process - Siemens Global Website · 30/07/2003 · By integrating two ﬁlling lines using Simatic...

Systems and Solutions for the Process Industry

processnews

3rd edition July 2|2004

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Benefits of MES:Interview withDr. Horst J. Kayser

Simatic PCS 7 and Simatic IT at RohMax Öl Additive

Benefits of MES:Interview with Dr. Horst J. Kayser

Simatic PCS 7 and Simatic IT at RohMax Öl Additive

Danone integrates production and ERP level

Information BackboneDanone integrates production and ERP level

Information Backbone

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By integrating two filling lines using Simatic IT,Danone Spain could achieve significant processimprovements: higher availability, betterquality management and better compliancewith regulatory requirements

The German company RohMax Öl Additiveexploits the benefits of Simatic PCS 7 toproduce tailor-made additives for industrial,automotive and aerospace applications

Offshore challenge: Siemens is currently migrating a Teleperm M system to SimaticPCS 7 for Norsk Hydro

CONTENTS2

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3 EDITORIAL

4 NEWS

Siemens supplies automation and electrical equipment for newstainless steel works in Shanghai

Siemens equips new AMD chip factory

Process Instrumentation and Analytics Promotion Truck “on Tour”

LuoYang Float Glass and Siemenssign cooperation agreement

MicroSAM wins iF design award

TECHNOLOGY

MES Solutions6 Full Potential

Manufacturing Execution Systems: What they do and how they work

MES Solutions10 Highly Flexible, Standard-based

and ScalableDr. Horst J. Kayser on the benefits of Simatic IT

Process Control Systems23 Flexible On Any Route

Simatic Route Control

Process Instrumentation25 Conductive According to ATEX

Ultrasonic sensors for conditions of explosive dust

CASE STUDIES

MES in Dairy Production12 Information Backbone

Efficient integration from plant floor to ERP

Tobacco Processing16 Flexible on Principle

Component-Based Automation at Philip Morris

Basic Chemicals19 Always Online

Real-time analysis of process gases with Maxum and MicroSAM

Specialty Chemicals20 Well-oiled Machinery

Production of oil additives at Degussa

Migration22 Offshore Challenge

Upgrading the Oseberg Field Centre to Simatic PCS 7

process news 2/2004

Yogurt productionwith Danone

Photo: Siemens

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Dear Readers,

Our customers demandsolution expertise, opensystems and concepts, anda global presence from us –

that is the result of a poll conducted among well-known industrial companies by Morgan Stanleyon the subject of automation technology.

“We always knew that”, we from Siemenscould say, and in fact the study confirms ourexcellent position as one of the leading solutionproviders for industrial automation, with goodindustry knowledge and a remarkable globalpresence.

However, we still consider our strengths to bein innovative, high-performance, technicallysuperior products. We have made use of thisstrong, healthy foundation to consistently buildup and expand our solution expertise in recentyears and to offer our customers more than “just”an integrated technology and product range. In this issue of Process News you will find some examples of this approach – such as themodernization of the process control technologyat RohMax Öl Additive.

The Morgan Stanley study also confirms ourstrategy in this respect: Total cost of ownershipand life-cycle costs are much more importantthan the mere initial investment in a newautomation or IT solution. Therefore, flexibility,scalability, and openness are very importantfactors – particularly in the market for manufac-turing execution systems (MES), on which thisissue focuses. Our solution is called Simatic IT.Simatic IT is the only MES software developedand implemented consistently according to theS95 regulation. Simatic IT is based on open,standardized interfaces, is structured modularlywith the central workflow as a productionprocess model, and offers optimum integrationthrough Totally Integrated Automation. You canread what Simatic IT can really do and how youas a user can benefit from that from page 6onward.

I hope we will give you a few valuable tips.

Easy route control in complex systems: Simatic Route Control simplifies material transportoptimization in pipe and transport networks – fast, convenient, and without additional programming

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Weighing Technology24 Perfect Dosage

Siwarex A at Mercator in Ljubljana, Slovenia

TRENDS

MES Business Benefits8 Targeting Costs

MES provides long-term revenue and marketbenefits beyond easy-to-quantify operational cost savings

Process Instrumentation and Analytics9 Information Becomes Knowledge

Intelligent process instruments support MES and asset management

Process Automation18 Tracks to Success

User Community conference explores the future of process automation

SHORT LIST

26 ATR GmbH & Co. KG

Fritz Hunziker + Co AG

ETH Zurich

27 DIALOGUE

EDITORIAL

process news 2/2004

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Dr. Horst J. KayserHead of Industrial Automation Systems

Find out more:www.siemens.com/metalse-mail: [email protected]

process news 2/2004

4 NEWS

S iemens has received an order from theChinese company, Baoshan Iron & Steel

Group Co. Ltd. (Baosteel), to supply all theautomation and electrical equipment for thesecond production line of the ShanghaiNo. 1 stainless steel works. With an ordervolume of around 19 million Euros, the new

stainless steel line is to start operating inSeptember 2005 and will consist of a scrapyard, a 90 MVA electric arc furnace with atapping weight of up to 120 metric tons, anargon-oxygen decarbonization converterwith a capacity of 135 metric tons, a 135metric ton ladle furnace and a continuouscasting plant.

For these facilities, Siemens is deliveringall the electrical equipment, including in-strumentation and drive technology, as wellas a dynamic reactive-current compensa-tion system. Moreover, the new productionline will also be provided with a process con-trol system based on the Simatic PCS 7, withintegrated technological functions for thecontinuous casting plant. Siemens is alsoresponsible for the engineering as well as formonitoring the installation work and com-missioning. �

Siemens supplies automation and electrical equipment for new stainless steel works in Shanghai

Find out more:www.siemens.com/semiconductore-mail: [email protected]

S iemens has been commissioned byM+W Zander, Stuttgart, to equip the sec-

ond AMD factory in Dresden, the Fab 36 forproduction of AMD64 microprocessors, withbuilding and process automation. The workcontracted to Siemens comprises buildingand process automation for all buildings andplants from the planning phase throughcomplete construction to commissioningwork – including technical building equip-ment and process supply for the 14,500square meter clean room. The constructionphase of the 2.4 billion Euro project beganwith the groundbreaking ceremony on 20November 2003. “Ready for equipment” isscheduled for the end of 2004.

Siemens will be in charge of project han-dling within the scope of the contract fromM+W Zander. This includes complete projectmanagement and execution planning aswell as field instrumentation, installationand application programming. The SimaticPCS 7 process control system will be used as

a plant-wide system platform for all buildingand process automation tasks – from theclean room to auxiliary systems such ashigh-purity water, waste water, chemicalsupply and technical gases. �

Siemens equips new AMD chip factory

Find out more:www.siemens.com/processinstrumentatione-mail: [email protected]

Agile and fast with short startuptimes – these are the key features

of the promotion truck for process in-strumentation and analytics that iscurrently on tour in eastern Germany.The truck covers the entire spectrumof Siemens solutions for process con-trol, instrumentation and analytics,focusing on new technologies such asradar and ultrasonic devices for levelmonitoring as well as flow meters us-ing the Coriolis effect or the ultra-compact process gas chromatographMicroSAM.

The truck is nearly fully bookedright through to November 2005. Af-ter touring through southern Ger-many, it is heading for Great Britainand Switzerland, continuing its tour innorthern Germany in the fall and vis-iting customers in Austria and westernGermany in Spring 2005. After that, itis heading east again, to Poland andthe Czech Republic before visiting theNetherlands, France and Spain. �

ProcessInstrumentation andAnalytics PromotionTruck “on Tour”

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On tour in Europe: ProcessInstrumentation and AnalyticsPromotion Truck

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F rom April 11 to April 14, Beijing Inter-national Exhibition Center was home to

the fifteenth International Glass Exhibition.More than 2,100 companies attended theexhibition and 40 percent were from foreigncompanies, illustrating the growing globalsignificance of the Chinese glass industry.China is becoming one of the most impor-tant glass-producing centers with one ofthe most rapid growth rates worldwide.Siemens Ltd. China showed the latestSimatic PCS 7 technology including thenewly launched Simatic PCS 7 Box as wellas motion control products, and SiemensShanghai Industrial Automation Ltd.showed its solutions for the glass industry.

During the exhibition, Siemens and theChina LuoYang Float Glass Group held anAdvanced System Integrator cooperatingsignature ceremony. China LuoYang FloatGlass Group was founded in 1956, and af-ter more than forty years development, ithas become a huge enterprise group con-taining technology development, produc-ing and marketing, import and export trade,

finance and stock business. The companyhas developed the LuoYang Float process,one of the three main float glass techniques,and is China’s top float glass manufacturingcompany.

The president Mr. Liu Baoying and gen-eral manager Dr. Zhu Leibo of China Luo-Yang Float Glass Group expect that with the

signature, Siemens and China LuoYangFloat Glass Group will both venture into afruitful cooperation that will provide a goodplatform for future projects. �

LuoYang Float Glass and Siemens sign cooperation agreement

Find out more:www.siemens.com/processanalyticse-mail: [email protected]

S iemens automation and drive productswere awarded no less than six of the

renowned design awards. The SinamicsS120 and Sinamics G110 frequency con-verters, the head module of the distributeddevice Simatic ET 200X, the Vision SystemSimatic VS120 and the machine controlpanel of the Sinumerik 840D impressed withtheir outstanding fusion of functionality anddesign. The MicroSAM process gas chro-matograph was the winner of the sixthaward demonstrating that good looks anda clever interior do indeed go together well.

The iF design award is the internationallymost acclaimed German design award. It isawarded annually by a jury of internationalexperts during the CeBit tradeshow andHanover Fair. The prize-winning productswere on show both at the CeBit and HanoverIndustry Fair this year in the iF pavilion at theexhibition center. �

MicroSAM wins iF design award

Representatives of LuoYang Float Glass and Siemens signing the cooperation agree-ment during the fifteenth International Glass Exhibition in Beijing

One of six award-winning products: the MicroSAM process gas chromatograph

Find out more:www.siemens.com/glass-industrye-mail: [email protected]

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The objectives and capabilities of busi-ness systems are different from those of con-trol systems, yet there is a fundamental needfor them to work in synchronization witheach other. Any distortion leads to inefficient

Laboratory Management

Seamless integration ofquality control and qualityassurance

Planning & Scheduling

Optimizing accuracy andflexibility based on real-timedata and plant visibility

Analysis & Optimization

Continuous improvementof performance and quality

Production

Continuous coordinationand synchronization of allproduction related processes

Tracking & Tracing

Wall-to-wall tracking &tracing and productgenealogy

Resource Mapping

Producing identical qualitydespite different localresources and systems

LocalProductDesign

OrderDownload

Planning &Scheduling Production

Tracking &Tracing

Optimization

ResourceMapping

Analysis

GlobalProductDesign

LaboratoryManagement

TECHNOLOGYMES Solutions

Shortened product lifecycles,increased product variety, changingregulatory requirements, squeezedprofit margins, and global marketscontinually present manufacturerswith new and complex challenges.Moreover, manufacturing has becomea cross-plant, cross-country, cross-enterprise process involving the entiresupply chain.

To remain competitive, manufacturersneed to simultaneously reduce timeto market; increase process visibility

and production flexibility; optimize fore-casting and scheduling; and reduce rejects,stocks, and downtime – all while ensuringoptimal quality and production efficiencyacross global facilities.

Meeting these goals requires an inte-grated IT infrastructure that helps coordi-nate production on a global scale and, ifnecessary, in real time. This optimized co-ordination must cover such things as spec-ifications, equipment, facilities, processesand procedures, quality tests, and person-nel resources.

Current IT infrastructures, however, aretypically not able to effectively accommo-date such levels of integration. There is aninformation and functionality gap betweenthe business processes run by ERP systemsand the automation of production pro-cesses and equipment.

Totally Integrated Quality with Simatic IT

Manufacturing Execution Systems: What they do and how they work

Full Potential

operations, higher costs, and lower quality,which ultimately translates into lower prof-its. Therefore, ensuring tight integration,perfect communication, and efficient coor-dination between these systems is vital.

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Linking business and control systems

A new family of software – manufacturingexecution systems (MES) – has emerged,which provides effective integration ofproduction processes and enterprise busi-ness systems. Manufacturing executionsystems not only provide a layer of com-munication between business and control,they also represent a set of coordinatedfunctions capable of optimizing plant ac-tivity during all phases of production.

An MES solution usually includes sup-port for the following functions: resourcemanagement and resource allocation, dis-patching, data collection and acquisition,quality assurance management, mainte-nance management, performance analysis,scheduling, document control, and labormanagement, as well as material and pro-duction tracking.

ISA-95: An international de factostandard

International organizations have estab-lished a clear definition of MES function-ality and have developed models that de-scribe and standardize MES systems. TheANSI/ISA S95 – ISA-95 for short – interna-tional standard defines terminology andmodels used in the integration of MES sys-tems and has achieved broad industry ac-ceptance. The first two parts of the standardhave already been published, and the finalpart is currently under development by theISA SP95 committee.

A typical MES environment helps man-ufacturers to answer critical productionquestions: How to produce? What can beproduced? Where and when must it be pro-duced? What was produced and when?

These questions have a direct and im-mediate counterpart in terms of ISA-95modeling. Product definition, productioncapability, production scheduling, and pro-duction performance represent the funda-mental business processes to create thelink between control and business systems.

Essentially, ISA-95 defines the criticalmodules required for the development ofan effective MES system: software func-tions, a physical model of production ca-pabilities, and the corresponding businessand production processes.

Simatic IT and ISA-95

The functionality and architecture ofSiemens’ MES offering, Simatic IT Frame-work and Components, are fully compliantwith ISA-95.

Each Simatic IT component is dedicatedto a specific task, which corresponds to one

Find out more:www.siemens.com/simatic-ite-mail: [email protected]

S95 at a Glance

The international standard ANSI/ISA S95consists of three parts:

Part 1, “Models and Terminology,” waspublished in 2000 and provides basicmodels and the terminologies needed todefine the interfaces between a company’sbusiness processes and the process andproduction control systems.

Part 2, “Object Model Attributes,” waspublished in 2001. This part defines, inconjunction with part 1, the interfacecontent between manufacturing controlfunctions and other enterprise functions.

Part 3, “Models of ManufacturingOperations,” is still under development.Closely related to parts 1 and 2 of the S95standard, part 3 will provide detaileddefinitions of the main activities ofproduction, maintenance, inventory, andquality control.

MES GlossaryElectronic Signature: Electronic

proof that a person performed an

action; part of the permanent

electronic batch record (EBR) and

required by several regulatory bodies

Genealogy: Element of tracking and

tracing defining a product’s family tree

KPI (Key Performance Indicator):

value calculated from process and

equipment data (e.g., equipment

efficiency)

Library: Collection of partial models

saved for later reuse

Object Oriented: Programming

methodology allowing for simple reuse

of programmed or modeled

functionality (objects) in other projects

or programs

Production Operations: Executable

workflows of business and production

logic

Tracking and Tracing: The complete

manufacturing history of a product,

stored for performance analysis and

regulatory purposes

ISA-95 software function. Together theycover all standard production functions re-quired by ISA-95.

The Simatic IT Framework provides anobject-oriented methodology to model thephysical plant and all equipment con-straints. This physical model allows for aclear, well-structured, and self-document-ing approach during the analysis phase ofan MES project. Due to their object-orientednature, these physical models are highlyreusable and therefore reduce rollout andmaintenance costs.

Simatic IT Framework offers a graphicalenvironment allowing for intuitive busi-ness and production process modeling.The resulting workflows (production oper-ations) define the behavior of the plant andcoordinate all manufacturing-related soft-ware and equipment functions. This dra-matically increases the flexibility, respon-siveness, and transparency of the system.Again, these workflows are easily reusable,reducing risk, cost, and duration of solu-tion development, rollout, and mainte-nance. �

process news 2/2004

8MES Business Benefits

TREND

MES attacks a number of easy costreduction targets. Those reportedmost frequently as measures used

for project justification are shown in theillustration.

Classical targets for cost reduction –inventory measures, quality, and laborcosts – were cited by most respondents asthe measures by which their projects werejustified.

Customer service was a key perform-ance improvement target for the high-vol-ume low-margin manufacturers that weinterviewed, which focus on managing lateorder and partial shipment situations.Though the dollar value was not quanti-fied, one manufacturer reported, “sufficeit to say that customer irritation means lostrevenue.”

Developing the business case for an MES project

Reducing the cost of regulatory compli-ance was a concern almost exclusively lim-ited to medical device manufacturers andfood/pharmaceutical manufacturers. Forone medical products manufacturer, the in-tegration of MES into weigh/mix operationshas eliminated 1.5 million manual entriesper year. This same manufacturer hasachieved a phenomenal 15 to 1 reductionin the time required to handle a batch ex-ception, on top of a substantial reductionin the total number of exceptions.

Another major player in the pharma-ceutical arena anticipates combined sav-ings of at least $3M per year across a num-ber of facilities through a 50 % reductionin batches discarded because of processingproblems and human error. �

80%0% 10% 20% 30% 40% 50% 60% 70%

Percentage of Responses

Introduction Cycle

Reduction in Cycle Flow/Lead Time

Improve Customer Service

Reduce Indirect Labor Cost

Improve Product Quality/ Right First Time

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Reduction in InventoryCarrying Costs (work in process, finished goods inventory)

Food, Pharmaceuticals,and Medical DeviceManufacturing only

NPI was not used to justify the business casefor MES, but was reported by severalrespondents as an area in which substantialbenefits had ultimately been realized.

Cost of RegulatoryCompliance

MES provides long-term revenue and market benefitsbeyond easy-to-quantify operational cost savings

Targeting Costs As part of ongoing research into the performance of manufacturing IT invest-ments, AMR Research recently interviewed manufacturers across variousindustry verticals about the kind of ROI that they were seeing from their Manu-facturing Execution System (MES). Across the board, we found that MES paid foritself on traditional cost reduction measures within 6 to 24 months of going live.

Reprinted with the friendly permissionof AMR researchCopyright © 2004 AMR Research, Inc.www.amrresearch.comBill Swanton, Alison SmithThe AMR Research Report, July 30, 2003


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Intelligent process instruments support MES and asset management

Information Becomes KnowledgeIntelligent process instruments help provide exactly the information that is critical for effective processcontrol. Three examples demonstrate how tangible improvements in the workflow can be achievedwith minimum investment.

process news 2/2004

9TREND

P ractically every production processoffers potential for increased produc-tivity when it is possible to measure

the right data, place them in relationshipto each other, and use them to automati-cally influence the process. Expensivehardware investments are often unneces-sary; the use of intelligent field devices andtheir integration into the manufacturingexecution system (MES) suffices.

Quality analysis superfluous

The chemical industry is a typical example:Different process media enter a prepara-tion tank before being passed on to an agi-tator for mixing. For reliable process mon-itoring, not only the filling level in thepreparation tank is measured according tothe given recipe, but also the flow volumeduring transfer to the agitator. Then thetwo measured values are subjected to aplausibility test using an MES tool, and anautomatic batch release is derived fromthis. This guarantees a reliable process,

and expensive analysis of the end productcan be eliminated.

Optimum energy usage

In very energy-intensive productionprocesses in particular, energy consump-tion must be kept within exactly definedlimits in the form of steam and electricalcurrents, both to guarantee optimum op-eration of the plant and to avoid unneces-sary extra consumption. In the MES, thevalues measured by several process instru-ments are combined with an appropriatealgorithm and an equivalent value is cal-culated which is used to directly affect theworkflow. The result is not only a low ener-gy requirement but also constant opera-tion of the whole plant at its most cost-ef-fective utilization levels.

Maintenance as required

Scheduled maintenance protects againstunscheduled downtimes and thereforeconsiderably increases the cost effective-

ness of a plant. Here too, intelligent pro-cess instruments must be used to monitorall the critical operating states and makesure, for example – in connection with aspecial maintenance analysis in the MES –that wearing parts are replaced beforetheir failure leads to downtime for thewhole production process. �

Process Instrumentation and Analytics

Find out more:www.siemens.com/processinstrumentationwww.siemens.com/simatic-ite-mail: [email protected]

Always ready to listenThe forum for users of process instrumentsand analytics will answer your questionsabout these and other topics.E-mail: [email protected]

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process news 2/2004

10MES Solutions

TECHNOLOGY

Dr. Kayser, MES such as Simatic IT claimto help users by bridging the gapbetween ERP and production. But why doyou need an extra system for that –couldn’t ERP systems do the job?Kayser: ERP systems consider a plant tobe an ideal “black box”. In reality effectivemanufacturing requires coordinating andsynchronizing the use of machines, peopleand applications throughout the entireproduct lifecycle – this is exactly what MESdoes. It is, so to speak, the missing link be-tween the automation and ERP layer and ac-tively supports ERP in better carrying outits job. As a result, MES dramatically opti-mizes plant productivity, product quality,and production flexibility. It also increasesthe productivity of customers’ ERP systems.

What does the user expect from an MESsystem?Kayser: To protect their investments andobtain a maximum return on investment,customers expect two things: products ofthe highest quality, with state-of-the-artfunctionality, and unparalleled compati-bility – and also comprehensive servicesand support. This also includes productconsulting, documentation, training, andwarranties. At the same time MES solutionsneed to fully match customer’s require-ments without the risk and duration in-volved in a custom software project. WithSimatic IT, Siemens is living up to these ex-pectations.

What makes Simatic IT so different fromother MES products?Kayser: Many MES solution based on a com-bination of different software packages andcustomized software have grown overly

Dr. Horst J. Kayser on the benefits of Simatic IT

Highly Flexible, Standard-based and ScalableWith the economy slowly picking up speed, enterprises around the globe are more and more inclined to invest innew technologies to ensure and increase their competitive edge. But more so than ever, new technologies alsohave to prove their worth – and that is also true for MES solutions. Do investments in MES in general and SimaticIT really pay off? And what can Simatic IT actually do for a company’s production processes? We spoke with Dr. Horst J. Kayser, President of the Industrial Automation Systems Division at Siemens, to give some answers to these questions.

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complex in an attempt to cover allthe requirements of a vertical mar-ket. We believe this “best-of-breed”approach cannot fulfill today’s de-mand for highly flexible, standard-based and scalable MES products.Simatic IT Framework explicitly rep-resents the customer’s productionprocesses as graphical workflows.Our Simatic IT Components thenprovide the MES functionalityneeded to address the specific man-ufacturing issues identified in theISA-95 standard. You could say thatthe Simatic IT Production Suitecombines the advantages of provenand tested productswith those of a fullytailored solution.

ISA-95 has becomethe internationalstandard for MES. To which extent doesthis standard influence the developmentof Simatic IT?Kayser: Just as S88 for Batch execution, ISA-95 has become the de facto standard forMES. Today, an increasing number of cus-tomers are requesting ISA-95 compliance tosecure their investments in MES. Softwarethat is developed according to ISA-95 is par-ticularly modular and can be customized tocustomer’s current and future requirementsin a very efficient and fast way. The stan-dardization of interfaces and terminologyensures optimal compatibility, and this re-duces the solution’s total cost of ownership,increases the return on investment and alsosecures investments in existing systems. Asa member of the ISA-95 Committee, Siemensactively contributes to the further develop-ment of the standard. Siemens also was thevery first MES vendor to offer a product thatimplements the ISA-95 standard. Indeed,Simatic IT not only covers ISA-95 functionsbut also actually uses ISA-95 as a blueprintfor its product architecture.

Apparently, standardization and inte-gration seem to be key issues with MES.

Kayser: That’s right: By its nature, MESmust work seamlessly with any system itencounters. Simatic IT offers unrivalled in-tegration capabilities and is of course fullyintegrated into the Siemens Totally Inte-grated Automation family of products.Simatic IT’s native integration with TIA alsoguarantees quick project implementationsand compatibility across different genera-tions of products. We paid great attentionto integrating our process automation sys-tem PCS 7 and Simatic IT.

But exactly how does Simatic IT increaseproductivity and competitiveness?Kayser: Simatic IT customers model theirentire production know-how, exactly definethe behavior of their operations and gatherreal-time data from the ERP and Plant Floor.Therefore, manufacturers can drive theiroperations much more effectively, increaseflexibility and augment productivity. By re-acting more quickly and appropriately toany kind of production event, Simatic IThelps manufacturers to reduce downtimes,scrap and rework, optimize inventory lev-els and respond more rapidly to customerrequests. Simatic IT also provides the wall-

to-wall traceability required by reg-ulatory bodies, and the resultinginformation can be used for opti-mized decision making at everyorganizational level. Ultimately,Simatic IT reduces the total cost ofownership of an MES solution.

What about system integrators –how can they benefit fromSimatic IT?Kayser: Siemens offers a clear com-petitive advantage to its integrationpartners. Simatic IT is explicitly de-signed for implementation by Sys-tem Integrators. It delivers cross-

industry MES func-tionality leaving roomfor system integra-tors to add significantvalue. The unique in-dustrial expertise of

our partners can be captured and protectedin Simatic IT libraries. This allows our part-ners to productize their know-how andreuse it efficiently in their projects. Indeed,Simatic IT partners have been able to saveup to 40 percent of project costs using thisapproach.

What are the priorities for improvementin the future?Kayser: At first we have deliberately fo-cused on the primary processes of our cus-tomers in the so-called hybrid industriessuch as chemical, food and beverage, aswell as the batch and continuous processindustries. Now we are adding substantialfunctionality in order to increase our pen-etration into the Discrete Manufacturingmarket. These new capabilities will allowour customers to extend their capabilitiesto their secondary processes.

Thank you very much for the interview.

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“Ultimately, Simatic IT reduces the totalcost of ownership of an MES solution.“

Efficient integration from plant floor to ERP

InformationBackboneDanone SA, part of the Groupe Danone, has entrusted the implementation ofits Manufacturing Execution System (MES) to Siemens Spain. The focus of theproject is the management of the filling lines and the ERP integration of two of its plants in Spain. The Siemens MES solution Simatic IT automates andintegrates production processes. Now Themis, the worldwide SAP versiondesigned for Danone, can achieve overall integration through a single interface.

process news 2/2004

12MES in Dairy Production

CASE STUDY

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T he Groupe Danone is widely recog-nized for the dynamism and strengthof its brands. Through its three core

businesses, Fresh Dairy Products, Beveragesand Cereal Biscuits and Snacks, GroupeDanone generally leads the way in settingtrends in consumer tastes. It was amongthe first to recognize the need for a widervariety of healthy, easy to consume anytime, any place foods.

The Groupe is number one worldwide infresh dairy products and packaged waterand number two worldwide in biscuits andcereal snacks. Danone is also the numberone dairy manufacturer in Spain, produc-ing many of the best known brands. In theyogurt segment alone, such householdnames as Vitalinea, Yoghourt Griego, Bio,Yoghourt Natural and the probiotic drinkActimel immediately come to mind.

The solution that was initially imple-mented to cover plant information and keyperformance indicator (KPI) managementof the filling lines was so successful thatDanone Spain decided to turn to SiemensServicios Industriales, the Simatic IT Cer-tified Partner, once more for help. Theyneeded a seamless integration of Themis,the Danone worldwide ERP system, with thedifferent plant systems of the plants inParets del Vallès and Aldaia.

Danone’s confidence was inspired by theproven expertise of Siemens Spain’s proj-ect team and its Simatic IT-based MES so-lution.

The business challenge

The backbone of Danone’s worldwide pres-ence and leading position is its ability to ad-just quickly and successfully to changes inbusiness environments. Themis, the group-wide SAP version, was launched in 2001 toenhance this level of responsiveness. Byimproving the information flow and sim-plifying and harmonizing operating pro-cesses in all business functions, Themisenhances the effectiveness of operationsworldwide.

For Danone Spain, Themis highlightedthe need to optimize existing productionprocesses and data flows and ensure high-level integration and communication be-

tween management and production. Astandardized solution to these require-ments was needed; one allowing for futuregrowth and improvements and includingthe capability to rollout to the other plantsof the group with minimal additional ef-fort.

The IT challenge

The plants in Parets and Aldaia required anMES system for the filling lines that wouldend the paper-based maintenance and dis-tribution of plant data that was causingwaste, errors and delays and resulted inpoor KPIs. A tighter integration between dif-ferent processes and systems was neededto avoid the same information having to bemanually introduced and processed withindifferent plant systems.

What Danone wanted were tools and so-lutions that could manage productionprocesses and synchronize the ERP-de-fined product and production require-ments with the plant capabilities. They alsowanted to gain real-time visibility of pro-duction processes to avoid high costs andto improve forward scheduling and re-source utilization.

New production lines at the greenfieldplant in Aldaia were planned that wouldhave their own functionality. What wasneeded was a standard and parameter-basedsolution that could be easily rolled out toother plants quickly and without reengi-neering. B

Benefits at a glance:Simatic IT at Danone

• Improved production efficiency,scheduling and planning

• Improved resource utilization andthroughput

• Reduced waste, errors and delays• Increased process visibility• Improved real time reaction to plant

events• Improved traceability• Improved operator interaction and

facility of operator procedures• Reduced downtime• Improved KPI quality and analysis

standard, guaranteeing future-proof tech-nology. It combines a stable, standardproduct with the capability to adapt it tospecific manufacturing processes at otherDanone plants. This is due in part to the useof libraries that allow storing of function-ality and plant models for later deploy-ment. Simatic IT thus combines the ad-vantages of a standard product with thoseof a tailored solution, perfectly capable ofaddressing all of Danone’s particular qual-ity and production issues.

Simatic IT now serves as the platform co-ordinating and modeling the productionprocesses of the different Danone plants.Its integration capabilities cover the entireplant, from the automation level up to theERP level, delivering the functionality re-quired for optimized production manage-ment and control.

Starting from the automation level ofthe plant, Simatic IT collects the relevantfield data in real time and archive them forlater analysis. Continuous monitoring ofKPIs increases responsiveness to any event,resulting in improved overall process man-agement.

The integration with the ERP level,which was realized through Simatic ITServer, allows continuous and transparent

downloaded from ERP to MES, which thendistributes these data to the rest of theplant systems. Production orders are alsodownloaded from ERP to all the plant sys-tems through Simatic IT once a day. Theorder status is uploaded in real time fromMES to SAP. Every time the status of an or-der changes in the filling lines, ERP receivesa message from MES with informationabout performance and order times. An In-bound order confirmation takes place forevery pallet that is produced, which con-sists of an online message from MES to SAPwith relevant information about this pallet.

Standardized approach

The Simatic IT implementation at Danoneis a clear demonstration that the new ap-proach of MES resulted in savings and bet-ter integration of earlier IT investments.Simatic IT follows the ISA-95 international

process news 2/2004

14MES in Dairy Production

CASE STUDY

B

A statistical evaluation ofalarms and failures supportsmaintenance and helps elimi-nate bottlenecks at Danone –for example, in filling lines

MES solution with Simatic IT

In the first phase, Simatic IT was intro-duced to address the need for a manage-ment system in the filling lines. This re-quired monitoring of the plant area, dataacquisition and KPIs, production ordermanagement, batch management, opera-tor management, maintenance operationsmanagement and quality data acquisition,among others. In the second phase, SimaticIT was implemented as the data integrationplatform between Themis (SAP) and thethree main plant areas: processing, fillingand packaging, and incubation.

The production data flow from the en-tire production line to SAP is handled nowby Simatic IT. The interaction basicallyconsists of four interfaces. Once a day allproduct-related Master Data, such as prod-uct data, BOM, and production data, are

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process news 2/2004

15

information flow between the differentplant systems and SAP.

Simatic IT covers the MES level atDanone Spain, acting as the single interfacecommunicator between the enterprise-wide business system SAP, where high-level decisions on production are taken,and the production process. But Simatic ITalso offers the functionality to provide flaw-less collection, management and presen-tation of appropriate data, all according toDanone specifications.

Simatic IT offers top-down visibilitywithin the Danone plants and productionprocess, allowing the full configuration oftracking and tracing functions with itsbuilt-in capability for upstream or down-stream product genealogy. This function al-lows tracking of which batches were usedfor a specific product and which end prod-ucts result from a specific batch. In case ofa product recall, the product genealogyhelps to identify risks and reach timely de-cisions on appropriate actions to limitdamage and liability.

Multiple benefits

The automation of the information flow re-sults in an optimized availability of pro-duction information, from production

management to plant systems and viceversa. The results and KPIs from produc-tion data collection are now available on-line. The automatic real time data integra-tion between the plant systems ensurestop-down plant visibility. The automaticquality data acquisition and maintenancemanagement puts Danone in a particularlystrong position in terms of regulatorycompliance requirements.

The Simatic IT solution proved to be soflexible that the redesigned and modifiedconcepts and data flows from the existingplants can be implemented in new pro-duction lines as well. Now, required func-tionality is covered with only minimal ad-ditional reconfiguration.

Going ahead

The MES project with Simatic IT in the fill-ing lines took place in 2002 and was com-pleted in 2003. Since the go-live date, theproject has been extended, due to the im-plementation of new production lines inthe Danone plants and new functional re-quirements resulting from changes in in-formation flows and management withinDanone.

In 2003, the implementation of Themis(SAP) as the Danone corporate ERP system

led to the launch of the SAP integrationproject, with the necessary implications forthe production management systems. Thefirst phase of the SAP integration was fi-nalized and went live in January 2004.

Simatic IT has armed Danone Spain withthe capabilities it needs to face future chal-lenges, consumer requirements and chang-ing regulatory standards. Productivity ofmodern filling machines isn’t measured bythroughput alone. Today, other factors alsoplay an equally important role, includingflexible and efficient order handling, theoptimization of downtime, and improveduse of warehouse capacities. All of these,in fact, describe the functions of a fillingmanagement system linked to the state-of-the-art Simatic IT Manufacturing ExecutionSystem.

With the completion of the Simatic ITreports and the adaptation of the FillingLines System to the new SAP criteria, theDanone Spain Parets and Aldaia plants areready for any upcoming regulations and fu-ture growth. �


Danone Spain integrated theplant systems of the plant inParets del Vallès and the plantin Aldaia using Simatic IT

Dan

one

P hilip Morris International is continu-ously developing and testing new pro-cesses at its Neuchâtel facility, that

then go into operation on a larger scale atother locations. A typical example is a pi-lot plant in which the production automa-tion has been implemented consistently forthe first time with Component-Based Au-tomation.

In this “Mini-Primary,” new tobaccoblends and processing methods are devel-oped, tested, and finally transferred to pro-duction plants all over the world. The newplant is identical in process technology to

the approximately 10-times-larger pro-duction processing lines. It is made up ofstations for storing, weighing, condition-ing, cutting, blending, flavoring, casing,and drying different raw tobaccos. The in-dividual stations are connected to eachother by conveyor belts and vibration con-veyors. Machines from different manufac-turers are used.

The Mini-Primary is used both for mak-ing control blends and for testing adapta-tions and optimizations of existing lines –a very important aspect in the design of theMini-Primary. Here, not only the parame-

ters of the individual stations are beingchanged constantly for optimum results,but the stations themselves often have tobe replaced by newer and improved solu-tions. The innovation cycles for dryers inparticular are very short and the results inthe application very different, so the sta-tions in the Mini-Primary need to bechanged often.

Flexibility by modularity

A system such as the Mini-Primary atPhilip Morris demands a complex automa-tion technology which is not only capableof adapting a large number of parametersto each other but which can be adapted tonew technologies without great effort atany time. Philip Morris achieved this witha totally new plant concept based on con-sistent modularity.

The automation technology of the newplant was implemented by the experts fromISIS (Industrial Software and InformationSystems), based in Treviso, Italy. ISIS is anexperienced systems integrator that hasearned itself a good reputation, particu-larly in the tobacco industry.

Machines as building blocks

The nucleus of the component-based solu-tion from ISIS is a strict delineation of all

process news 2/2004

16Tobacco Processing

CASE STUDY

Component-Based Automation at Philip Morris

Flexible on PrincipleSetting up a production line or simply changing individual functional unitsnormally means rewriting or completely changing parts of the automationsoftware. With Component-Based Automation, plant operators can noweliminate much of the work – and at the same time considerably increase theflexibility of the plant, as the application at Philip Morris shows.

In Component-Based Automation, theindependent, intelligent modules can betested and completed in advance. Thenthe plantwide interaction of the modulesneed only be configured locally. Theconfiguration of the communicationbetween the intelligent devices isperformed with the Simatic iMap engi-neering tool. The software componentsare imported to the project library andconfigured graphically by drawing lines.There is no need for intervention in theindividual devices and controls.

Component-Based Automation isbased on Profinet and Profibus. Profinetenables manufacturing-wide communica-tion, plantwide engineering, and smoothintegration of Profibus by proxies. As an

open Industrial Ethernet standard forautomation established by the Profibususer organization, Profinet meets all therequirements for automation with Indus-trial Ethernet and supports uniformcommunication from the enterprisemanagement level to the field level.Profinet relies on integrated real-timecommunication and the unrestrictedutilization of open IT standards andTCP/IP. Profinet offers the real-time (RT)feature for transmitting time-criticalsignals. For high-performance synchro-nized motion control applications,Profinet offers isochronous real-time(IRT). The direct linking of distributedfield devices to Industrial Ethernet iseasily accomplished.

Component-Based Automation

process news 2/2004

17

application programs of the individualfunction units. These units include, for ex-ample, the Feeder, Tunnel Belt, Dryer, Fla-vor Cylinder, and Direct Conditioning &Casing Cylinder and have been defined asself-contained, separate units, each with itsown distributed Simatic ET 200X devicewith an integrated CPU. The controls of theindividual units are linked via Profibus andone Simatic Net IE/PB link each with proxyfunctionality to a master Industrial Ether-net ring in redundant configuration. Twomaster Simatic WinCC servers are used forthe visualization of all plant parts; theysupply several clients with the latest pro-cess data locally via Ethernet.

Systems become transparent

The result is essentially plug-and-play au-tomation technology. Because every func-tional unit – that is, every component – op-erates as a self-contained system, no moreexpensive and work-intensive adaptation ofindividual devices and controls is neces-sary when the unit is changed. Instead, theself-contained machine program has onlyto be linked to the rest of the system andgiven the right parameters – a job that issoon done with the help of the Simatic iMapengineering tool with a graphical user in-terface.

But the time advantage in setting up theautomation technology is only one of thebenefits of Component-Based Automation.The clear separation of the individual func-tion units allows sources of error to be eas-ily identified. With this solution, individualsensors and conveyor drives can be ad-dressed directly via Profinet, in addition totrouble-free machine-machine communi-cation. Countless interfaces can thereforebe dispensed with, the entire system diag-nostics can be performed by uniformmechanisms, and the function of the wholeplant becomes more transparent.

After the positive experience with the pi-lot plant, Philip Morris was so convinced ofthe merits of Component-Based Automa-tion that the company has already startedinitial projects aiming to introduce theprinciple in ongoing production. �

Find out more:www.siemens.com/cbae-mail: [email protected]

The individual components and processing modules can beindividually combined, giving Philip Morris maximum flexibility

A broad range of tobacco blends is being tested and processedin the Neuchâtel Mini-Primary

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process news 2/2004

18Process Automation

TREND

U sers of Siemens process automa-tion, process safety, and manufac-turing execution systems from

throughout the world came together in At-lanta from March 17 through 19 to sharetheir own experiences and best practiceswith process automation and to learn aboutlatest product developments. This year’sconference provided attendees with morethan 40 sessions covering product en-hancements, system efficiencies, and newtechnology developments and also in-cluded, of course, hands-on training andproduct demonstrations.

An ideal format for process control en-gineers and managers, the conference al-lows participants to exchange informationabout challenges they are facing and howthey are using Siemens products to meetthem. “The conference has proven to be aninvaluable asset to all participants,” said

Gary Dickinson, new chairman of the usercommunity, and superintendent, I&E at CFIndustries. “Hands-on experiences frommembers, coupled with Siemens’ technicalexpertise, work well together to advancethe process automation knowledge base.”

Networking knowledge and experience

“We took full advantage of the availabilityand accessibility of the Siemens product ex-perts, product managers and senior man-agers to provide feedback and identify ad-ditional opportunities for improving ourcompany’s bottom line,” said Chris Da-Costa, controls platform manager at AirProducts and Chemicals, Inc., who became

user community vice chairman at the con-ference. “The conference also provided theideal environment for networking, sharingand learning from the real life experiencesof other Siemens users around the world.”

According to Joe Borkowski, marketingmanager, Siemens Process AutomationSystems US, the company also benefited.“We came away with a better understand-ing of our customers’ current and futureneeds, which is invaluable input for ourown product and service development ef-forts,” said Borkowski.

The next Siemens Process AutomationUser Conference is scheduled for thespring of 2005. �

User Community conference explores the future of process automation

Tracks to Success“The user conference demonstrated the broad range of Siemens capabilities inthe process and hybrid industries. We share more than just our leading PASsystems and software with our customers,” said Paul Camuti, vice presidentchemical and pharmaceutical business, and general manager Siemens ProcessAutomation Systems US. ”We also share a commitment to delivering consistentand innovative solutions in close cooperation with our customers.”

“Hands-on experiences from members,coupled with Siemens’ technical expertise,work well together to advance theprocess automation knowledge base.”

Gary Dickinson, superintendent, I&E at CF Industries

“The ideal environment fornetworking, sharing and learning fromthe real life experiences of otherSiemens users around the world.”

Chris DaCosta, controls platform manager at Air Products and Chemicals, Inc.

Find out more:www.sea.siemens.com/processe-mail: [email protected]

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ens

zefa

Siem

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Real-time analysis of process gases with Maxum and MicroSAM

Always OnlineDetermining critical process parameters and concentrations directly, withoutcomplicated sampling and delayed evaluation – these are the importantadvantages of online process gas chromatography. Lonza AG exploits theseadvantages and uses the Maxum and MicroSAM process gas chromatographsfor optimum control of the cracking process in one of its production plants.

process news 2/2004

19CASE STUDY

L onza AG’s history goes back to 1897when the company began manufac-turing calcium carbide for the light-

ing market. Today the group manufacturesvarious chemical products through thecracking of light petrol or liquid gas.

Online analysis with short cycle times

The Lonza group runs a naphtha crackerfor the production of ethylene, acetylene,and hydrogen in Visp, Switzerland. Thecombustion gas used and the crude gasproduced in the cracking process are now

being analyzed directly during the on-going process with the aid of two MaxumEdition II process gas chromatographs.Maxum is equipped with the flexible dou-ble-oven concept of one energy-saving air-less oven and one programmable airbathoven. Different detectors can be used to runcomplex analyses in a process.

The purposely simple valveless designof this device allows simultaneous analy-sis of up to eight components within onecycle of approximately two minutes. Thishas helped eliminate the previously nec-

Basic Chemicals

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A look inside the new analytics container:two Maxum Edition II process gas chro-matographs and the extremely compactMicroSAM process gas chromatograph

essary offline analysis – with the significantadvantage that the operating parameterscan now be adapted without delay accord-ing to the actual gas composition at thetime. That helps keep the plant running un-der optimum operating conditions at alltimes.

Maximum precision in a confined space

Lonza uses the extremely compact Micro-SAM gas chromatograph to monitor theliquid gas. The smallest explosion-proofonline process gas chromatograph fromSiemens can be integrated easily in almostevery plant. The entire device is only aboutas big as a saucer.

MicroSAM’s multiple parallel detectorsgive extraordinarily accurate analysis re-sults because the thermal conductivity de-tector array measures not only at all col-umn and vent flows but also picks up thedosing peak before the chromatographycolumn. A new electronic pressure controlalso ensures maintenance-free columnswitching. �

Find out more:www.siemens.com/processanalyticse-mail: [email protected]

process news 2/2004

20Specialty Chemicals

CASE STUDY

RohMax Öl Additive employs about400 people at numerous locations inEurope and North America. The pro-

duction plants for additives at the Weiter-stadt site in Germany went into operationin the early ’70s and were state of the artfor automation at that time. However, spareparts procurement was becoming increas-ingly difficult and expensive, and the ex-isting technology needed to be replacedby a modern process control system thatcould be optimally adapted to the require-ments of production. After careful re-search, Degussa chose the Simatic PCS 7process control system, which, thanks to itsopen interfaces and scaleable system plat-form, was best suited to meet the require-ments for flexibility and economy.

The software challenge

The project began in the fall of 2000. Tominimize interference with ongoing pro-duction, the new system was to be installed,set up, and a dry run that covered the en-tire functionality was conducted in paral-lel to the producing plant. Only then wasthe new process control system to beplaced into operation.

The user software for controlling thepumps, valves, and shutoff devices in thepipeline system between the productionand mixing tanks posed a particular chal-lenge. Every vessel had to be capable of be-ing shut off by gate valves. When pumpingfrom one tank to another, the HMI systemof the PCS 7 needed to automatically dis-play the target tank corresponding to thestart tank and then select the appropriatepipe route. All other tanks connected to this

pipe route have to be locked automaticallyand only released after the pump processwas completed.

Rapid conversion

The user software was created in just fourmonths, in close cooperation with expertsfrom Siemens and the local Degussa serv-

ice. After exhaustive testing with the Win-mod simulation tool, production was con-verted during the scheduled shutdownover Easter 2001. Together with Degussastaff, the Siemens team reconnected the ex-isting sensors and actuators to the pre-pared control modules and tested the sys-tem. The uniform central access and mon-

Production of oil additives at Degussa

Well-oiled MachineryThe Degussa RohMax Öl Additive division is a world leader in the demandingmarket for tailor-made additives based on polyalkylmethacrylates for applicationsin industrial, automotive, and aircraft lubricants. A well-oiled production planthas been running for the last two years in Weiterstadt, and, thanks to SimaticPCS 7, it is well prepared for future challenges.

The tanks forstoring theproduct batches

A dense network of pipes transportsthe products from one process stepto the next

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process news 2/2004

21

itoring possibilities of the Simatic envi-ronment ensured rapid progress, eventhough the work extended over two build-ings and various outdoor plant compo-nents.

In just five days, 800 valves with feed-back sensors, 158 drives, 64 control cir-cuits, and 124 analog values were con-nected to the new Simatic PCS 7 processcontrol system and placed back into oper-ation one by one.

On the Tuesday following Easter, the“ready” message reached the managementat RohMax Öl Additive exactly as scheduled.Production was then able to continue with-out delay with the new process controltechnology – right on time and without ahitch.

New design possibilities

The successful commissioning was by nomeans the end of the effective partnershipbetween RohMax and Siemens, however.The originally planned implementationhas since led to new design and optimiza-tion possibilities in production. Due to thehigh degree of flexibility and the straight-forward engineering of PCS 7, ideas forprocess optimization can be implementedquickly and without great risk.

The plant can be adapted much moreflexibly to changing conditions with theSimatic PCS 7 process control system.Maintenance is also much easier. The sim-ple archiving and rapid access to processdata in the form of online trend diagramsof the process and control parameters arean indispensable tool for plant operators

and engineers. Operating errors and un-wanted product intermingling are virtuallyeliminated with the new technology.

As a result of this project, the RohMaxÖl Additive division decided in August2003 to continue its successful cooperationwith Siemens and upgrade PCS 7 to the cur-rent Version 6 with a client/server archi-tecture and the Simatic Batch modularbatch system. Siemens is currently imple-menting a manufacturing execution system(MES) with Simatic IT Framework and anSAP link. In the future, RohMax will be ableto decide for every SAP order whether pro-duction is to run fully automatically viaSimatic IT or conventionally with standardproduction cards. This option will be re-tained in the future as an emergency al-ternative in order to guarantee operationin case of possible failure of the IT infra-structure.

In the meantime, both Simatic PCS 7Version 6 and the Simatic IT solution havebeen implemented. Simatic IT is runningin the trial phase in Weiterstadt. The nextstep, the final integration of Simatic IT andPCS 7, is planned for August of this year.Both Siemens and Degussa are already cer-tain that this project will also be a huge suc-cess. �

Find out more:www.siemens.com/pcs7www.siemens.com/chemicalse-mail: [email protected]

The plant operator has allthe relevant informationavailable at a glance

Numerous inspections – automatic, in the lab, or visual, as here – guarantee the high quality of the additives

process news 2/2004

22

systems with approximately 35,000 I/O ona ‘hot’ plant, not to mention the 50 new HMIcomputers, will definitely be a major chal-lenge. This is considerably more complexthan replacing controllers onshore. There-fore, we are building the new system in aroom the same size and layout as the off-shore control room to make sure it worksperfectly before we transfer it to Oseberg.”

Exchange of expertise on-shore

Offshore operators are spending time inBergen working on the new systems’ keyhealth, safety and environment featuressuch as HMI and reliability during the 18-month onshore phase. For Hydro Techni-cal Manager Fritz Eilertsen the involvementof offshore workers is vital. He says: “We allwant this project to succeed so we need theday-to-day knowledge of people from Ose-berg Field Centre to work through the de-tails of the new system.”

So far, progress with this challengingoffshore project has been steady. Already,the benefits of Simatic PCS 7 are beginningto show. Operator Tom Eckholdt is one ofthe people testing the new system and heis delighted about the upgrade: “It is muchmore modern, offering better visualizationtools and is more reliable. The new systemwill make our jobs easier.” �

Find out more:www.siemens.com/pcs7e-mail: [email protected]

Migration

CASE STUDY

S ince last October, a joint team fromNorsk Hydro and Siemens has beenworking together in Bergen and Oslo

on the DISCOS to SAS project. They arereplicating onshore the ‘old’ and ‘new’ sys-tems. The end date for the SAS implemen-tation offshore is mid-June 2006.

The Oseberg Field Centre is locatedabout 130 km northwest of Bergen, includesthree platforms, produces some 150,000barrels of oil and exports up to 30 millionstandard cubic meters of gas per day. In-cluding the adjacent fields dependent onthe Oseberg Field Centre, the total exportvolume is 400,000 barrels of oil per day.

‘Hot’ replacement

At present, the plant is being operated viaa 1980s Teleperm M computer systemknown as DISCOS (Distributed SupervisoryControl and Safety System). Talking in theproject’s Bergen headquarters – a 100-year-

old former fishing net factory acquired spe-cially for the project by Siemens – HydroProject Manager Gunnar Flakstad says:“When Siemens put in the equipment inthe late 1980s it was seen as state-of-the-art. Now technology has moved on, and thisis why we decided to implement SimaticPCS 7. It offers greatly improved function-ality especially related to the Human Ma-chine Interface (HMI), which is an impor-tant aspect closely related to Health andSafety. The main challenge of this projectis that we intend to do the changeovermainly while the offshore system is up andrunning and partly during a maintenancephase of four days.”

Neither Siemens nor Hydro has ever un-dertaken a project of this scale and com-plexity before. Bård Berle, Siemens SiteManager in Bergen, emphasizes the unique-ness of the project: “The gradual replace-ment of 100 process and safety automation

Upgrading the Oseberg Field Centre to Simatic PCS 7

Offshore ChallengeNorsk Hydro has issued a contract to Siemens for the upgrading of the controland safety systems at the Oseberg Field Centre. This contract is worth aboutNOK 250 million, and the project will be completed in mid-June 2006. The“Oseberg Field Centre DISCOS to SAS” contract is a major one, covering thecomplete process automation, safety systems and control room facilities forthree platforms in the Norwegian sector of the North Sea.

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Oseberg Field Centre and Oseberg D

process news 2/2004

23

S imatic Route Control is an extensionof the Simatic PCS 7 process controlsystem. The system is industry-neu-

tral by design and can be used in conjunc-tion with various goods and products. Thesmooth integration with the process controlsystem provides an optimally adapted com-prehensive solution with which not onlyproduction processes and related ware-houses can be controlled automatically, butalso the entire material transport.

A notable feature of Simatic Route Con-trol is the practical and intuitive user in-terface. It offers extensive support for theuser in every operating phase and allowseasy adaptation, optimization, and modifi-cation of transport routes.

Configuration instead of programming

Operators of complex production plantswith numerous and interconnecting trans-port routes can benefit from the flexibility

Find out more:www.siemens.com/pcs7e-mail: [email protected]

Siem

ens

Complex pipe systems – here an examplefrom the sugar industry – are one area ofapplication for Simatic Route Control

of Simatic Route Control, especially whenit is necessary to frequently convert or ex-pand the route network. Route Control isnot an independent system that has to bereprogrammed with every change; rather,it is integrated directly into the configura-tion of the Simatic PCS 7 process controlsystem. All elements of the route controlsystem are modified using the CFC-Editor,and uniform interface components from aspecial library are used, providing all con-trol, parameter, and connecting elements.

An engineering tool is available for theconfiguration itself. The configuration dataare kept on a special server, which then cal-culates the optimum transport route dy-namically, based on the parameter valuesvalid at the time the material transport isrequested. This online approach allowschanges to be made at any time, and thesechanges are then taken into account for thenext transport route request.

Flexible through and through

Simatic Route Control uses the basic hard-ware of Simatic PCS 7 and can be imple-mented as a single-station system in smallplants. As a rule, however, a client/serverconfiguration is used, with up to 32 clientsassigned to the server. The Route ControlCenter can be set up both on the OS clientand on the batch client or a separate RouteControl client. The entire system is there-fore extremely flexible and almost infi-nitely scalable. Availability can be in-creased even further by using a redundantdesign. �

Process Control Systems

TECHNOLOGY

Simatic Route Control

Flexible On Any RouteA flexible route control system is especially crucial in production plants withinterconnecting transport routes. Simatic Route Control integrates smoothlywith Siemens process control technology and can be adapted to any situationat any time without programming effort.

process news 2/2004

24Weighing Technology

CASE STUDY

The filling volume of cocoa packetsmay only deviate from the nominalby 5 grams – even if the specific

weight of the cocoa powder is subject tonatural fluctuation. The weighing proces-sor, together with the plant automationsystem, must perform this dosing task re-liably 2,200 times every hour. The com-pany A.C. S.p., which has specialized formany years in the automation of fillingplants, made use of an order to upgrade an

existing machine and implemented such adosing solution for the first time with theSiwarex A weighing module.

Totally Integrated Automation: Simaticand Siwarex

The cocoa powder is fed from two tanksover feed trays into four containers. Thesecontainers empty into seven hoppers,which, in turn, fill the plastic cans. FourSiwarex A with one OP7 operator panel and

one Simatic S7-300 control the four-headdosing plant. The operator selects a nomi-nal value on the OP7 and can check the cur-rent weight, the nominal-actual deviation,and the status of the machine at any time.The operator can also parameterize andcalibrate the scales with the OP7. In this ap-plication, the stainless steel version of thehigh-precision Siwarex R system is used .

A.C. S.p.’s experience with the first Si-warex A solution has been entirely posi-tive. The project was implemented in avery short time because the automationand the dosing systems work togethersmoothly, thanks to Siwarex and Simatic.Moreover, the prefabricated software mod-ules saved a great deal of time in config-uring and parameterizing the systems.Mercator is also very pleased with Siwarex.The throughput has been increased to theset target, and the required accuracy hasbeen attained. �

Siwarex A at Mercator in Ljubljana, Slovenia

Perfect DosageThe filling and packaging of food products is becoming subject to increasinglycompetitive conditions under stricter and stricter hygiene regulations. Themechanical and electrical components of a filling plant must therefore beoptimally adapted to each other and to the appropriate software. One exampleof an integrated solution is in operation at Mercator in Ljubljana: Siwarex andSimatic systems guarantee highly accurate dosing of cocoa powder.

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Now there is a successor to theSiwarex A weighing module. Thenew, flexible, and calibratableSiwarex FTA weighing modulehas been developed for highspeed and accuracy require-ments. Integrated diagnosticfunctions reduce the life-cyclecosts and increase availability.An integrated event recordersupports plant optimization, andfinished software modulessimplify control, commissioning,and service


process news 2/2004

25TECHNOLOGY

T he ATEX directive 94/9/EC – alsoknown as ATEX 100a – was passedby the European Union to support

the free traffic of goods and came intoforce on July 1, 2003. It unifies the legalprovisions of the member states regardingproducts destined for use in areas wherethere is a risk of explosion. This directivecovers protective systems and electrical ormechanical equipment. One category ofthe ATEX directive deals with conditions ofexplosive dust.

The elimination of ignition sources suchas static electricity is an important meas-ure for the prevention of dust explosions.

Therefore, special requirements apply forthe use of equipment – including processinstruments and sensors, in particular –to prevent electrostatic discharges. Onemethod is to make the material of the con-tact device conductive enough to dissipatethe static charge.

New casing material prevents staticcharging

Echomax XPS ultrasonic sensors are fre-quently used in dust-intensive applica-tions in mining, quarrying, and cementand food industries and already have theEx II 2 G/D license. To obtain the license for

Process Instrumentation


Monitoring systems for oxygen play an

important role in active explosion

protection because oxygen – right in

inflammable gases and next to ignition

sources – is the third most common

cause of explosions. The Oxymat 6 gas

analyzer, in both the 19-inch and field

unit versions, was successfully tested

by Deutsche Montan Technologie

GmbH (DMT) in 2003 according to

ATEX 95 specifications. It can therefore

be used in the appropriate

constant use in conditions of explosivedust as specified in the ATEX guideline, aversion has now been developed which iscovered in a special conductive casing ma-terial. The new Kynar compound materialprovides the necessary conductivity toeliminate damaging static charges and atthe same time retains all the advantages ofthe original Kynar. �

Ultrasonic sensors for conditions of explosive dust

Conductive According to ATEXA new version of the Echomax ultrasound sensors comes with a specialpatented black casing material that makes them conductive in accordancewith the requirements of the ATEX guideline. They comply with the safetyclass Ex II 1D and can be used in conditions of explosive dust, typical forapplications involving grain, coal, flour, and sawdust.

configuration for all monitoring tasks

relating to explosion protection in

industry, in zones 1 and 2, in

conditions of explosive gases.

Oxymat 6 licensed as a gas monitor

Find out more:www.siemens.de/processanalyticse-mail: [email protected]

Siem

ens

One of the first companies to use thenewly certified Oxymat 6 is DEUREXMicro Technologies GmbH in Tröglitz

process news 2/2004

26 SHORTLIST

ATR GmbH & Co. KG recently implemented a 21 CFR

Part 11–compliant visualization solution for a new fill-

ing line for a customer in Vienna. From all the various

possibilities, ATR and the end user ultimately chose a

solution based on Totally Integrated Automation using

the Simatic WinCC visualization system and special

add-ons for validation-relevant aspects. The excellent

price/performance ratio was ultimately decisive, in ad-

dition to the ease of use and scalability.

You can find more detailed information about these case studies at:

www.siemens.com/processnews

Baxt

er

Fritz Hunziker + Co AG is a leading manufacturer

of sweets. In addition to various kinds of sweets

and iced tea, the company’s range of products also

includes gummi bears. A Pointek level switch

ensures that the casting plant never runs out of

cornstarch and the bears always stay in good

shape as a result.

Siem

ens

Siemens has equipped a laboratory at ETH Zurich with

the Simatic PCS 7 process control system. Aim: to offer

trainee engineers a short, informative introduction to

visualization and implementation in two afternoon

sessions. Professor Dr. Adolf Hermann Glattfelder of

the Institute for Automatics heads this project, which

was launched about two years ago.

Siem

ens

Knowledge base: Literature about process automation and related fields

Technical books “made by Siemens” have been among the mostacknowledged publications on automation technology worldwide –and are revised and edited continuously so they will live up to theirexcellent reputation. Apart from true classics like “Automating withSimatic”, the books also cover the latest trends such as the appli-cation of augmented reality technologies for development, pro-duction, training, and maintenance. You can find out more on theInternet:

www.siemens.com/automation/newscenter

––> Publications ––> Magazines & Literature

infoinfoDo 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

know-how

www.siemens.com/processnewsHere you can download the current issue and past issues ofProcess News in PDF format, and search directly for articles aboutspecific topics, technologies or systems in the Reference Center.

know-how

27DIALOGUE

process news 2-04PublisherSiemens Aktiengesellschaft,Automation and Drives Division (A&D), Gleiwitzer Str. 555, 90475 Nuremberg

Germany

www.siemens.com/automation

Group Executive ManagementHelmut Gierse, Anton S. Huber, Alfred Ötsch

Responsible for ContentPeter Miodek

Responsible for Technical ContentCornelia Dürrfeld

ConceptChristian Leifels

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

Editorial CommitteeCatherine Derkosh, Boris Diekmann, Dr. Michael Gilluck, Achim Heim, Hans-Jürgen Huber, Walter Huber, Bernd Langhans, Harald Mag, Yves Masson, Hartmut Oesten, Rüdiger Selig, Dieter Stolz,Roland Wieser

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

[email protected]

Editor in chief:Kerstin Purucker

Layout: Jürgen Streitenberger

Copy editing:Irmgard Wagner

DTP: Doess, Nuremberg

Druck: Stürtz AG, Würzburg

process news is published quarterly

Circulation: 32,000

Job number: 002100 RPE42

© 2004 by Siemens Aktiengesellschaft Munich and Berlin.

All rights reserved by the publisher.

This edition was printed on environ-mentally-friendly chlorine-free paper.

ISSN 1430-2292 (Print)

The following products are registeredtrademarks of Siemens AG:OXYMAT, SIMATIC, S7-300, WINCC, SINUMERIK,TOTALLY INTEGRATED AUTOMATION

If trademarks, trade names, technicalsolutions or similar are not listed above,this does not imply that they are notregistered.

The information provided in thismagazine contains merely generaldescriptions or characteristics ofperformance which in case of actual usedo not always apply as described or whichmay change as a result of furtherdevelopment of the products. Anobligation to provide the respectivecharacteristics shall only exist ifexpressly agreed in the terms of contract.

Order number: E20001-M6204-B100-X-7600

Printed in Germany

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