Systems and Solutions for the Process Industry process news 11 th edition October 3 | 2006 s Collaboration in process instrumentation: Hach-Lange and Siemens Simatic PCS 7 at the Aarberg sugar factory: Sugar “On the Ball” Collaboration in process instrumentation: Hach-Lange and Siemens Simatic PCS 7 at the Aarberg sugar factory: Sugar “On the Ball” Water for Life Solutions for water and wastewater technologies Water for Life Solutions for water and wastewater technologies
Transcript
Systems and Solutions for the Process Industry
processnews
11th edition October 3 |2006
s
Collaboration in processinstrumentation:
Hach-Lange and SiemensSimatic PCS 7 at theAarberg sugar factory:
Sugar“On the Ball”
Collaboration in processinstrumentation:
Hach-Lange and SiemensSimatic PCS 7 at theAarberg sugar factory:
Sugar“On the Ball”
Water for LifeSolutions for water and wastewater technologies
Water for LifeSolutions for water and wastewater technologies
proce
06 14 24
The central purified water plant at the HöchstIndustrial Park is one of the largest of its kind worldwide. Simatic PCS 7 fulfils thestringent requirements for plant availabilityand water quality
Infraserv met growing requirements for wastewater treatment that resultedfrom a changing production environ-ment at the Höchst Industrial Park witha new pretreatment concept
Raps implemented a Siwarexelectronic weighing module inits new, flexible dosing stationsthat fully meet the highdemands of the food industry
nprocess news 3/2006
Cover photo:Siemens AG(Christian Höhn)
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3 EDITORIAL
4 NEWS
Veolia opts for joint offer from Hach Lange and Siemens
Siemens is partner of the Process Management Academy
New approaches in vaccine production
Water treatment solution for Technip-France
Symposium ChemPharm 2007
COVER STORYWater Treatment
6 Solutions for a Blue PlanetSiemens broadens its water technologies portfolio
CASE STUDIESWater Treatment
8 Guaranteed CapacityUpgrade of the central purified water system at the Höchst Industrial Park
Wastewater12 Big Impact
Soft starter in wastewater treatment plant saves 20 percent on electricity costs
Wastewater13 Combined Approach
Meeting the needs of biopharmaceuticalcustomers
Wastewater14 Perfect Treatment
Innovative wastewater treatment system at the Höchst Industrial Park
Irrigation17 Optimum Water Usage
Flowmeter retrofit improves irrigation management
Process Instrumentation20 Optimized Vent-Gas Recirculation
Maintaining stable vent-gas pressure with process analytics
Drive Engineering21 Efficiently Controlled
Frequency-controlled pump drives at DSM Nutritional Products
Weighing Technology24 Clean and Tasty
Siwarex sets new standards for weighingterminals in spice factory
CONTENT
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“We take care of the world’s water.” Siemens hascommitted itself to this vision of the future becausewater has always provided and will continue to provideprosperity and progress worldwide.
However, in the coming years, the cost andavailability of water will affect economies worldwidejust as much as the dependency on oil and gas importstoday. Water will become a significant cost factor thatwill influence not only the competitiveness of tradeand industry, but also the sector of municipal andprivate water consumption.
New and improved strategies for water processing,water reuse and water cycle management offer ananswer to the growing needs and requirements of the water quality, reduce costs and, thus, strengthenthe competitiveness of municipalities and industries.This is where Siemens wants to make a contributionwith its expertise and solutions, and this is why wefocus on our offer for water technologies in this issueof Process News.
With our wide range of process and automationsolutions, we consider Siemens well-equipped for themultifaceted demands of customers in Europe, Asiaand the Americas. Based on our experience gatheredwith more than 200,000 installations throughout theworld, we can serve the heavily fragmented market forwater and wastewater treatment. We see considerableopportunities for our systems and solutions not only inthe municipal sector, but also in industrial applications.With our membrane, UV and chemical disinfectionsystems and biological processes, we can introducereclamation methods that meet country- and sector-specific requirements of water quality.
In this issue, we will introduce you to our conceptsand strategies for the water market and presentseveral case studies that illustrate our expertise insome key markets such as ultrapure water for thepharmaceutical industry. We hope you enjoy readingthis issue of Process News!
The process control upgrade to Simatic PCS 7at a sugar production facility in Switzerlandresulted in higher production reliability,greater convenience for the operatingpersonnel and higher production standards
newsprocess news 3/2006
Jørgen Ole HaslestadPresident of the Siemens Group Industrial Solutions and Services
Manufacturing Execution Systems26 New Efficiencies
Simatic IT at Canadian chemical plant
Sugar Industry28 Sugar “On the Ball”
Simatic PCS 7 installed in the outdoor area of the Aarberg sugar factory
TECHNOLOGIESProcess Instrumentation
16 More Intelligence, Fewer CostsTargeted pump control with ultrasound
Training30 Totally Integrated Automation Made Easy
Hands-on training at the TIA training plant
TRENDSProcess Analytics
18 Perfect PartnershipCollaboration in process instrumentation
Partner22 Partners in Pharmaceuticals
Siemens Solution Partner program for the pharmaceutical industry
31 DIALOGUE
Dear readers!
EDITORIAL
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4 NEWS
A t the urging of the US Congress, repre-sentatives of major governmental and
nongovernmental as well as industrial andregulatory organizations met in Cleveland,Ohio, to discuss the topic of a global viralpandemic.
The development of a new flu vaccine isnot particularly difficult, but manufactur-ing a sufficiently large number of vaccinedoses, in case of a pandemic outbreak, isbeyond the present capacity of the phar-maceutical industry.
The goal of the meeting was to identifychallenges to manufacturing influenza vac-cines, including rapid production for pan-demic influenza, and to discuss specific
Find out more:www.siemens.com/chemicalswww.pm-academy.com
Find out more:www.siemens.com/processinstrumentation
Find out more:www.siemens.com/pharma
The framework agreement between Veo-lia, Hach Lange and Siemens was recently
extended to include North America. Theagreement now covers all of the countriesof the world, enabling Veolia to exploit thebenefits of the comprehensive offer of HachLange and Siemens in its North Americabusiness operations. This extension alsounderscores the significance of the cooper-ation between Hach Lange and Siemens(see article on pages 18 and 19). Together,both companies offer a comprehensive andbroad process instrumentation and analyt-ics portfolio for water technologies.
To further strengthen the collaborationwith Veolia, the Siemens process instru-
Siemens is partner of the ProcessManagement Academy for the first time
Trends in ProcessAutomation
The next Process Management Academywill be held in Neuss from January 22 to
24, 2007. In addition to the main organizer,the ARC Advisory Group, Siemens will alsobe acting, for the first time, as co-sponsorand organizer of the successful series ofevents which is aimed at process industryspecialists.
The upcoming event will focus on inno-vative concepts and technologies whichsupport the process industry in more effec-tive management as well as optimization ofproduction systems.
The two-day, informatively staged pro-gram offers users, manufacturers and sys-tem integrators of automation solutions ahighly interactive forum for exchanginginformation about the latest developmentsin process automation. In view of the greatsuccess of the first two events, the organiz-ers are expecting more than 300 decisionmakers and experts from all sectors of theprocess industry. �
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The process instrumentation roadshow toured on a remodeled truck
mentation roadshow toured several sub-sidiaries of Veolia, wrapping up the tourat the Veolia headquarters in Paris.
The French leg of the tour closed off theSiemens process instrumentation roadshowthat had traveled through Northern andEastern Germany for two and a half weeks.The roadshow presented the Hach Langeand Siemens instrumentation portfolio tocustomers in the water and wastewaterbusiness in a truck that had been remodeledas a mobile presentation platform. �
approaches for increasing influenza vaccineproduction using both existing and „nextgeneration“ technologies.
Ingrid Maes, Siemens, a well-knownexpert in the PAT (Process Analytical Tech-nology) field, was invited by the FDA (Food& Drug Administration) to speak on the roleof PAT in speeding up process developmentof a new flu vaccine and maximizing the uti-lization of manufacturing capacity.
Siemens is considered a leading supplierof PAT solutions in vaccine developmentand production. �
New approaches in vaccine production
Combating Influenza
Veolia opts for joint offer from Hach Lange and Siemens
Better Together
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Technip-France has chosen Siemens to sup-ply a produced water filtration system and
a seawater injection system to Total UpstreamNigeria Limited for its Floating Production Stor-age and Offloading (FPSO). This project followsthe successful completion of other projectsSiemens has executed for Total, including theDalia FPSO water injection system.
The water treatment system comprises aprimary vessel (oily water drum), a secondaryvessel (hydrocyclones) and a tertiary vessel(induced gas flotation system) and is designed
Water treatment solution for Technip-France
Oil & Gas Success
Find out more:www.siemens.com/water
The early and interdisciplinary cooperation betweenprocess and automation technicians will be a central
topic of the ChemPharm 2007 Symposium. On February 8and 9, 2007, experts from industry and universities will bepresenting ways for faster development, control and mod-ification of complex productions at the Lichtenberghaus inDarmstadt. Under the motto “Innovations in chemical-pharmaceutical production by total methods,” participantscan expect a top-level lecture program oncurrent trendsand developments – from the microreaction technologythrough traceability by RFID to quality management andIT security in the process industry. An attractive evening
event with a visit to the control center of the EuropeanAerospace Organization ESA rounds off the symposium.
The symposium is being organized by the ThermalProcess Technology School of the TU Darmstadt in coop-eration with the companies Merck KGaA, Siemens AG,Bayer Technology Services GmbH and Boehringer Ingel-heim GmbH. �
ChemPharm 2007 Symposium – ways of cooperation between science and industry
Together for Success
Find out more:www.chempharm.org
to handle up to 17,800 cubic meters of waterper day.
In addition, Siemens Water Technologies wasawarded an order for a seawater electrochlori-nation package for controlling marine growthas well as eight media filters to filter up to50,600 cubic meters of seawater per day forreservoir injection. �
Siemens supplies a water treatmentsystem for an FPSO ship of Total UpstreamNigeria Limited
process news 3/2006
6Water Technology
COVER STORY
Two years have passed sincethe acquisition of USFilterand the establishment of theSiemens Water Technologiesdivision. What has beenaccomplished so far?
Roger Radke: We are on trackto achieving great success.Our overall objective is to bethe leading water and waste-water treatment equipmentand service company in theworld. Already, more than 90percent of the Fortune 500companies utilize our sys-tems, along with numerousmunicipal water services andtreatment companies aroundthe world. We offer an ex-tremely broad portfolio oftechnologies and services to
adress a variety of water andeffluent needs, and use theseto develop innovative solu-tions. By combining our ex-pertise in membrane filtra-tion and biological watertreatment, we were able to de-velop one of the most ad-vanced membrane bioreac-tors on the market today.Moreover, we put together anew municipal water servicesand industrial water servicesportfolio, which we will intro-duce at WEFTEC in Dallas,Texas.Ralf Wegner: Water is a busi-ness of strategic significancefor Siemens. This was also thereason for establishing theCompetence Center Water
and Wastewater, which will ensure thatproducts and systems will be adapted tothe needs of our water customers evenmore consistently in the future. Our cus-tomers can leverage the combined compe-tence of Siemens.
Water reuse and energy savings are trendsfor which you see a great deal of potential.What is your strategy for this market?
Roger Radke: The sustainable use of theprecious resource water forms the key chal-lenge for both municipal as well as indus-trial water supply providers. This also in-cludes water reuse. Our technologies cantreat water to any quality specification, in-cluding everything from purified water for the pharmaceutical industry to drink-ing water taken from rivers. We therebycombine several technologies: filtration,desalination, contaminant removal, dis-infection, disposal solutions for processwaste, as well as, of course, automationsolutions for process control. All of theseofferings are included in our portfolio.Ralf Wegner: Another topic increasinglygaining in importance in terms of watersupply and water treatment involves energyuse. Our products and systems help cus-tomers to save energy, thereby, at the sametime, reducing the life-cycle costs of theirsystems. We offer everything from energy-saving components and soft starters fordrives to intelligent systems for cost- andenergy-efficient operation of entire pumpstations, to name but a few examples. Werank among the technology leaders in manyfields. Thanks to our extensive expertise, weare able to develop innovative water and waste-water treatment solutions, such as systemsthat require very little space – particularlyappropriate for metropolitan areas – orsystems that produce very low emissions.
Siemens broadens its water technologies portfolio
Solutions for a Blue PlanetEarth is a blue planet indeed: roughly two-thirds of its surface is covered withwater. Without water, there would be no life – and the world as we know itsimply would not exist. Water plays a crucial role in almost every aspect of ourlives. We spoke with Roger Radke, head of the Water Technologies division atSiemens Industrial Services and Solutions, and Ralf Wegner, head of theCompetence Center Water and Wastewater at Siemens Automation and Drives,about the growing significance of water technology solutions.
„The sustainableuse of the precious
resource waterforms the key
challenge for bothmunicipal as well as
industrial watersupply providers.“
Roger Radke
process news 3/2006
7
Can you cite specific examples of suchinnovative projects?
Roger Radke: In Orange County, Califor-nia, our systems are used to purify waste-water to be reinjected into the groundwater.Thus, the pressure of the so-called aquifer,the water-bearing ground stratum, is up-held while salt water intrusion is prevented.In Mexico and the United States, industrialplants use our technology to reclaim mu-nicipal wastewater and reuse it for coolingwater and boiler feed water. In Singapore,we’ve combined membranes, reverse osmo-sis and disinfection to create high-puritywater from secondary effluent. In China, theBeijing Drainage Group recently selected usto supply membrane technology for the BeiXiaohe Wastewater Treatment Plant, andwhich will also meet the needs of the OlympicPark for recreational water and reuse waterin 2008. In addition, Siemens will supply themechanical, electrical and automation sys-tems, as well as instruments and services. Allof these customers, as well as many more,are committed to promoting sustainablewater supplies, and we are proud to be theirbusiness partner.
Just one more word about the future: What new trends do you see emerging in the market?
Ralf Wegner: In Asia especially, but also inEurope, operation of wastewater treatmentsystems will be increasingly privatized.
With the so-called operatormodel, a private companybuilds a wastewater treat-ment system at its own ex-pense, and also handles theoperation of the system forthe community. In return, theprivate company collects thewastewater fees.
In this context, the issue oflife-cycle costs is of central im-portance, and takes on a com-pletely new meaning. Thestandardization of globallyavailable technologies createsstreamlining potential for in-creasing the productivity ofwastewater treatment sys-tems. As a result, large com-panies active in wastewatertreatment are currently work-ing to standardize their tech-nology platforms.
Thanks to Totally Integrat-ed Automation and Totally In-tegrated Power, we are able to offer cus-tomers a consistent platform for all waste-water treatment tasks – everything fromthe instrumentation, an area in whichSiemens is a full-scope supplier, to SCADAsystems with Simatic WinCC for small andmid-sized systems as well as large-scalecontrol system solutions with Simatic PCS7and Sinaut telecontrol technology. Our To-
tally Integrated Power con-cept covers all aspects of ener-gy management. Customersbenefit from easy installationand maintenance.
In addition, Siemens hasan excellent reputation as faras spare parts availability andsystems reliability are con-cerned. Our thinking is alwaysgeared toward the life cycle ofthe customer’s system, there-by helping to effectively pro-tect investments.Roger Radke: Water is a glob-al topic, now and particularlyin the decades to come. We seetremendous potential in thewater industry. In the US, forexample, we are currently out-pacing the market. The waterindustry will experience dou-ble-digit over the next three tofive years. Our global networkputs us in an ideal position
to respond to these developments, and toimplement projects in all countries, includ-ing the current growth centers in Asia. Weare where our customers are, and are there-fore able to support them with all of ourcompetence and expertise.
Mr. Radke, Mr. Wegner, thank you for speaking with us.
[email protected] 20 percent ofthe world’s population hasno access to clean water
Approximately 40 percent ofthe world’s population is notconnected to wastewaterdisposal facilities
Approximately 50 percent ofthe world’s population has nosantiary facilities
20%
40%
50% 50%
60%
80%
Water: Ressource No. 1
„Water ist abusiness of
strategicsignificance for
Siemens. This wasalso the reason for
establishing theCompetence Center
Water andWastewater.“
Ralf Wegner
process news 3/2006
Upgrade of the central purified water system at the Höchst Industrial Park
Guaranteed CapacityThe central purified water system at the Höchst Industrial Park is one of thelargest of its kind worldwide with a capacity of approximately 300 cubic metersper hour. Maximum availability and guaranteed water quality are decisive criteriafor the system, which supplies purified water for 19 pharmaceutical operations.The Simatic PCS 7 automation solution fully meets the system requirements.
8Water Treatment
CASE STUDY
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Modernization of the purified waterproduction and distribution plantalready got underway at the end
of the 1990s. The upgrade was prompted bywater quality problems at the existing taplines of the operations, which were tracedback to the water distribution system. Con-sequently, the water distribution system forthe pharmaceutical water was upgradedfirst, which went into operation in 2000 (seeinsert on page 10).
During the course of the project, the pro-duction system was also examined. It was re-vealed that, although the quality of waterproduced was sufficient, the system was nolonger able to meet the higher validationrequirements after 40 years in service. In-fraserv, the site operator of the Höchst In-
dustrial Park, therefore decided to build anew production system.
Unique system
The awarded contract involved special re-quirements as Dr. Jörg Klauer, water treat-ment project manager at Infraserv, re-members: “Pharmaceutical water is princi-pally only desalinated drinking water witha high microbiological purity, and whichmust be manufactured according to thespecifications for pharmaceutical produc-tion industry. However, the central phar-maceutical water system at the industrialpark is something special. On the one hand,it is too small for a full-size desalinationsystem with a capacity of approximately300 cubic meters per hour. On the other, it
is too big for pharmaceutical water pro-duction system, because systems of thistype generally have a maximum capacitythat does not exceed 50 cubic meters perhour. We therefore asked ourselves whatcompany would be capable of building asystem of this scale while also meeting thequalification and validation requirementsstipulated by the pharmaceutical industry.”
Only three bidders were able to offer asolution to the problem, and Hager + El-sässer, which belonged to Ondeo at the timeof the contract award, ultimately submittedthe most convincing offer for implementingof the project. For the automation system,there was a preference in favor of Siemens,because Siemens technology had alreadybeen used for the system, as Jörg Klauerpoints out. “We had already had good ex-
The pharmaceutical waterproduction at the HöchstIndustrial ParkThe system installed by the Hager + Elsässer GmbH,Stuttgart, consists of a preceding softener with fivedownstream production lines which can be switchedindependently of each other. After softening, the waterpasses first through the reverse osmosis and then throughan electro deionization. The system is also equipped witha CIP system with which the production can be cleaned ifnecessary. The CIP cleaning is only carried out with hotwater to avoid the introduction of contaminants into thesystem. Siemens was responsible for the planning andengineering, qualification and installation of the controltechnology.B Capacity of the system: 300 cubic meters per hour
B Process control system: Simatic PCS7
B Converters: Simovert Masterdrives
B Low-voltage switchgear: Sivacon
B Pressure transmitter: Sitrans P
B Flow meter: Sitrans FM
B Thermometer: Sitrans T in head transmitter version
B Radar level measurement for brine measurement:Sitrans LR400
B Limit level measurement: Pointek CLS
B Profibus DP for linking the distributed devices such asfrequency converters and motor controllers
B Binary and analog sensors and actuators are wiredcentrally on the Simatic ET 200M system
The new pharmaceutical water purificationat the Höchst Industrial Park
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perience with Siemens, but were naturallyalso open for alternatives. However, wewould then have demanded proof that thesolution works with the other technology.”Together with Intraserv, and given Siemenscompetencies in the pharmaceutical indus-try, Hager + Elsässer finally made the deci-sion to automate the new pharmaceuticalwater production unit with Simatic PCS 7.Moreover, Hager + Elsässer also commis-sioned Siemens to supply the entire field in-strumentation.
High demands for quality andavailability
In order to satisfy the key criterion for phar-maceutical water, microbiological purity, it is essential that the system has specialdesign features. Here, one of the featuresof large, central systems has proven par-ticularly beneficial. Water production isprovided around the clock. There is practi-cally no standstill in the water supply. Dueto the large water volumes involved, pipediameters and dimensions in the systemare also larger on average, so that it iseasier to build the system to meet hygienestandards.
On the other hand, the central supply forthe pharmaceutical companies at the in-dustrial park also carries with it special de-
mands. Jörg Klauer describes the situation:“A total of 19 companies are connected, in-cluding two insulin production operationswhich develop so-called blockbuster med-ication. A system failure would thereforeresult in enormous sales losses. For us, asthe system operator, this quite simplymeans: Production downtime is an ab-solute no!”
The water production system was de-signed accordingly, both in terms of processdesign as well as the automation technolo-gy. “The system has five lines, of which fouralways have to be ready for operation. Theline concept was also implemented in thepipe technology to ensure the availability ofa constant water capacity of 240 cubic me-ters per hour.” In the Simatic PCS 7 archi-tecture, the required operational reliabilityis implemented exclusively on the softwarelevel without high-availability controllers.That was also the special challenge for thecontrol system’s engineering: program-ming the interconnection of the individuallines and ensuring that one controller as-sumes the operations of another without in-terruption in the event of a controller fail-ure. Siemens came up with an elegant solu-tion during the course of the project, whichalso enables updates and even future ver-sion upgrades of the control system to beimplemented during operation.
Excellent on-site cooperation
In order to ensure the uninterrupted supplyof pharmaceutical water during the up-grade, the new system was integrated stepby step. First, one half of the old system wasremoved and then half of the new systembuilt whilst the remaining old parts of thesystem upheld the production. After that,the rest of the old system was removed andthe second half of the new production sys-tem installed. The first part was put intooperation in November 2004, and the sec-
Modernizing the pharmaceutical waterdistribution systemSiemens had already designed and installed the new water distribution system at theHöchst Industrial Park for Infraserv, which went into operation in 2000. The systemdistributes pharmaceutical water to connected operations at the industrial site using 14 kilometers of sterile pipes with diameters measuring between 50 and 300 mm.
The distribution system consists of the main ring pipe and four distributedcompensation tanks, each of which supplies a number of the operations via a sub-ringpipe. 14 sterile pumps maintain constant circulation of 500 cubic meters ofpharmaceutical water in the ring pipes to ensure that the microbiological quality ismaintained.
Another method for suppressing the growth of germs and ensuring water quality overthe long transport distances is ozonization. Ozonization is performed at several points inaccordance with a special process developed by Axiva involving electrolysis cells, whichrequires no additional operating media, particularly oxygen and cooling water.
The distribution of the pharmaceutical water is also controlled by Simatic PCS7. Thestations are interconnected by an Industrial Ethernet designed as a fiber optic cable witha total length of approximately six kilometers. A ring bus structure was chosen foroptimum availability of the system. The process control system processes data from atotal of 260 measuring points which are located in 15 production buildings spread overan area of several square kilometers. Twelve converters with a drive power of up to 90kilowatts as well as two intelligent motor contactors for motors with a maximum drivepower of 11 kilowatts are controlled via Profibus.
Siemens also provided almost all of the process instrumentation
10 CASE STUDYWater Treatment
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process news 3/2006
ond part in May 2005. The on-site coopera-tion during installation and commission-ing of the new system was excellent, asAlexander Dietze, head of water treatmentat Infraserv, confirms: “The local supportwas very good – for the programming aswell as for the installation.”
The equipment qualifications for a phar-maceutical production system were con-ducted in parallel to the engineering, in-stallation and commissioning. “We reliedon Siemens know-how for the EMR tech-nology. Siemens knows what documenta-tion is necessary for a pharmaceutical pro-duction system. Not every company pos-sesses this competence, and that was one ofthe factors that played an important role inthe cooperation,” Jörg Klauer stresses.
Optimal operation
Alexander Dietze is fully convinced of theoutcome of the modernization: “We are re-
ally very pleased. After a few minor start-updifficulties, which occur with all projects,we now have exactly the system we wanted:it operates fully automatically, and thequality is just fine.”
As a result of increasing water demands,the system is now operating at full capaci-ty. In fact, the implementation of an addi-tional system is already being considered,if the water demand continues to rise. “Asfar as we are concerned, we would have noobjections to once again cooperating withHager + Elsässer GmbH and Siemens,” asJörg Klauer and Alexander Dietze con-clude. �
The Masterdrives converters whichcontrol the motors in the system areintegrated in PCS 7 via Profibus
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The ventilation of the activationbasins is one of the costliest items onthe energy balance sheet of awastewater treatment facility. Thesavings potential is also very high. Atthe wastewater treatment facility inMinden-Leteln, Germany, savings ofup to 20 percent on electricity costswere achieved through the softstarting the fan turbines alone.
The basic principle of biological waste-water treatment is really quite sim-ple: micro-organisms feed on the pol-
lutants in the wastewater, literally eatingthem up – under one condition that is: thewater must contain enough oxygen.
Power drain: ventilation
At the Minden-Leteln wastewater treatmentfacility, twelve turbines with a power ratingof 38 kilowatts each offer adequate oxygensaturation by spinning the wastewater inthe activation basins through the air,thereby causing it to take up the necessaryamount of oxygen. Up to 55 percent of thepower needed for this operation is pro-duced in two on-site power stations. The
rest has to be purchased. The system oper-ator is therefore faced with the difficult taskof ensuring continuous sufficient oxygencontent in the water on the one hand while,at the same time, controlling the ventilatorturbines to make certain that no consump-tion peaks occur, if possible.
“That’s why this is so crucial,” as plantmanager Heinrich Denzer, explains, “becauseevery kilowatt of connection load over theload limit of 1,000 kilowatts costs an addi-tional 148 euros.”
Electricity savings with torque control
Siemens solved the task by installing elec-tric turbine drives with 3RW44 soft starters.The soft starter devices provide actualtorque control of the drive during start upwith the help of dedicated limiters. The tur-bines are powered up one after the othervery similar to a relay race to enable a totallysmooth flowing soft start-up. The start-upis triggered whenever the measuring probedetects a diminishing oxygen content levelin the wastewater. Denzer observes: “We wereable to reduce our electricity consumptionin the biological area of the wastewater sys-tem approximately 20 to 25 percent withthis solution.”
Moreover, the soft start-up of the drivemotors also means that there are no inrush
currents, which represent an extremelyhigh load for the gears. “The great massmoment of inertia of the turbines placedsuch a strain on the gears that they had tobe repaired at a cost of 18,000 euros everyfour years at the latest,” Denzer commentson the previous situation, and adds: “Wenow have far fewer failures thanks to thesoft starter solution, and we expect to cutthe gear servicing period in half to abouteight years.”
Permanent cost reductions
During the course of the upgrade, the con-trol technology was also updated to meetlatest industry standards. The existing sys-tem was replaced by a Simatic PCS 7, whilethe periphery was largely retained.
The investment in a soft starter solutionhas paid off very quickly for the Minden-Leteln wastewater treatment plant, and isexpected to make a major contributiontoward reducing operating costs over thenext ten to twenty years. As such, it is a rel-atively simple solution with a big, long-term impact. �
The treated wastewaterleaving the facilitythrough a drain leadinginto the Weser Rivervirtually possessesdrinking water quality
Soft starter in wastewater treatment plant saves 20 percent on electricity costs
Big Impact
Twenty percent of theelectricity costs were saved atthe water treatment facility bysoft starting the fan turbines
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Siemens Water Technologies providedan Oregon-based biopharmaceuticalcustomer with a water treatmentsolutions that helped them meetstringent regulatory requirements.
Synthetech, Inc. of Albany, Oregon,USA, a specialty chemical producer,found a wastewater treatment solu-
tion in Siemens Water Technologies’ inno-vative products. When the US Environ-mental Protection Agency (USEPA) imple-mented new pharmaceutical pre-treatmentstandards, also adopted by the city of Al-bany, Synthetech had to install a waste-water treatment system to comply with thenew standards. Because they manufactureda wide range of chemicals and used a vari-ety of manufacturing processes, there werelarge fluctuations in the variety and con-centration of contaminants in their waste-water.
Combined treatment strategy
Siemens Water Technologies conductedbench-scale testing to determine the bestsolution, and designed a full-scale systemthat included an evaporator for the processstream and a PACT treatment system for theevaporator distillate plus the non-processwastewater.
The PACT system comprises the heart ofthe treatment process. The system combinespowdered activated carbon and live micro-organisms to treat the wastewater. The acti-vated carbon initially adsorbs the volatile or-ganic compounds and other organics. Mostof these contaminants become the substrateupon which the microorganisms live. Air isdiffused into the system to ensure that themixture remains homogeneous and to pro-vide sufficient oxygen to the microorgan-isms. With opportunistic access to the con-taminants, microorganisms more efficientlyoxidize, or destroy, the adsorbed organics.
Siemens supplied the system as a facto-ry-built, sequencing batch reactor, consist-ing of an aeration/settling tank, aerationblower, air distribution systemand deliv-ery system for various other inputs. Thesystem is designed to handle a waste streamof approximately 13 cubic meters per day ofnon-process water and 13 cubic meters perday of evaporator condensate.
Considerable savings
The system is not only allowing Synthetechto meet federal and local pharmaceuticalpre-treatment standards, but is also savingthem over 18,000 US dollars per month inoff-site disposal costs, sewer charges andPOTW (publicly owned treatment works)site development charges. �
The PACT system combines powdered activated carbonand live microorganisms to treat wastewater
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13Wastewater
CASE STUDY
process news 3/2006
14Wastewater
TREND
The water treatment experts at Infra-serv decided to initiate the projectwhen it became clear that a new waste-
water purification system would be neces-sary in view of the changing wastewaterconditions at the site. Two insulin plantswent into production on the site, produc-ing biodegradable wastewater with a highchemical oxygen demand (COD). This waste-water could not be treated directly in thecentral wastewater treatment system oper-ated by Infraserv because it had reachedthe limits of its capacity.
Thorough pretreatment with COD reduction
The pharmaceutical wastewater is now pre-purified using both an anaerobic pretreat-ment unit (APU) and a nitrification pre-treatment unit (NiPU). In the APU, theinsulin wastewater is subjected to an anaer-obic process. Here, the contamination inthe water is turned into biogas and a smallquantity of new biomass, the excess sludge.
The biogas is biologically desulfurized andconsists of 80 percent methane. This biogasdrives the engines of the three block-typeheating power stations of the system. Thus,the unit operates using a completely inde-pendent source of energy and also feedselectricity into the Infraserv network.
Infraserv Höchst contracted the processspecialists at Siemens to plan the system.Infraserv and Siemens had already workedtogether previously on trials to select theoptimum process type and in designing thesystem.
As the general planner for the anaerobicpretreatment unit, Siemens was respon-sible for all planning phases, from thesupervision of tests at the technical centerto the prebasic/basic engineering and fromthe detail engineering to assembly andcommissioning support.
Siemens designed the system and car-ried out the pilot tests necessary for processadaptation. Proof was therefore provided inadvance that the selected process variant
would meet the requirements for COD reduc-tion. In addition, all the project-specific fea-tures, such as the tolerable level of toxic ingre-dients, were satisfied in the pilot tests.
Together with Infraserv, Siemens devel-oped a solution that exploits the excess heatproduced in the process, generates elec-tricity from the generated biogas, and pro-duces hardly any excess sludge. The adaptedprocess automation with Simatic PCS 7enables reliable process control of the com-plex system.
Biological oxidation
The drain from the APU flows without pres-sure into the NiPU, where the remainingCOD and the ammonium compounds areoxidized to nitrate in the aerobic-activatedsludge process. The drain from the NiPU isfed in turn to the existing central waste-water treatment plant, the eliminationcapacity of which is sufficient, in the firsthigh-load stage, to process the nitrate con-tent of the NiPU.
Innovative wastewater treatment system at the Höchst Industrial Park
Perfect TreatmentBy building a new wastewater treatment system and a nitrification system, the owners of the Höchst Industrial Park,Infraserv Höchst, have responded to the changing wastewater conditions at the Höchst Industrial Park to guaranteethe companies at the site safe and ecological disposal of their production wastewater. Siemens supported theimplementation of this state-of-the-art wastewater treatment system in almost all phases of the project.
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The new nitrificationpretreatment ofInfraserv Höchst
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The building of the new NiPU completedthe measures taken by the industrial parkowner, Infraserv Höchst, to meet the cur-rent wastewater purification requirementsof the complex. After extensive preliminarytests, Infraserv chose the process variant ofbiological nitrification.
Two years from initial studies to commissioning
Just two years were required to complete thesystem – from the detailed requirementsanalysis in 2003 to the comparison of tech-nical process variations, concept design,the experimental confirmation of the full-scale system design through conventionalpilot tests, the granting of legal concession,the invitation to tender, implementation,and the on-schedule commissioning of thesystems in the summer of 2005.
Infraserv Höchst, as the plant builder,took over both the planning of the buildingtechnology and the purchase and installa-tion of all the package units, as well as the
commissioning and operation of the units.Siemens was responsible for the front-endengineering and the general planning dur-ing the implementation phase for themechanical equipment/pipework and elec-trical engineering units. Siemens fielddevices were installed for the first time inwastewater treatment at Höchst IndustrialPark. The expertise of the teams on site,
especially in process development, laid thefoundation for the successful partnershipbetween Infraserv and Siemens in laterproject phases. As in the APU, the processesin the NiPU are controlled by Simatic PCS 7,which was integrated into the overall con-trol system of the wastewater treatmentplant. All processes can be controlledeither from the control center just over amile away or locally.
Clean water for the long term
Both systems are operating perfectly andmeet the requirements for purification per-formance. Combining the APU and NiPUwith integration into the existing centralwastewater treatment system guaranteesthat the industrial complex can effectivelytreat wastewater for the long term. �
Process and service expertiseUsing their extensive expertise, the
process specialists at Siemens, together
with the customer, developed tailor-
made processes and solutions for
special tasks in water and wastewater
technology – including the technical
implementation and automation
technology.
Basic data of the AVA/NiPUAVA:
B Wastewater volume:up to 3,000 cubic meters per day
B Reactor volume:3 x 800 cubic meters per day
B COD load: up to 32 tons per day
B Biological desulfurization:maximum 500 cubic meters per hour
B Cleaning: from maximum 15,000 parts per million to 100 parts per million
B Maximum generated electrical power:about 1.3 megawatts
B Excess heat for water heating:about 1.7 megawatts
NiPU:
B Active sludge process
B 2-line 1-stage system (advantages formaintenance and modification)
B Total water flow can be divided betweenboth lines at any ratio
B Hydraulics: 3,680 cubic meters
B Capacity: 2.9 tons total nitrogen per day
B Nitrification rate: more than 96 percent
B Two aeration tanks with a diameter of 20meters and water depth of 9 meters
B Fine bubble diaphragm aeration
B Compressed air provided by screwcompressors
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The pharmaceutical wastewater at the industrial complex is pretreated using both ananaerobic pretreatment unit (APU) and a nitrification pretreatment unit (NiPU)
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process news 3/2006
16Process Instrumentation
TECHNOLOGY
To operate pumps in the water orwastewater system as cost efficientlyas possible, plant operators can use
the tariff system of the electricity providersto their advantage. Tariffs often vary accord-ing to the time of day. If pumps are specifi-cally controlled to operate on a demand-driven basis, yet preferably at low tariff
times, costs can be reduced without affect-ing ongoing plant operations.
Demand-driven and cost-optimized
Sitrans LUC500 ultrasonic measuringtransmitters are ideally suited for the task.Not only do they reliably measure the level,for example, in a wastewater well, their
integrated electronic control elements alsoenable programming of the pump switch-ing points dependent on certain timezones. This allows the following scenario tobe implemented, for example: The well ispumped down to its lowest level just beforethe start of the high tariff period. Duringthe high tariff period, the filling level isonly allowed to rise to a fixed maximumlimit. On reaching this level, the well ispumped back down to a specific level justabove the lowest level setpoint.
Naturally, the system is designed to reactflexibly to changing wastewater level situ-ations. High inflow rates during rainfall,for example, are reliably detected and auto-matically activate switchover to normalpumping operation. All of the necessaryfunctionalities for the pump control, dataacquisition and network communicationshave been directly integrated into thetransmitter, thereby enabling setup of ahighly operation- and cost-efficient systemwhich has proven to reduce electricity costsby up to 10 percent.
Keeping an eye on the pumps
But the Sitrans LUC500 has a lot more tooffer than simply intelligent pump control.It can be used, for example, to also exten-sively monitor the function of each indi-vidual pump. The status, performance andpumped volume are monitored continu-ously, making routine on-site inspectionslargely superfluous. Instead, a system ofneeds-based maintenance governed byactual requirements can be adopted.
In addition, for pumps with varyingcapacities in a pump station, the measuringtransmitter can also be programmed toswitch the most suitable pump on and offrespectively depending on flow rates. Thereare also functions for reducing grease col-lars. Thereby, the pump switch-on pointsare variably switched in a certain rangein order to minimize the formation ofdeposits, along with the associated clean-ing and maintenance requirements.
The Sitrans LUC500 measuring trans-mitter is available in three design versions:for installation in a rack, in a control panelor in a field housing. It is indeed an intelli-gent solution to flexibly reduce costs. �
Targeted pump control with ultrasound
More Intelligence, Fewer CostsPumps are typically the biggest electricity consumers in fresh water andwastewater systems. They are responsible for up to 50 percent of the electricitycosts of such a system. An efficient pump control therefore plays an importantrole in energy management.
In a water treat-ment plant, pumpscan account for upto 50 percent ofelectricity costs
The SitransLUC500 measuringtransmitter in thefield housing canbe equipped with a manual pro-gramming unit
Find out more:www.siemens.com/processinstrumentationE-mail: [email protected]
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medium as water flows past the ultrasonicsensors. Either one-track or two-track ul-trasound sensors can be used, dependingon accuracy requirements and inlet condi-tions.
Two-track ‘X’ installation is recom-mended for accurate measurement undershort inlet conditions. The accuracy is typ-ically one to five percent for the retrofitflowmeter kit, which is factory preset to thenominal dimensions of the pipe type andsize. After installation, adjustments can bemade to improve accuracy using a softwaretool. When supplied as a pre-calibrated setwith piping, the flow meter accuracy is typ-ically 0.5percent.
The FUS880, backed by Siemens consid-erable experience in the irrigation field,enables district operators to enjoy all of the
W ith clean water becoming in-creasingly scarce and its price onthe rise, suppliers and users alike
are focusing greater attention on waterconservation and correct billing. Correctbilling, fast leakage detection and accuratequantification of losses can be achieved byusing the latest flowmeter technology.
Minimum downtime, maximum benefits
The Sitrans FUS880 is a retrofit flowmeter kitideal for use in irrigation systems. Thanksto its simplicity of installation, downtime isminimized, enabling the FUS880 to beginconserving the irrrigation water supply inrecord time.
The meter measures flow by producinga signal proportional to the velocity of the
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benefits of modern irrigation manage-ment. Accuracy and reliability, coupledwith cost-effective performance, give man-agers credible data while minimizing theirmaintenance costs.
Siemens – the right partner for flowmeters
Siemens has 25 years of experience inretrofitting flowmeters on existing pipes,with 10,000 retrofit units now installedworldwide. This unique experience andcapability in retrofit and flow conditionshas led to the development of the SitransFUS880, and the irrigation managementbenefits it provides. �
Selection criteriaB Competitive acquisition cost
B Minimum maintenance
B Static measuring principle with nomoving parts and no risk of blockage
B Simple installation on various pipe types,including concrete, standard PVC,corrugated double-wall PVC and steel
B Suitable for underground installation onexisting pipelines
B Performance unaffected by long periodswithout water flow
B Accuracy of 1–5 percent of actual flow
B Wide dynamic range
B High accuracy with short inlet condition
B Operation independent of line power, if desired
B Low energy consumption
B Operable at temperatures up to 65degrees Celsius
B Communications compatibility enablingdata coordination and control
Optimum Water UsageWhen selecting a flowmeter, irrigation managers look for operating efficiency, accuracy, and reliability as well as protection against waterpenetration. All Siemens Sitrans F flowmeters used in irrigationapplications meet these requirements.
process news 3/2006
17CASE STUDYIrrigation
Installion of the Sitrans FUS880
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process news 3/2006
18Process Analytics
TREND
Hach Lange, a specialist in the field ofwater analytics, and Siemens haveformed an alliance aimed at creating
a leading position in the growing world-wide water and wastewater treatment mar-ket inview of the increasingly competitiveglobal market. The two companies aretherefore in a position to offer the entiresystem, including measuring and controltechnology, as a complete, customizedsolution. Because there is no overlap in thecompanies’ product portfolios, the pro-grams of Hach Lange and Siemens comple-ment each other perfectly.
Interactive technologies
Within the scope of this strategic partner-ship, Siemens has already completed alarge number of projects in cooperationwith Hach Lange, especially in EasternEurope. A current project in Germany is themodernization of the wastewater plant inOberammergau. The town at the foot of theAlps is known not only as a tourist attrac-tion. Twelve percent of the land owned bythe town consists of nature reserves, whichform an essential part of the charminglandscape. The conservation of the land is
a prime interest of the community, and thisconservation effort also includes expensivemeasures for the protection of the town’swaters. For example, the local wastewaterplant, which went into operation in 1960, iscurrently being extensively modernizedto meet environmental protection require-ments, which have grown increasingly strictover the years.
Hach Lange outbid a well-known com-petitor in the invitation to tender for themodernization of the system. The main rea-son was that in cooperation with Siemens,Hach Lange was able to offer a compre-hensive total solution that included therequired liquids analyzers in addition tothe entire process technology. By workingtogether, the two companies offer compre-hensive expertise and a product line thatincludes all the measurement, process,and control technologies, thereby enablingclients to obtain customized total solutionsfrom one source.
Hach Lange supplied the measuring andanalysis technology for monitoring thenitrate and phosphate parameters, the con-ductivity, and the turbidity, as well as thepH value and the proportion of dissolvedoxygen. Calibration-free optical LDO tech-nology with high-precision blue light exci-tation was used for the oxygen measure-ment. Siemens supplied the equipment formeasuring the flow, filling level, pressure
Collaboration in process instrumentation
PerfectPartnershipThe best solutions are found whenever the right experts work togetherand the right partners form a team. As far as water treatment isconcerned, Siemens and Hach Lange are the right partners. The twocompanies complement each other’s expertise and are able to offercustomers comprehensive and customized solutions.
Anne De Greef-Safft, president of Hach Lange:
“The Oberammergau wastewater plant projectis an example of the successful collaborationbetween Siemens and Hach Lange: Siemens asa specialist for flow and level monitoring andHach Lange as a specialist for process water,wastewater and analytics. Both partners offeroptimum products for customers’ applicationsand both offer excellent worldwide consulting,service and support.”H
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19
and external temperature – componentsthat are indispensable for safe automatedprocesses. Like the measuring results ofthe probes from Hach Lange, the signalsfrom the Siemens devices flow via Profibusinto the process automation system withthe Simatic PCS 7 process control system.The commissioning of the system is planned
for October 2006 and the work is now closeto completion. This project shows how thecompetencies of Hach Lange and Siemenscomplement each other. The jointly offeredproduct line covers the entire spectrum ofinstrumentation tasks in water supply anddisposal, providing the customer with acomplete solution. �
Find out more:www.siemens.com/processanalyticswww.hach-lange.deE-mail:[email protected]@hach-lange.de
Sitrans FM MAG 8000 WBattery-Operated Electronic Flowmeter
The Sitrans FM MAG 8000 W battery-operatedflowmeter with a high protection level (typeIP68/Nema 6P) is also suitable for difficult ambientconditions – for example, underground installationor in flood hazard zones. MAG 8000 W, whichcontains no moving, wearable parts and is thereforemaintenance-free, has a typical battery life of sixyears and is used primarily in areas in which a mainsconnection would be too complicated and expensive.
With a built-in infrared interface and two pulse outputs, MAG 8000 W is integrated intoconsumption-metering systems, either wired locally or wirelessly via GSM (global systemfor mobile communications) for Internet applications. The integrated data logger savesconsumption values as well as alarms for unusual events (e.g., values that are too high ortoo low) for up to 26 months. The flowmeter meets the CEN EN 14154 European water-meter standard as well as the OIML R49 international water-meter standard.
The Sitrans FM MAG 8000 W
battery-operated flowmeter
is also suitable for
underground installation
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Analyzing Water,Guaranteeing WaterQuality
Hach Lange is part of the Water QualityGroup of Danaher, a Fortune 500company headquartered in Washington,D.C. The water analytics specialist hasextensive expertise in the analysis ofwastewater, drinking water, andindustrial process water and supplies abroad product portfolio for field,laboratory, and process analysis.This portfolio includes, among otherthings, probes, analysis systems, andcontrollers for measuring the variouscharacteristics of water quality, such asthe following:B nutrient parameters (ammonia,
phosphate, and nitrate)B pH value, conductivity, and dissolved
oxygenB solid parameters (turbidity, sludge
concentration, and sludge level)B salt, chlorine, and ozone contentIn addition to production facilities andresearch and development centers in theUnited States, Europe, and China, thecompany operates in almost everycountry in the world. New operationsand partnerships have emergedespecially in the markets of EasternEurope.
Hac
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The Hach Lange office in Düsseldorf
process news 3/2006
20 CASE STUDY
S ample flows from process analyzersoften used to be released into theatmosphere. This modus operandi is
in many cases no longer possible today,owing to the stricter environmental legis-lation or to the corrosiveness of the sam-ples. In some cases, catalytic combustionmay provide an alternative. However, emis-sions cannot be totally ruled out, and themaintenance effort is relatively high andthe flow volumes limited. Recirculation intoan exhaust gas flare is another possibility.
However, the input pressure is not constantin many cases and may rise to more than 1bar counterpressure, depending on theload, so the measured values may be falsi-fied by these changes.
Solution based on proven standards
The vent-gas unit consisting of provenSiemens standard automation componentsmeets these challenges in a unique way.The vent header pressure is measured witha Sitrans P pressure transmitter that is con-nected to the Sipart DR 19 controller unit.The Sipart DR 19 controls the pump rate bymeans of the Micromaster 410, which setsthe pump rate at such a value that the ventheader pressure remains in the specifiedrange. The set point and actual value of thevent header pressure are shown on a digi-tal display, where the set point can be eas-ily adjusted. Pressure fluctuations in theflare, as well as flow rate fluctuations, canbe effectively controlled with this inte-grated solution. The pump section can bebuilt up as a redundant system to enableservice during operation.
Reliable, low wear and low cost
The vent-gas unit has proven itself innumerous installations. The entire systemhas no moving parts except for the pump,which minimizes maintenance expenses.It has an extraordinarily simple structure,is based on proven standard components,and is easy to install and operate. The oper-ating costs are also low, which in turn hasa positive effect on the profitability of theentire system. �
Maintaining stable vent-gas pressure with process analytics
Optimized Vent-GasRecirculationNot only the analyzer itself, but also the environment in which it is installedplays an important role in the successful operation of process analytics. In addition to complete shelter designs, Siemens also supplies made-to-measure solutions aligned with the overall installation environment.
Find out more:www.siemens.com/processanalyticsE-mail: [email protected]
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Process Instrumentation
The compact vent-gas unit is easy toinstall and offers a low-wear solution
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Frequency-controlled pump drives at DSM Nutritional Products
Efficiently ControlledDSM Nutritional Products introduced a new energy-saving concept at itsproduction facility in the Swiss canton of Wallis, in which large cooling circuitswere equipped with frequency-controlled drives. The new solution not onlyallows for more dynamic control of the system as compared to the previousvalve control, but also helps save costs due to the much lower consumption ofprimary power.
process news 3/2006
21CASE STUDY
Among other things, the Dutch com-pany DSM Nutritional Products AGproduces isophytol, a preproduct of
vitamin E, in its Lalden factory in the Swisscanton of Wallis. To reduce energy costs,DSM chose a modern technological systemfor the process cooling. At the heart of thetwo optimized cooling water systems aretwo redundantly designed pump drives thathandle the continuous heat dissipationthrough the gigantic plate heat exchangersof the two existing circuits.
Expected savings of 70,000 Swiss francs
Previously, fixed-speed pumps with valvecontrol supplied the mass flows for the nec-essary cooling activity. However, throttlingdissipates large amounts of energy in mixedoperation so that efficiency is reduced sig-nificantly. In the course of redesigning thesystem, DSM introduced variable-speedpumps whose mass flow could be adjustedby Micromaster 440 frequency converters.As Christoph Fux, head of electrical engi-neering and automation at the factory,
points out: “With this new type of control,we expect annual power savings in the areaof 70,000 Swiss francs.”
The entire system is monitored from thefactory’s control room, to which the fre-quency converters are linked via ProfibusDP. The Micromaster 440s have six digitalinputs, two analog inputs and a PTC/KTYinput for monitoring the winding temper-ature in the motor. An analog operatingpressure sensor, installed between thesupply and return of the circulating coolingwater, monitors the pressure level. If thepressure falls, the drop in pressure isreported and the frequency converterincreases the pump speed. In the oppositecase, the frequency converter ensures thatthe respective electric motor runs moreslowly.
System approach is part of the service
With the use of the Micromaster 440 fre-quency converters, a new era has begun atDSM in Lalden. Previously, the companyprimarily relied on frequency convertersof the Masterdrive series. “We have hadgood experiences with them for manyyears,” says Fux. The initial results of usingthe Micromaster 440 for simpler applica-tions also look very promising in Fux’sopinion: “So far, we haven’t had any prob-lems .” �
Micromaster 440B Sophisticated vector controlB Controlled start-upB High overload capacityB Evaluation of pulse transmittersB Constant and square torqueB Load torqueB Three switchable drive data recordsB Compound brakingB Integrated brake chopper up to 90 kWB Free function modulesB Four fade frequenciesB Automatic restartB “Capture” motor-conservingB Bus compatibleB PC commissioningB Plug-in control panel
To save energy, the massive cooling water system was equipped with frequency-controlled, 75-kilowatt pump drives
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process news 3/2006
22Partners
TREND
S iemens has been working success-fully with numerous specialist ma-chine manufacturers and system plan-
ners for many years. Together with thesepartners, Siemens develops tailor-made, fu-ture-safe solutions for automation anddrive technology as well as energy distri-bution – for the maximum benefit of endusers all over the world.
Local and global expertise
For the pharmaceutical industry, theSiemens Automation and Drives Compe-tence Center Pharma is working to estab-
lish a dedicated Solution Partner commu-nity for the pharmaceutical industry that isclosely coordinated with the relevant part-ner program modules and the regionalsales organizations. This allows Siemens toprovide even better support to the phar-maceutical industry as it successfully im-plements its projects in cooperation withhighly qualified partners.
The network includes locally operatingSolution Partners who are able to offer theend customer a high degree of flexibilitydue to their concentrated local presence.However, Siemens also works with globally
active Solution Partners who can meet therequirements of global customers in thepharmaceutical industry.
Certification and auditing guaranteeproject quality
The Competence Center Pharma signs con-tracts with selected Solution Partners for ex-tensive and close cooperation. These phar-maceutical industry Solution Partners notonly have access to the wide range of Siemenssystems and products; Siemens also supportsits partners with training measures andother offers so that the partners can receive
Siemens Solution Partner program for the pharmaceutical industry
Partners in PharmaceuticalsIn order to provide its customers in the pharmaceutical industry worldwide optimum support for automation andprocess optimization solutions, Siemens exploits the expertise and local presence of specially certified and qualifiedpartners who guarantee a high level of project management and engineering quality in their specific solutions forthe pharmaceutical industry.
process news 3/2006
continuous advanced training with regardto systems and industry requirements.
Through intensive cooperation on proj-ect handling, system design, and valida-tion, successful project execution in com-pliance with the valid GxP guidelines is en-sured. Siemens also guarantees the high
quality of its partners through regular cer-tification of their employees, services andproduct development processes.
This is particularly important in view ofGAMP 4, which requires pharmaceuticalcompanies to ensure the quality of theirsuppliers in order to be able to guarantee
that automation systems meet all relevanttechnical, commercial and legal require-ments. This is done, for example, by per-forming supplier audits. By auditing andcertifying its partners, Siemens works toactively build a technology network thatnot only has the necessary expertise, butthat is also able to meet the quality expec-tations of pharmaceutical customers. At thesame time, the pharmaceutical industry So-lution Partners are optimally prepared forsupplier audits carried out by pharmaceu-tical customers.
Committed to the pharmaceuticalindustry
The Siemens Pharma Competence Centerpursues the aim of identifying the best part-ners for customers in the pharmaceuticalindustry – partners who take their projectresponsibility seriously and complete endcustomers’ project plans successfully. �
AGU Planungsgesellschaft mbHbecomes the first SolutionPartner Pharmaceutical Industry
On August 24, AGU Planungsgesellschaft mbH from
Leverkusen signed a partnership contract with the
North Rhine Sales Region and the A&D Competence
Center Pharma in Karlsruhe, becoming the first
certified Siemens Solution Partner for the
pharmaceutical industry.
The contract crowns a long, successful partnership
between AGU Planungsgesellschaft mbH and Siemens
and at the same time creates incentives for continuing
the collaboration. The goals of the partnership are
coordinated with the management of selected
customers in the region, common development in
technical areas such as migration solutions, and the
Siemens Solution Partner Compas automatizace successfulin biotech production
Compas automatizace, a leading Czech engineering companyfocusing on the automation of production processes as well asMES solutions, has been a Siemens Solution Provider since 2004.In the upcoming months, the company will also be signing acontract as a Siemens Solution Partner Pharmaceutical Industry.
The company was founded in 1990. With a staff of about 70,Compas automatizace develops solutions for the electricalequipment and automation of industrial production plants andhandles validation of the systems in accordance with GMP (GoodManufacturing Practice). An example of the project expertise ofthe company can be found in a new biotechnology plant ofLonza Biotech in Kourim in the Czech Republic. The client, whichbelongs to the Swiss Lonza Group, decided to expand itsbiotechnology capacity at Kourim with the construction of a newplant on the existing premises.
Good teamwork and flexible systems
Close cooperation between Compas specialists and Siemensexperts was of paramount importance to the success of theproject, particularly with regard to finding a flexible solution to
meet all of the requirements relating to the design andimplementation of the control system. The solution developed byCompas automatizace uses the Simatic PCS7 process controlsystem with Simatic Batch to control the complex batchprocesses. Different products can be manufactured with variousrecipes on the same line, and the operators can usually set thenecessary values freely, or in some cases, also select directmanual control. Two lines with 4,500 I/O were implemented inthe first stage, and plans call for the eventual implementation ofabout 10,000 I/O.
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First Solution PartnerPharmaceutical Industry: AGU Planungsgesellschaft mbH
The Lonza biotech plant in Kourim, Czech Republic
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process news 3/2006
24 CASE STUDYWeighing Technology
ent spice varieties in a three-shift operation, was equippedwith a modern, automaticdosing device last year.Since some products requireonly two hours, while othersrequire a few days to pro-duce, all of the systems aredesigned to allow for quickconversion. “We chose themodule technology because
it enables variable application of bothscales on all sifting machines,” as HaraldSchischeg, head of control engineeringat Raps, points out. In addition to offer-ing mobility, the solution had to be inte-grated into the control, designed assimply as possible, as well as enable cali-bration. The Raps spice factories expectsthat customers will want to see theweighing logs for their deliveries. There-fore, the company has also made archiv-ing and recording a criterion for thefilling.
Flexibility is the key
Since customer demand in this area hasbeen particularly strong in recent years,demands on the filling process have alsorisen. Raps supplies precisely the packagesizes the various manufacturers requirefor their production. Manual weighingprocesses are no longer necessary, and er-rors have been reduced to an absoluteminimum.
The filling plant in factory III, where thecompany produces more than 100 differ-
R aps produces morethan 4,000 differentspice mixtures and
spice-related products forthe meat and food industry,as well as for the wholesalegastronomy industry in itsfour spice factories in Kulm-bach. Coated raw materials,known as “Coatec,” are one ofthe specialties of the house.Thanks to a protective film, the powdersand crystals remain pourable, and do notbecome lumpy. Coating products are alsoof great interest for another market: name-ly, for use in marinated steaks such asthose offered in butcher shops and super-markets, especially during the barbecueseason. Since every single grain of salt inthe marinade is coated with a fine film ofgrease, the salt is prevented from drawingwater from the meat. As a result, the meatquality remains intact over long marinat-ing times.
Siwarex sets new standards for weighingterminals in spice factory
Clean andTastyRaps, one of the leading European spice producers, has
combined an electronic weighing module with a load cell for
its new, flexible dosing stations which requires no adjustment,
has virtually no dirty edges, and which enables a variable plat-
form size. The functional weighing terminal fully meets the
high demands of food producing companies in every respect.
Competitively priced versatility
Harald Schischeg was very impressed withthe presentation of a new weighing moduleat Siemens. “As far as the electronics areconcerned, the Siwarex FTA weighing mod-ule offers a lot of advantages. We can use itas a controller module in the distributedperiphery.
Since the weighing module is a S7-300component, we do not need any additionalinterfaces either. Siwarex FTA also providesall of the weighing modes we need. In ad-dition, the entire process, including thecontroller and Touch Panel TP 170B, canalso be calibrated for legal-for-trade scales.”
Adding to the appeal of the solution isthe fact that complete calibration and pa-rameterization can be variably performedeither over the software, the programmingdevice or with the help of the touch panel.The in-house control technology suppliedeverything that was needed for the mobileweighing terminals at low cost and from a
single source, including everything fromthe design and the development to the soft-ware and hardware.
Various challenges had to be overcomein the process. Every scale, for example,has to “know” which sifting machine it islinked to at any given time, and both dos-ing stations must be able to communicatewith all of the four sieving machines.
Also, tampering with the calibration dis-play must be prevented at all costs. HaraldSchischeg solved the complexity of the PLCprogram for the internal data flow with thehelp of coded, multifunctional Profibusplugs.
The Profibus link is also one of the ad-vantages of the implemented weighingmodule. The cable transfers the data to theSimatic ET 200M station. From there, theygo directly to the Touch Panel. Everythingis also prepared for activating the archivingand recording. The specialists at Raps haveto change only a single bit in the controllerprogramming.
An amazingly simple solution
The features of the Siwarex solution are ide-ally suited for the high hygiene standards ofRaps, says Harald Schischeg: “In general,platform scales are very difficult to clean. The652 platform cell typ consists only of a singlepiece of metal with a single external cable. Ithas a thread at the top and bottom so that aholder can be mounted on the bottom, and anappropriate plate on the top.” Since Siemensalready specified the center of gravity of theSiwarex weighing system in advance, alongwith the maximum plate size, the correctbasic loads are already ensured. The scalesplatform can therefore also be adapted opti-mally to the standard box sizes. The completeweighing terminal consists of one weighingsensor, one plate and a central display, andmeets all hygiene requirements. �
process news 3/2006
The weighing system can becalibrated and parameterizedvia software, programmingdevice or touch panel
Mobile weighing terminals forvarious siftings systems offer
a high level of flexibilityduring product filling. The
scale communicates with theSimatic ET200 station viaProfibus, and from there
directly with the touch panel.The entire weighing process
is calibratable and tamperproof – a decisive advantage
of the Siwarex FTA solution
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process news 3/2006
26Manufacturing Execution Systems
CASE STUDY
R eagens Canada, a Royal Group Com-pany, specializes in PVC stabilizers andadditives used to manufacturer fin-
ished goods. The company, which grew outof a joint venture with an Italian-based sup-plier, sought to shorten its supply chain linkbetween raw materials coming from Italyand its production plants in Canada. Witha mandate from top management at RoyalGroup, Reagens Canada turned to Siemensfor assistance in implementing an improvedautomation control system for its rapidly ex-panding chemical processing business.
Siemens had already proven its merits asa competent supplier of a Siemens control
architecture and Simatic IT Historian infor-mation platform at the Reagens Canadaplant. Thus, it was a natural choice for theaddition of an automation solution withcritical plant modeling capabilities and amanufacturing execution system (MES)functionality to provide overall real-timevisibility of all operations.
Expansions result in new information challenges
Rapidly growing market demand promptedRoyal Group to acquire Reagens Canada,converting the company from a warehous-ing operation into a chemical processing
production facility. In a later expansionmove, another plant for compounding ma-terials into PVC pellets used in the extrusionof final products was added. Today, ReagensCanada processes over 500 different batchrecipes for the broad Royal Group globalproduct portfolio. Expansion plans also fo-cused on technology upgrades to enable thecompany to better manage the increasingmaterial flow volumes and production com-plexity across the enterprise.
Consequently, manually managing allof the recipes and the scheduling and se-quencing of production had simply becomeoverwhelming. There was no easy way to
Simatic IT at Canadian chemical plant
New EfficienciesIn an effort to gain better control over its rapidly expanding chemicalprocessing business, Reagens Canada turned to Siemens as a long-trusted automation partner. At present, Reagens Canada is well intothe initial Simatic IT implementation phase, and is already seeingfirst significant results.
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Overall benefits:B Reduced errorsB Better material managementB Increased throughput B Improved safety due to higher visibility
to capacity of silos and the proper mixing of ingredients
B Reduced downtime B Better management reporting of
production status B Enhanced material visibility, netting
improved efficiency and reliabilityin purchasing
B Improved sequencing of productionorders throughout the plant
Reagens CanadaRoyal Group Technologies is a leadingglobal manufacturer of polymer-basedconsumer, home improvement andconstruction products, providing con-sumers and businesses with a broadarray of products, from vinyl housewares and furniture to windows anddoors, construction products and build-ing systems. Highly vertically integratedwith companies under its corporateumbrella, the Ontario, Canada-basedenterprise controls everything from rawmaterials to finished goods in numerousindustry segments. Its vertical approachto the market is viewed as strategic tothe successful development and rapiddelivery of products to customers.Annual turnover in 2005 topped $1.7billion Canadian.
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27
The production lines send productiondata to the ERP and inventory system
accurately track the production status, theconsumption of raw materials, the outputof production lines, or to know what re-sources were available for starting new or-ders. Errors and inefficiencies were costly.As a result, real-time visibility of inventoryand operations was absolutely imperative.
Simatic IT helps gain significantbenefits in production
The Simatic IT Production Suite proved anoptimal solution. With Simatic IT, the plantmanager is always aware of order status,resources availability and plant capacity.Recipes can be brought online and areavailable to operators in real time. Raw ma-terial consumption is precise, based on ac-tual usage and yield, rather than rough av-eraging calculation based on order sizes.Reagens Canada is well into the initial phaseof the implementation and is already see-ing significant results. Reagens plans toevaluate adding additional Simatic IT com-ponents once this phase is complete.
On one line in one of the older plants, atest pilot compared output on a mixer usingSimatic IT Production Suite versus out-put on another mixer using the tradi-tional manual methods. The output for theSiemens managed mixer proved twice thatof the other.
Reagens interfaces Simatic IT with theERP to provide real-time inventory manage-ment. “We can give customers much morereliable information on the status of theirorders this way. Managers have better visi-bility to maintenance histories, so we canschedule preventive maintenance better,check each machine’s maintenance history,order spare parts efficiently, and manage pro-duction better since we know the availabil-ity of specific machines”, Reagens stated.
Sales people now also have the ability“to check inventory or to check productionschedules so they can guarantee deliverymore precisely,” down to the point of check-ing availability of raw materials. “Everytime we take an order, we can tell when weneed something and how much, and we canautomatically ensure that we have the mate-rial in the right place when we need it.” �
Simatic IT also integrates informationfrom the batch control system
All vital utilities, such as the hot-oilfurnace, are integrated into the Simatic ITsystem and the maintenance system
“Our operation covers everythingfrom the very harsh, quarry-likeconditions during the delivery andcleaning of the beets to the pointwhere the sugar is packaged as a purefood product,” as Heinz Nufer, who isin charge of the electrical equipmentat Aarberg, describes the broadspectrum a sugar production covers.Together with his colleagues in theprocess control technology depart-ment, he managed to upgrade andautomate the plant in a series of steps.The upgrade brought with it manyadvantages: improved productionreliability, greater convenience for theoperating personnel as well as higherproduction standards.
The Aarberg factory was first auto-mated over 20 years ago with a Tele-perm M-type process control system.
At that time, however, only in the frontoperation and the sugar house. The out-door area continued to be operated withthe help of conventional relay technologyall the way up to the year 2000. This area isnow also fully automated with a SimaticPCS 7 control system. The convenience ofthe operation has increased considerably.“Previously, the operating staff had to controlthe outdoor area with a control panel approxi-mately six meters wide,” as Max Specht and
Andreas Schiegg from the process controltechnology department recall.
“Today, the staff can perform the tasksitting comfortably at their PCs.” The mod-ern distributed client-server architecture ofthe control system also enables setup of anynumber of operating stations. This has theadvantage that the respective system sec-
tion can be monitored from another controlroom during maintenance work.
“We design, implement and maintainthe entire control system ourselves, boththe Teleperm M and the PCS 7,” as AndreasSchiegg explains. Thus, there is no needfor an external integrator. He and his col-leagues acquired the necessary know-how
Sachets – single sugarportions packed in small
paper bags – are becomingincreasingly more popular
in the consumer market
Simatic PCS 7 installed inthe outdoor area of theAarberg sugar factory
Sugar“On the
Ball”
process news 3/2006
28Sugar Industry
CASE STUDY
Aarberg and Frauenfeld AG sugar factories
After the upgrade,the outdoor areawas alsointegrated intoSimatic PCS 7
The factory in Aarberg started productionin 1913, and the Frauenfeld factory tookup operations 50 years later. Together,they handle the entire sugar productionin Switzerland of approximately 200,000tons annually. The products includecrystal sugar, loose or in sacks, molassesand shredded beets. Biologically refinedsugar is also produced in Frauenfeld,while at Aarberg, gelling sugar, cubes andsachets are produced for the consumermarket. The three factory silos can storeup to 60,000 tons of sugar. Approxi-mately 80 percent of the Aarberg sugargoes to large-scale consumers such asbeverage or chocolate industryoperations.
During the three-month “campaign,” inother words, the harvest and productiontime, 8,500 tons of sugar beets per dayare delivered to the Aarberg sugar fac-tory. Two-thirds of the beets are directlyprocessed into crystal sugar, one-third isstored as a syrup. The sugar beets aredelivered, weighed, tested for their sugar
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troller each is used to convert the protocolsaccordingly.
Higher production standards
The higher production standards achievedat Aarberg through the modernization areespecially important given the fact that thesugar factory is certified according to stan-dards of the British Retail Consortium (BRC).
themselves as well as by attending Siemenstraining courses.
Distributed intelligence
But Andreas Schiegg also finds the tech-nology itself very accommodating. He cancarry out engineering at a high level with-out having to trouble himself too muchwith the computer details. As a specialistwho is very familiar with the processes inthe sugar factory, he can concentrate onwhat is important, and combine individualmodules in a logical system adapted to hisneeds.
The system architecture at Aarberg isbased on an intelligent periphery. SimaticS7-400 controllers handle the local signalprocessing. The control system, for exam-ple, sends a command to the S7-400 unitsto move to a specific position or to monitora rotational speed. The controller processesthe command as an object and reports backthe status or any errors. The local controllerand the control system therefore commu-nicate with the help of a standardized pro-tocol.
Two generations in agreement
Over time, Andreas Schiegg, Max Spechtand their colleagues managed to sustain-ably automate the entire control technol-ogy of the operation. The outdoor areawas newly automated, for instance, usingSimatic PCS 7 technology. The sugar trans-port system is an exception. Here, thechoice was made to go with a direct migra-tion from the Teleperm M control systemto PCS 7. Thus, only system components ofthe PCS 7 family were used for the upgradewhile offering the option of continuing touse Teleperm M I/O units. “We also upgradedhere and there within Teleperm M,” An-dreas Schiegg recalls. The existing AS 220and 235 automation systems were migratedto the AS 488/TM module. As a result, theproven functionality of the old system wasable to be retained, “and, at the same time,a whole new world of IT technology becameavailable to us,” the specialist adds.
But what if the two generations conflictwith one another? According to AndreasSchiegg, there are but a few signals thatare transmitted between Teleperm M andPCS 7, “because we made certain to auto-mate the individual production areas eithercompletely with the more modern PCS 7 gen-eration, or to leave them on Teleperm M.”Wherever connecting points exist, one con-
content (16 to 18 percent) and washed inthe outdoor area. Limestones used forcleaning the raw juice are also fired therein lime kilns.
In the so-called front operation, hotwater is used to extract the sugar from theshredded beets. The raw juice is cleanedby precipitating the foreign ingredientsusing milk lime and then filtering it. Thinjuice is thereby produced which is steampressurized until it has a sugar content of65 percent, and which can then be storedin tanks without the threat of sponta-neous crystallization.
This syrup is injected with an alcohol-sugar dust suspension in the sugar houseand cooked in a vacuum at 78 degreesCelsius. The sugar crystallizes and is thenseparated from the syrup in a centrifuge.The brownish syrup is then injected asecond time and processed into rawbrown sugar. The last discharge, themolasses, is no longer suitable for sugarproduction. It is used for making bakingyeast and as a component for animal feed.
The standards, for example, require man-ufacturing data be available for review at alltimes – a demand which is easily met withSimatic PCS 7. �
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process news 3/2006
30Training
TECHNOLOGY
The fully operational automation sys-tem was designed by a Siemens teamin Karlsruhe, Germany. It is intended
to teach process control technology and sys-tem environment knowledge in an authen-tic environment. Two “real-life” productscan be manufactured with the training sys-tem: Smarties sweets and suntan lotion.
Real technology in a real process
The TIA training system consists of eightfully functional, individual modules thatcan be networked either as two subsystems,or as a single system. In the first four mod-ules, Smarties are filled, tested and stored,while modules five to eight are responsiblefor the manufacturing, filling and storageof the suntan lotion. Instead of a bare-bones laboratory environment, trainees are
able to experience a varied and real-life pro-cess scenario using real-life equipment andcomponents. The two subsystems are con-trolled by eight Simatic S7-400 controllers.In addition to the low-voltage switching tech-nology and Simodrive servo motors, a wholerange of filling-level, flow and pressure meas-uring instruments are employed, which arelinked via Profibus PA and the Simatic ET200M distributed periphery, as well as byvarious position and process controllers.The system is operated and configured withthe help of a Simatic PCS 7 process controlsystem.
A future-oriented project gains momentum
To make the benefits of the project availableto a broader audience, the real-life system is
simulated virtually with all of the technicalcontrol and regulating functions using theSimit simulation platform. The trainingsystem will be further expanded to ensurethat ideal training conditions will also beavailable in the future. The next step, theimplementation of Simatic Batch function-ality, is already being implemented. MESlinks are also planned, as is a Web link forthe training system and virtual model.
The new TIA training system is not onlyof interest to trainees, interns and stu-dents. It also provides new training oppor-tunities for internal and external cus-tomers. Siemens has already receivedinquiries for Simatic PCS 7 system upgradecourses on the system from promoters andengineering consultants. Gradual intro-duction of other training locations with sim-ilar systems, integrated into the Siemenstraining program, are also currently beingplanned. �
With its uniform, integrated automation platform, Totally IntegratedAutomation (TIA), Siemens prepares production systems in all industry sectorsfor current market demands and for the future. The same applies to trainers,trainees and students: the future-oriented TIA concept was implemented forthe first time in an actual training system that permits hands-on demonstrationof the full range of capabilities TIA offers.
An entire factory in miniature: suntan lotion is produced under real-life conditions with this subsystem
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Fairs and tradeshows all over the world
During the final months of 2006, several major trade fairs andevents will showcase the latest trends and developments, attract-ing visitors from all over the world. Solutions for the pharma-ceutical industry will be presented at the ChinaPharm and thePack Expo International, while the BRAU Beviale will presenttrends and solutions for the food and beverage industry. Finally,the SPS/IPC/DRIVES is one of the most important industry fairs forautomation and drive technology. Naturally, Siemens will also bepresent at all these events to display and demonstrate its products,systems and solutions expertise.
Pack Expo International 2006Chicago, October 29–November 2, 2006
ChinaPharm 2006Beijing, November 7–10, 2006
World Drugs Summit 2006Berlin, November 13–14, 2006
BRAU Beviale 2006Nuremberg, November 15–17, 2006
SPS/IPC/DRIVES 2006Nuremberg, November 28–30, 2006
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
events
www.siemens.com/processnewsHere you can download the current issue and past issues ofProcess News in PDF format, or search directly for articles aboutspecific topics, technologies or systems in the Reference Center.
events
31DIALOGUE
process news 3-06PublisherSiemens Aktiengesellschaft,Bereich Automation and Drives (A&D), Gleiwitzer Str. 555, 90475 NurembergGermany
www.siemens.de/automation
Group Executive Management Helmut Gierse, Hannes Apitzsch, Dr. Peter Drexel, Anton S. Huber
Responsible for ContentPeter Miodek
Responsible for Technical ContentCornelia Dürrfeld
Editorial CommitteeAlexandre Bouriant, Sigrun Ebert-Heffels, Michael Gilluck, Birgit Gottsauner, Walter Huber,Keiren Lake, Bernd Langhans, Bernd Lehmann,Silvana Rau, Rüdiger Selig, Roland Wieser, Wolfgang Wilcke
This edition was printed on environ-mentally-friendly chlorine-free paper.
ISSN 1430-2292 (Print)
The following products are registered trademarks of Siemens AG:ET 200, MICROMASTER, SIMATIC, S7-300, S7-400, PCS 7, SIMATIC IT, SIMOVERT, SIPART, SITRANS, SIWAREX, TELEPERM,TOTALLY INTEGRATED AUTOMATION, WinCC
If trademarks, trade names, technicalsolutions or similar are not listed above,this does not imply that they are notregistered.
The information provided in this magazinecontains merely general descriptions or characteristics of performance whichin case of actual use do not always applyas described or which may change as a result of further development of theproducts. An obligation to provide therespective characteristics shall only existif expressly agreed in the terms of contract.
Order No.: E20001-M6306-B100-X-7600
Printed in Germany
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