reactingnitrogen from the atmosphere could easilybe converted into mineral and organic ni-trogen compounds – and therefore enablesimple and targeted nitrogen fertilizationin agriculture. The enormous increase inagricultural yields since then is, to a greatextent, due to the achievements of thechemists Haber and Bosch, whose researchlaid the foundation for industrial exploita-tion of nitrogen in the air.
Even today, a large percentage of nitro-gen fertilizers are made from the basicproduct of ammonia. This is the case in anew fertilizer plant in Turkmenistan. Thecountry, which lies between Iran, Afgha-nistan, and Uzbekistan, is one of the largestcotton producers in the world.
The completely new complex is locatedin Tejen, about 220 kilometers east of theTurkmenian capital of Ashgabat. The plantwas built by GAP INSAAT, a subsidiary of theTurkish Calik Holding of Istanbul, for thestate-owned Turkmenkarbamid company.Uhde was contracted to design and deliverthe plant, and also supervised the commis-sioning.
The production facility consists of anammonia plant that operates on the en-
24 CASE STUDYChemical Industry
process news 4/2005
this project. Previously independent sec-tions such as the cooling system were inte-grated directly into PCS 7, with the benefitthat the entire plant can be monitored andoperated through one user interface.
During engineering and commission-ing, the demands on the process controlsystem increased continuously. conse-quently, the project team decided to replacefour of the five PCS 7 AS417-H automationsystems with the new AS417-F/H model.The control system processes some 6,000I/O, about a third of which are F signals,which are processed by Simatic ET 200Fmodules. Two thousand HART field devicesfrom different manufacturers were also in-tegrated quickly and easily into the process
control system with the aid of the SimaticPDM process device manager. The smoothintegration of the fail-safe technology inPCS 7 was particularly important in thisproject.
Successful reference project
After the entire system was installed, com-missioning began in mid-2004, and in-volved close cooperation between GAP IN-SAAT, Uhde, and Siemens. The plant hasbeen operating at full capacity since the be-ginning of 2005 and produces more than1,000 tons of fertilizer per day. In March2005, the production facility was openedwith an official ceremony by the Turkmen-ian president, Saparmurat Niyazov.
The project was not only a challenge forSiemens because of the rather unusuallocation in Turkmenistan. It also gaveSiemens a first reference plant for fertil-izer production using the Simatic PCS 7process control system – and successfullycontinued the effective partnership withUhde. �
Find out more:www.siemens.com/pcs7E-mail: [email protected]: [email protected]
Fertilizer specialistsFor decades, Uhde has been one of theleading enterprises for planning andconstructing large-scale fertilizerplants. The company has extensiveexpertise in this field and can boastmore than 360 plants for single, mixed,and complex fertilizers installedworldwide. Uhde has set newstandards, especially within the last tenyears. Over this time frame, fivefertilizer complexes with a totalcapacity of more than five million tonsof urea per year were built, mostly inextremely hot and cold regions.
The new plant was opened with an officialceremony that was attended by both visitorsfrom politics and the local population
With Simatic PCS 7, all processes are monitored and controlled through a common system
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26Semiconductor
CASE STUDY
T he new production line for 300-mil-limeter wafers includes a pullingline on which the polycrystalline sil-
icon is melted and pulled into monocrys-tals; a wafer factory in which the crystals arecut into discs; and, of course, the supply in-stallations as well as the wastewater andexhaust air treatment plants. One of themost striking features of the new plant isthe new wafer factory, which is located in abuilding measuring 130 times 70 meters.
M+W Zander, which was commissionedas the general contractor for the waferfactory, placed an order with Siemens tosupply the automation technology, energysupply, and building control technology.Tenders for all of these packages were re-quested and examined separately. As Hel-mut Höller, production manager at Sil-tronic in Freiberg, reports, “Siemens wasable to win many of the packages outright.Besides, we had already made a basic deci-sion at the beginning of the project to useSimatic PCS 7 as a platform for the processautomation. The result is a high degree ofstandardization in the plant because almostall units and assemblies are equipped withSimatic technology. This makes mainte-
New wafer factory benefitsfrom a high degree ofstandardization and anexperienced projectmanagement team
ConsistentlySuccessfulSiltronic’s new wafer factory inFreiberg produces 300-millimeterwafer discs for export all over theworld. With a high degree ofstandardization and consistent use of Simatic PCS 7 as a process controlsystem, as well as standardizedSiemens technology for the energysupply and building technology,Siltronic is poised to fully exploit the rationalization potential of thenew plant.
In the pullingplant, thepolycrystallinesilicon forproducing 300-millimeter wafersis melted andpulled intomonocrystals
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Many well-known customers in the industryhave already chosen Simatic PCS 7 as a systemplatform for all of the units of their semicon-ductor factories. In addition to the classicclimate conditioning in the clean room, thesystem is also used for water treatment (ultra-pure and wastewater), as well as for thechemical and gas supply.
Simatic PCS 7 offers the modularity, flexibil-ity, and openness of an industry-neutralprocess control system, connected to a SEMI-conformant component library with a sophis-ticated engineering system that addresses allof the automation requirements of semicon-ductor production.
The use of PCS 7 and the component libraryapplication guaranteed the on-time comple-tion of the factory, for which a maximumconstruction time of one year from laying thecornerstone to “ready for equipment” wasmade available.
As a system platform, PCS 7 also guaran-tees a reduction of the total cost of ownership(TCO), by minimizing spare parts variation,reducing training effort for personnel, andoptimizing service. The integration of theenergy supply and monitoring in PCS 7 en-ables implementation of a real facility moni-toring and control system (FMCS).
Process control for semiconductors: Simatic PCS 7
process news 4/2005
27
nance, spare parts storage, and spare partsprocurement cheaper and easier. Havingthe same technology and the same look andfeel also means that the plant can be oper-ated more easily and with less manpower –which directly effects production costs.”
Reliable partners and technology
Cost was an important factor in favor ofchoosing Siemens technology for most of the packages. “Of course, wealso took factors such as relia-bility, service friendliness, andso on into account, in additionto the basic costs of the imple-mented technology,” explainsBernhard Schmidt, project man-ager at Siltronic in Freiberg.Moreover, Siltronic had alreadymade positive experiences withSimatic technology – in Singapore, for ex-ample, where Simatic PCS 7 was used forthe first time.
“One advantage of a long-standing part-nership is that you know what you are buy-ing and are familiar with the strengths and
weaknesses of the technology,” adds Höller.“In addition, we can continue to use ourown expertise that we have built up aroundSimatic and other Siemens solutions.”
Simple integration
A network of many central plants andsmaller units is necessary to producewafers. However, semiconductor produc-tion places very high demands on the
process control: all of the media and all en-vironments must remain absolutely clean,because even the slightest contaminationcan make the wafers useless. Siltronictherefore keeps a batch record for everydisc, so that it is always possible to trace
which materials were used to make thewafer, and under what conditions it wasprocessed – including all of the relevantprocess and environment data.
Totally Integrated Automation and thehigh degree of standardization simplify theintegration of the individual units into astandardized automation and informationlandscape. This also applies to the integra-tion of the energy supply and the building
technology, of course, whichwere delivered and installedby Siemens as well.
Complex projectcompleted successfully
Just one year after layingthe cornerstone in October2002, the wafer factory wasready for equipment in No-
vember 2003, and the first process machinewent into operation only two weeks later. InJune 2004, the fine-tuning was completedand the first product delivered. Höller andSchmidt are very pleased with the way theproject was executed. “Of course, there
Siltronic: The silicon expertSiltronic is one of the world’s largestproducers of wafers made of ultra-puresilicon, and is a partner of many leadingchip manufacturers. The companydevelops and produces wafers withdiameters of up to 300 millimeters atlocations in Europe, Asia, Japan, and theUnited States. The largest of thecompany’s three 300-millimeterlocations is Freiberg in Eastern Germany.
“Of course, we also took factors such asreliability, service friendliness, and so on
into account, in addition to the basic costs ofthe implemented technology.”
Bernhard Schmidt, project manager at Siltronic in Freiberg
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28 CASE STUDY
were some difficulties, but the great ex-perience and expertise of all of those in-volved helped us avoid many problems al-together, and resolved those that did cropup – thanks also to the outstanding coop-eration of the project team,” says Schmidt.
The plant is now in the ramp-up phase,on schedule, and will be producing 150,000wafers a month in 2006. The implementedtechnology performs well in routine oper-ation, as Höller confirms: “The plant is run-
ning well and is stable. Minor problems areeasy to eliminate. I have to say that the planttotally meets our expectations.” �
“One advantage of a long-standing partnership is that youknow what you are buying and are familiar with the
strengths and weaknesses of the technology.”Helmut Höller, production manager at Siltronic in Freiberg
Siemens also planned, delivered, andinstalled the entire power supply for thenew wafer factory from the extension ofthe existing high-voltage switchgear to the energy distribution at the low-voltage level.
In order to meet the necessary energydemands, two additional switch panelsand two additional 25 MVA transformerswere installed to augment the gas-insulated switchgear of the 8DN8 typealready installed by Siemens in 2000. Thiswas done without interrupting theongoing operation. The power reaches theproduction plants through a 20 kVswitching system, 6 kV switchgear of the
NXPLUS C type, 18 GEAFOL transformers,and nine low-voltage switchgear systemsof the Sivacon 8PT type, with a total of 160switch panels – all Siemens products.
The order also included the delivery andinstallation of the entire controltechnology and the high-voltage wiring,including the network calculation for thenew network, as well as the visualizationof the plants with SICAM components andthe integration of the energy supply withthe building control technology – suppliedby Siemens.
The positive experience with the powersupply systems previously installed atSiltronic played an important role in the
decision to also order the energy supplyinstallations from Siemens. Another reasonwas that M+W Zander, the generalcontractor, had already cooperated wellwith Siemens on previous projects.
Wolfram Naumann, the projectmanager at Siemens responsible forinstalling the energy supply system, sumsup the successful project: “The 110 kVtransformer station was extended duringproduction in the old factory withoutinterruptions or failures. The expansion ofthe energy supply was completed onschedule in April 2005, and the majority ofthe plants have been in operation sincethe end of 2003 without any trouble.”
Find out more:www.siemens.com/semiconductorE-mail: [email protected]
Semiconductor
From high to low voltage: the power solution for Freiberg
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Siltronic’s new waferfactory in Freibergproduces 300-millimeterwafer discs for export allover the world
process news 4/2005
29
W ith some 8,000 people at 40 sitesworldwide, M+W Zander is a trueglobal player, and one of the world
market leaders in plant design for the elec-tronics industry.
The new Siltronic wafer production fa-cility at Freiberg was a typical turnkey or-der for M+W Zander, which comprisedeverything from planning and design tothe operation commissioning of the fac-tory. M+W itself supplied the buildingstructure, including the clean-room pack-age and all of the technical infrastructure,
for the project. The production technologyand the associated peripheral plants wereoutsourced, as was the facility monitoringand control system from which all of thefactory functions are centrally monitoredand controlled.
Uniform solution
At the beginning of the project, Siltronicstipulated the implementation of a uniformcontrol system architecture at Freiberg.There were good reasons why the SimaticPCS 7 process control system was chosen
early on, as Klaus Schuster, proj-ect manager at M+W Zander re-sponsible for the entire electri-cal, measuring, control, andregulation technology of theSiltronic project, explains:“Siemens is the world marketleader in the field of industrialautomation. They already com-pleted a number of successfulprojects together with M+WZander. Thus, the decision wasa logical one.”
Simatic PCS 7 controls all of the sectionsat Freiberg that are crucial to the wafer pro-duction: building technology, ultra-purewater, chemicals, and sewage treatment.“When you rely on a standardized system inthe process control technology from thevery start, most of the criteria can be de-fined in advance. This has a positive effecton the project running time, because muchless effort is required for integrating dif-ferent systems,” explains Schuster.
Trouble-free upgrade
One unique aspect of the Siltronic projectwas the preannounced version change ofPCS 7. The control system was converted tothe new version 6.0 during the engineeringwork – a challenge that demanded a highdegree of interdisciplinary cooperationfrom all of those involved, as Schuster con-firms: “I was afraid that this would causemajor problems, but, at the end of the day,there were no significant problems, whichsays a lot about Siemens and, especially,about the maturity of the implemented sys-tems.” �
Find out more:www.siemens.com/semiconductorE-mail: [email protected]
All of the informationconverges at the newPCS 7 control center
M+W Zander sets up an entire factory in just two years
The Joint Work of SpecialistsWith its wide experience as a solutions provider for production plants in the semiconductor industry, as well as numerous references at home andabroad, M+W Zander was a good choice to assume the role of generalcontractor for the building of the new disc factory at Siltronic in Freiberg,Germany. The well-designed process and the team of experienced partners,including Siemens, ensured the successful completion of the project.
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CASE STUDYSemiconductor
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process news 4/2005
B ayer MaterialScience AG is one of theworld’s largest manufacturers ofpolymers and high-quality plastics.
The company runs a production plant forresins in Bitterfeld, Germany. the resins areused, for example, in the automotive indus-try, in industrial paint shops, and in thefurniture industry. The market is continu-ously demanding new properties and prod-uct features, and innovation is therefore akey issue for the resin production facility inBitterfeld, too.
The resin production presently pro-duces a total of about 200 different low-sol-vent, water-soluble resins in a four-shiftsystem with approximately 140 employees.These resins are produced for special appli-cations. New resins are developed in thepilot plant and transferred to productionwhere they are produced in batches accord-ing to specific recipes. In 2004, more than26 new products were developed, with 11new products being transferred to pro-duction scale. The plant automation must
therefore be able to keep pace with thiscontinuous process of change in recipesand products. There are a total of about500 basic recipes, with 25 control recipesrunning on average in the system. Theplants are continually being extended in parallel to the production, and thesechanges must also be taken into account in the process automation. The processcontrol system that automates the entireprocess – from raw material acquisition tothe recipe-based filling of the special con-tainers for production to filling – grew toinclude more than 6,000 measuring points.Following the commissioning of a new tankstore at the end of last year, the produc-tion facility with its 23 reactors is being
Operating system migration from Teleperm M to Simatic PCS 7 at Bayer
Modern PlatformWhen the operating level in the lacquer resin production facility at Bayer inBitterfeld was migrated from Teleperm M to Simatic PCS 7, more than 600,000variables and 1,000 operator screens had to be transferred to the newoperating system. Thanks to automatic migration tools and a well-planneddesign for the factory acceptance test (FAT), this task was performed to thecustomer’s full satisfaction – and the operating level was changed over to thenew solution during ongoing operation.
The plants produce about200 different resins
30 CASE STUDYSpecialty Chemicals
process news 4/2005
expanded to include special raw materi-als for UV hardening, and the productionvolume of dispersion products is beingincreased.
Migration instead of system change
During the course of the expansion andmodernization of the plant, Bayer decidedto bring the Teleperm M-based HMI systemup to the latest state of the art in 2004. Itwas obvious from the start that a total sys-tem change was out of the question, and asmooth migration to the latest generationof technology based on the Simatic PCS 7process control system was what waswanted. With this step, Bayer aimed to basethe operation of the processes on a mod-
ern, efficient, open platform that can alsoaccommodate future modifications andextensions.
In changing over to the new system,there was to be absolutely no interferencewith the operation of the plant, and theproven operating philosophy was to belargely retained to make the changeovereasier for the personnel. Safety in theprocess operation also had top priority atBayer.
Within the scope of the project, Siemenstook over the complete engineering of thenew operator system. During an intensespecification phase, risk assessments accom-panied by extensive bus measurementswere made, and various structural conceptsfor the migration with the appropriate sav-ings potential were discussed. Siemens alsomade showcase migrations for some partsof the plant using equipment provided byBayer so that the customer could evaluatethe end product – which in this case con-sisted of the new process graphs and face-plates on the Windows platform. After that,the decisions regarding the new systemstructures were made in intensive work-shops, and the individual migration stepswere defined in terms of content and sched-uled times.
Step by step
The project team decided on a gradualmigration in which configuration, testing,factory acceptance, installation, connec-
tion, and commissioning were conductedserver by server. In addition, every serverwas operated in parallel to the relevantexisting OS 265 for a specified period oftime to make the changeover to themigrated user interfaces easier for theoperators. The extensive migration projectwas completed on schedule, thanks toSiemens’ special migration tool for auto-matic image conversion for such projects.This tool also prevents manual errors inthe migration of the operating screens,which considerably speeds up the entireengineering process. Every image andevery faceplate type were tested on a simu-lated subsystem in the FAT and thenaccepted by the customer. A well-docu-mented FAT concept is essential in migrat-ing large plants such as the one in Bitterfeldwithout downtime.
Successful completion
After trials lasting two months, the new sys-tem was accepted by the project team of theresin facility in Bitterfeld in 2005. Bayer hasalready placed follow-up orders for theplanned modernization in Bitterfeld –clear evidence that the new solution haslived up to all expectations. �
Find out more:www.siemens.com/chemicalsE-mail: [email protected]: [email protected]
The new operating levelB Migration of six operator systems with
a total of 16 operator panels
B New solution: four redundant PCS 7 TM OS servers with a total of 11 PCS7OS clients
B Up to four LCD monitors on one client
B Optimized allocation of the plants to the servers
B More than 600,000 variables ofautomation systems relinked
B Faceplates for seven Teleperm Mstandard components, 26 usercomponents, and seven batchcomponent types redeveloped with the PCS 7 look and feel, and about12,000 entities created
B Migration of almost 1,000 processimages (overviews, recipes, parameters,and basic function images)
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The resin productionfacility at Bayer inBitterfeld is continuallybeing expanded andmodernized
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32Modular Automation
TECHNOLOGY
Modular automation pays off
The Key to SuccessThe idea is not new: the key to faster time to market and higherplant productivity lies in modularity. What machine manufacturershave already implemented in the mechanical field – that is, thestandardization of (mechanical) modular systems – is still in itsinfancy in automation and software. However, the softwareproportion in the machines is increasing constantly. The challengein the near future will therefore be to reduce the control softwarecomplexity by using a modular approach.
Newly developed machines must al-low the manufacturer to amortizethe development costs, and the
owner to amortize the investment costs, ina short period of time. This applies to pack-ing machines in particular, because the
Numerous machine manufacturers haveadopted a modular approach to design theirmachine mechanics, allowing them to usealready developed and tested modules againand again with only slight adaptations. Amodular or “building block” system devel-oped in this way offers enormous advan-tages in terms of time and cost savings.
However, the development time and costof machines can only be significantly re-duced if the modules of the drive, control,and visualization software are standard-ized in addition to the mechanical mod-ules. The greatest benefit for the machinemanufacturer results when current trendsin automation – such as the use of Ethernetright down to the field level, or component-based automation with distributed intel-ligence – are integrated into the modularmachine concepts.
Self-contained functional units
Machine modules are self-contained func-tional units with defined interfaces. Theycan be exchanged without effecting otherunits of the machine such as the mechani-cal, pneumatical, and electrical elementsas well as the control functions. Controlfunctions typically include the motion andlogic control elements, as well as technol-ogy functions (such as temperature regu-lation) and HMI.
Two basic topology structures are usedfor modular automation. For compact ma-chines with a central control, the automa-tion functionality of the machine is deter-mined during the engineering phase. Theprograms for motion control, logic control,and technology, as well as the user interfaceand the corresponding hardware configu-ration of the machines are put togetherfrom modules out of a library. The basic pro-gram in the control is identical in every ma-chine variant. Based on the machine optionsused, program modules are loaded and theappropriate graphic components are addedto the user interface.
The second topology variant is bestsuited for a distributed automation net-work with mechatronic function blocks.This allows for the modularization to beimplemented consistently, since the mod-
One of the challenges in modern machinemanufacturing is to reduce thecomplexity of the machine software
product life cycle for consumer goods isgetting shorter and shorter. To increasetheir competitiveness, machines must bebuilt in such a way that they can be quicklyand extensively reconfigured, and thusadapted to new jobs.
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User Organization developed a manufac-turer-neutral Ethernet standard in Profi-net for distributed automation that canintegrate existing Profibus field devicessmoothly, thus protecting plant owners’ in-vestments. Profinet addresses all of the im-portant aspects of industrial automation,including real-time communication, net-work management, network security, andsafety functions.
Plant-wide engineering
Engineering tools for the management ofdistributed automation structures simplifythe fast, effective implementation of com-ponent-based machine and plant solutions.The component-based automation concept,in which intelligent modules (for example,a robot, a filler, or an entire production line)integrate the mechanics, electronics, andthe user program within one unit, evolvedalong with Profinet. The functionality ofthe intelligent modules is encapsulated ina reusable software component with clearlydefined interfaces. The modules can un-dergo complete testing in advance by themanufacturer, and can be put into opera-tion in parallel on site – which saves a greatdeal of time.
Thus, during the commissioning of themachine or plant, the modules need only beconnected graphically with an engineeringtool such as Simatic iMap. The user needsno detailed knowledge of the communica-tion functions, and does not have to dealwith protocols and transmission media. Inaddition, embedded functions for networkmanagement allow efficient localization oferrors through integrated system diagnos-tics. With component-based automation,the entire functionality can be divided intodistinct application parts with defined in-terfaces. Easily reusable and maintainablestandard libraries also speed up the plan-ning and implementation of plants and,therefore, improve their quality. In thisway, machine manufacturers benefit froma much shorter time to market – and reachtheir goals faster, more reliably, and withless effort. ■
Find out more:www.siemens.com/simotionwww.siemens.com/cbawww.siemens.com/packagingE-mail: [email protected]
Mechanics
Special development/design
Modulestoday
Modulesin the future
Software
Special development/design
Modulestoday
Modulesin the future
Development costs
Today Future
Costs per machine project
Number of customized machines manufactured
Modular systemCopy and paste
Cost advantages through modular automation: the savings increasewith the number of machines produced
“Copy and paste” software development offers one way of reducingcosts in machine development
Modular concepts are the key to a fastertime to market, both for the machinemanufacturer and for the end user
Wol
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ules have their own intelligence and areconnected to each other by clearly definedinterfaces. The functionality of the moduleis encapsulated inside the module software.
Open and intelligent
The Simotion motion control system meetsall of the requirements of modular pro-duction machines. The embedded func-tions for modular automation are unique intoday’s automation landscape and makethe development of modular machines par-ticularly easy. Together with the HMI equip-ment, the entire automation functionalitycan easily be created in a modular fashion.
Profibus is the standard for communi-cation between the control, HMI, periph-ery, and drives. Industrial Ethernet can beused both for communication with mastersystems or for configuration. The Profibus
process news 4/2005
34Water
CASE STUDY
The Mannheim waterworks suppliesdrinking water not only for the Ger-man city of Mannheim, but also for
the city of Viernheim and the towns ofIlvesheim and Brühl. MVV Energie AG han-dles the distribution, and is responsible formaintaining the entire network in the sup-ply area.
Integrated solution
To be able to respond quickly and flexiblyto sudden fluctuations, the “SchwetzingerHardt” waterworks also relies on variablespeed drive technology in connection withSinamics G150 frequency converters. Inaddition to the highly accurate control ofthe flow volume, energy savings and lowwear on the pump mechanics are keyadvantages of this drive technology. High-quality process instruments – including theSitrans P DS III for pressure, Sitrans FM forflow, and Sitrans LU for filling-level meas-urement – transform the physical variablesinto a 4–20 milliampere signal or transferthe measured data to the control systemvia Profibus PA and Profibus DP.
All of the connections between the MVVwaterworks use Ethernet technology withfiber-optic cables, and are automated bySimatic S7 controllers. The Simatic WinCCprocess visualization system enables theclear representation of all of the processesin the waterworks. Since all of the compo-nents are integrated into a standardizedautomation structure, the works can bemonitored and controlled from any controlstation within the network.
Simplified operation and savings potential
The Siemens solution’s high degree of inte-gration simplifies the planning, configura-tion, commissioning, and ongoing opera-tion. Uwe Erny, the project manager respon-sible for automation at the Mannheimwaterworks, also appreciates the potentialsavings and the synergy effects. �
Find out more:www.siemens.com/waterwww.siemens.com/processinstrumentationwww.siemens.com/simaticE-mail: [email protected]
The process visualization with Simatic WinCC has beenadapted to the specific requirements of the MVV
Greater transparency and economy at the Mannheim waterworks
Controlling the FlowFrom the process automation and visualization to the processinstrumentation: all tasks at a waterworks operated by the Mannheim City Supply and Traffic Services (MVV) are automated with an easy-to-use solution.
Siem
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2006 Siemens Automation SummitThe Siemens automation user conference is the most popularSiemens event in the United States. Traditionally held for Siemensprocess automation and manufacturing execution systems users,the user conference in June 2006, held at the Mandalay Bay Resort& Casino in Las Vegas, will expand its experience to include motioncontrol, and discrete automation users. Attendees to the June eventwill now have a more complete package to discuss automation inthe most integrated environment ever offered to date.
The event is a fantastic opportunity for attendees to get togeth-er, exchange ideas, and learn new techniques, while also providingvaluable face-to-face product feedback to the Siemens senior man-agement team.
Noted industry experts will also be on hand to share and discussproduct changes, industry trends, and future changes that are hap-pening throughout the many industries currently using Siemensproducts. A variety of technical presentations and case histories il-lustrating best practices will also be given throughout the Summitto share how users are meeting their automation needs and gettingthe most out of Siemens products, services, and solutions.
Please contact
for more information or to be placed on the summit mailing list.
infosinfosDo you want to know more about the systems and solutions forthe process industry from Siemens Automation and Drives?Simply visit our information portal on the Internet:
www.siemens.com/processautomation
onlineonline
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35DIALOGUE
process news 4-05PublisherSiemens Aktiengesellschaft,Bereich Automation and Drives (A&D), Gleiwitzer Str. 555, 90475 NurembergGermany
www.siemens.com/automation
Group Executive Management Helmut Gierse, Hannes Apitzsch,Dr. Peter Drexel, Anton S. Huber
Responsible for ContentPeter Miodek
Responsible for Technical ContentCornelia Dürrfeld
ConceptChristian Leifels
EditorCornelia Dürrfeld, Siemens AG, A&D CC P MCSiemensallee 84, 76187 Karlsruhe, GermanyTel.: +49 (0) 7 21/5 95-25 91Fax: +49 (0) 7 21/5 95-63 [email protected]
Editorial CommitteeAlexandre Bouriant, Cristiana Cerrato, SigrunEbert-Heffels, Michael Gilluck, Birgit Gottsauner,Walter Huber, Keiren Lake, Bernd Langhans, Bernd Lehmann, Silvana Rau, Rüdiger Selig,Roland Wieser, Wolfgang Wilcke
Publishing HousePublicis KommunikationsAgentur GmbH, GWACorporate Publishing ZeitschriftenP.O. Box 3240, 91050 Erlangen, GermanyTel.: +49 (0) 91 31/91 92-5 01Fax: +49 (0) 91 31/91 92-5 94
Editor in chief: Kerstin Purucker
Layout: Jürgen Streitenberger
Copy editing:Irmgard Wagner
DTP: Doess, Nuremberg, Germany
Printed by: Stürtz GmbH, Würzburg, Germany
process news is published quarterly
Circulation: 45,500
Jobnumber: 002100 RPE54
© 2005 by Siemens Aktiengesellschaft Munich and Berlin, Germany
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ISSN 1430-2292 (Print)
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profibusProcess industry plants with a mix of continuous, batch, discrete and safety applications requirea fieldbus that handles the challenges of such a hybrid environment. PROFIBUS is the onlyfieldbus which provides access to data from all plant components, in a single uniform manner,across the entire production chain. The result is a “complete” solution – all under a single field-bus – improving profitability and maximizing productivity and performance for your peopleand plants.Want to reduce the Total Costs of Ownership of your assets? To learn more about the benefitsof a Totally Integrated Automation solution utilizing PROFIBUS products from Siemens, pleasevisit us under www.siemens.com/processautomation or send a fax to Siemens Infoservice+49 (911) 9 78 33 21, Infoservice AD/Z 1170.
w w w . s i e m e n s . c o m / p r o c e s s a u t o m a t i o n
Plantwide communication –saving time and costs in the process industries
