industrial aerogel production - industry - siemens
TRANSCRIPT
Systems and Solutions for the Process Industry
processnews
1st edition April 2|2003
s
Schering-Ploughand Siemens team up forproductionretrofit
Innovations inprocess analytics
First of its Kind:IndustrialAerogel Production
6 10
Feature article: Aerogels are exceptionallygood insulators and can be used for buildingtranslucent roofs – like the one shown in thispicture. In Frankfurt, Cabot produces Aerogelson an industrial scale in a first-of-its-kind plant
Using a new process controlsystem, Cytec was able todrastically improve productquality in their Mobile plant
Siemens offers a dedicated drivesand motors portfolio that covers awide range of applications in theprocess industry
CONTENT2
process news 2/2003
procen
3 EDITORIAL
4 NEWS
Significant reference project at Jilin Fuel Ethanol in China
Boosting Performance in Indonesian Gas Pipeline
Calomat 6 awarded prize by research center
Lloyd’s Register Approves Products for Marine Applications
CASE STUDIES
Aerogels6 First of its Kind
Production by Cabot
Specialty Chemicals10 Batch Done Right
Cytec Industries increased output with Batch Manager
Life Science14 A Winning Team
Siemens Ireland is a reliable partner in upgradingSchering-Plough's multi purpose facility
Chemical Industry20 Economic Innovation
Migration project from Teleperm M to PCS 7 at Wacker
Chemical Industry21 Comprehensive Solution
Siemens installs analysis systems at Dow Stade
Chemical Industry24 Premiere in Egypt
Simatic PCS 7 in CMC production
Chemical Industry25 A Database for Production
Integrated process control and data managementsystem at Akzo Nobel in Singapore
ACHEMA NEWS
Process Analytics12 Total Analytics Solutions
Innovations in process analytics at Achema
Cover, source: Focus, Peter MenzelHighly insulating aerogel
18 20
Dear readers,the rigorous requirements of the chemical andpharmaceutical industriesdemand partners with anextensive knowledge ofcustomer processes and the
necessary technical know-how. With expertise in bothprocess technology and automation engineering,Siemens offers a unique blend of competencies tomeet these requirements.
Industry solutions from Siemens range from singleindividual solutions to standard solutions for machineand plant building, systems integrators, andmanufacturers of chemical and pharmaceuticalproducts.
Naturally, the knowledge we acquire about ourcustomers’ requirements is continuously employed in the development of new products. Siemens hastherefore chosen the motto “Better together – fromprocess development to operation” for its presentationof products, systems, and solutions at this year’sAchema fair, which will be held May 19–24, 2003, in Frankfurt, Germany.
You will find a variety of new products in the fields of level monitoring technology, process analytics, anddrive technology at the booth. In the focus, of course,is our Simatic PCS 7 process control system with itsnew functions.
With our Totally Integrated Automation platform wehave furthered the horizontal integration ofproduction plants, and with the Simatic IT Frameworkwe are now accelerating the vertical integration andenabling close cooperation between planning andproduction.
Greater productivity, shorter time-to-market, betterquality, higher plant availability, and better assetmanagement – we understand what the processindustry needs.
The Industry Suites from Siemens show the wholerange of products, systems, services, and know-howthat we offer, along with the ways in which wesupport our customers throughout the life cycle of aplant.
Visit us at our booth in hall 10.2 and see our newproducts, systems and solutions for yourselves.
Hans Georg KumpfmüllerPresident of Process Instrumentation and Analytics Division
In their pilot plant, Wacker PolymerSystems is relying on Simatic PCS 7for controlling product developmentprocesses
3
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essnews
Level Monitoring16 A New Level
Siemens introduces remote monitoring conceptvia Internet and new monitoring devices
Drive Technology18 The Safer Side
Drive solutions for the chemical industry
Process Control Technology19 Even More PCS 7
Simatic PCS 7 further expands its scope of functions
TECHNOLOGY
Process Control22 ”We Too Can Learn From Siemens”
Comparison of fieldbus and control systems at Infraserv Höchst
TRENDS
Service and Support26 Time is Money
Services for operation, maintenance, and modernization
27 DIALOGUE
EDITORIAL
Indonesia is known as one of the biggestgas suppliers in the world. The 540-Kilo-
meter long Gas Transmission Pipeline in Su-matera Island, owned by Indonesia StateGas Company (PGN), was constructed inearly 1996 to transmit the gas from Jambiarea to Duri. There PT. Caltex Pacific Indo-nesia utilizes the gas as the fuel to genera-te steam for their Duri Steam Flood project.PGN sees increasing gas demand in the fu-ture required by Caltex; that is why they arebuilding a new Gas Booster station to incre-ase the transmission pressure in the pipeli-ne. Siemens will supply and install the ent-ire control system technology for the new
Boosting Performancein Indonesian GasPipeline
process news 2/2003
4 NEWS
W ith a convincing concept, Siemenswas able to beat off fierce competi-
tion and persuade a key customer in Chinato automate with the Simatic PCS 7 processcontrol system. The Jilin Fuel Ethanol Co.Ltd., a subsidiary of the China National Pe-troleum Corporation, is equipping a new
plant with the Siemens process controlsystem. The plant, which produces
ethanol from corn, has a capacityof about 600,000 tons of etha-
nol per year. It was not onlythe smooth integration
of the safety technology, the great open-ness of the system, and the excellent pri-ce/performance ratio of the concept but al-so the good groundwork of the Siemensproject team that tipped the balance in fa-vor of the PCS 7.The entire system, which includes a total of9,000 I/O points, is controlled from twoPCS 7 control rooms. Eight high-availabi-lity PCS 7 automation systems and aredundant optical industrial Ether-net ring form the reliable back-bone of the control system,
Significant reference project at Jilin Fuel Ethanol in China
The new GasBooster Station
will improve gastransmission
through PGN’spipeline
which is also equipped with a realtime-ca-pable production monitoring system. In ad-dition, a redundant OS server, seven OSmulti-clients, and two single OS stationsare installed in Jilin. The engineering and
commissioning will be perfor-med by Siemens Industri-
al Automation Ltd. inShanghai. ■
gas booster station, including SCADA ex-tensions, emergency shutdown and fire &gas detection systems. The system compri-ses a total of 1200 I/O points. ■
process news 2/2003
5
Calomat 6 awarded prize by research center
T he IRSID Institute in Metz, Lorraine, isthe premier European research center
in the field of iron and steel. IRSID recentlyconducted an assessment of various ther-mal conductivity gas analyzers for hydro-gen measurement in this industry.At the end of the six-month test phase, theCalomat 6 analyzer emerged with the bestresults of all the instruments in the compa-rison. The analyzer demonstrates good line-arity and long-term stability, excellent re-producibility of measured values, and very
The Calomat 6 is exceptionallywell suited for the iron andsteel industry, as the IRSIDresearch center confirms
short response times. It shows very low in-fluence of the measuring gas flow in therange of 40 to 90 liters per hour and insen-sitivity to fluctuating ambient temperatu-res. The Calomat also exhibits no hysteresiseffects and is exceptionally easy to handle.The conclusions of the testers: Calomat 6 isabsolutely appropriate for industrial appli-cations and is ideally suited for measure-ments on blast furnaces in the steel indus-try, for monitoring coke oven gas, and forheat-treatment ovens. ■
Siemens level monito-ring devices are now
approved for use inmarine applications
like this FPSO vessel(Floating Production,Storage, Offloading)
Lloyd’s Register Approves Products for Marine Applications
L loyd’s Register of Shipping has issuedapproval certificates for Siemens ultra-
sonic level monitoring systems. This appro-val meets customer requirements for use inmarine, offshore, heavy industrial, chemi-cal and petrochemical tank storage ap-plications as outlined in Lloyd’s environ-mental categories ENV1, ENV2, ENV3, andENV5.Approved products include Echomax XRSand XPS transducers, as well as AiRangerXPL, DPL Plus, and SPL electronic monitors.These products have been tested and meetthe requirements of the Lloyd’s Register Ap-proval System.
In addition, the Siemens facility in Breda,The Netherlands, has received a BureauVeritas Marine Project Approval that com-plements its existing ISO 9001 registrationfrom the Bureau Veritas Quality Internatio-nal B.V. This recognizes the quality systemof this location to coordinate marine andrelated projects.Other Siemens products that have theLloyd’s Register certificate include SitransLC 500 and Sitrans LC 300 level monitoringinstruments; Pointek CLS 100, 200 and 300point level devices; Sitrans LR 300 radar; Sitrans P pressure transmitter and SipartPS 2 positioners. ■
process news 2/2003
6 CASE STUDY
C abot Corporation’s acquisition of theAerogel Research Division of Aven-tis Research & Technologies in 1998
was an important milestone in the expan-sion of their nanogel division. The U.S.company secured the rights to a patentedmethod for the manufacture of aerogelson an industrial scale. Cabot also used a pi-lot plant where the process had alreadybeen tested on a laboratory scale andwhere first samples had been produced.
The Siemens Axiva team, at that timestill part of Hoechst AG, had developed themethod starting with its initial conceptionin the early 1990s, and Cabot wanted totake advantage of this know-how. SiemensAxiva therefore continued to develop theprocess after 1998 – which recommendedthem as a competent partner for furtherdeveloping the process all the way to full-scale industrial production.
But before industrial production, theexisting process had to be optimized on atechnical laboratory scale and adapted tothe requirements of the potential market.Applying integrated process development(IPD), Siemens Axiva can support suchprojects with a wide range of services.Cabot also benefited enormously fromthis integrated solution during the deci-sive phase of process development.
Starting with demands that Cabot madeon the product, Siemens Axiva first pro-duced samples in the pilot plant thatCabot evaluated and made partially avail-able to potential aerogel customers fortest purposes. These results were then fedback into process development and usedfor the further development of the pro-cess and of new optimized product sam-ples. After the first promising studies,Cabot then decided to pursue the next
step toward industrial production, erect-ing a semi-works plant with a capacity ofabout 1,000 tons per year.
Simultaneous engineering and processdevelopment
Official efforts to build the semi-worksplant on the Hoechst Industrial Park be-gan with the signing of the contract onJanuary 30, 2001. In this project, SiemensAxiva was able to demonstrate its tradi-tional expertise in the development, con-ception and building of so-called “first ofits kind” plants.
Siemens Axiva optimized the actualprocess further during the plant’s engi-neering and erection. This of course alsohad effects on the engineering processand construction already underway at thesite. At the same time Siemens Axiva hadto scale up the process from pilot scale tothat of the semi-works plant and also hadto convert from batch to continuous oper-ation. As a general contractor, SiemensAxiva was responsible for all units in this
Process expertise and automation technology – a perfect match in Cabot’s new aerogel production
First of its KindThe new aerogel plant of Cabot Nanogel is the first of its kind using aninnovative, cost-effective production process on an industrial scale.Siemens Axiva not only developed the process but also took over responsi-bility as general planner for the engineering, procurement and construc-tion of the new semi-works plant at the Industriepark Hoechst IndustrialComplex in Frankfurt, Germany. Siemens Axiva did the engineering for allcivil work, mechanical equipment, piping and also the total electrical,instrumentation and automation (EI&A) of the plant.
Aerogels
process news 2/2003
7
project – from civil work to mechanicalequipment, piping to EI&A.
To save time, Cabot chose to reactivatean old, shut-down plant and building onthe Industriepark Hoechst IndustrialComplex instead of constructing a grassroots plant. Siemens Axiva worked closelywith Cabot’s project leader, Eldor Classen,during engineering of the semi-worksplant to realize and erect the plant as fastas possible.
The Siemens Axiva project team, head-ed by Herbert Eidkum, put in a total ofabout 60,000 hours for the engineeringand supervision of all activities. In thefirst few months, the team gutted thebuilding on the Hoechst Industrial Parkand prepared it for the installation ofthe new equipment. Then they in-stalled the hardware – masonryand concrete, steel works, me-chanical equipment, piping,and EI&A equipment – andconfigured and installed theentire DCS.
Tough competition for everypurchase order
For this project, Cabot andSiemens Axiva followedan open book procedurefor the total invest-ment: Siemens
Axiva placed allpurchase orders,
but Cabot reservedthe right on every or-
der to examine the bidsand Siemens Axiva’s recom-
mendations and made the finaldecision on the contract award.As a result of the collaboration,
Siemens was able to convince Cabot ofthe value of its products and solutions for
several subprojects. For instance, Cabotchose the Siemens Simatic PCS 7 processcontrol system for the very first time.Siemens was also able to get the orders forlow-voltage switchgear including the vari-able frequency drives as well as the entirebuilding technology, including the accesscontrol systems.
Construction of the plant requiredamong other things installation of about250 pieces of new mechanical equipment,8 miles of pipes, and installation and inte-gration in the control system of about 100drives and 1,000 sensors and actuators.
A thin block of aerogelis deflecting the heatof a blowtorch
Foto
: Foc
us,
Pet
er M
enze
l
The Siemens team configured the DCSin two stages to save valuable time. Firstall instrumentation loops were configuredand were installed at site with the com-plete hardware by the first handover date,so that loop checks could take place in theplant. Then they implemented the basicand batch functions and the complete sys-tem software was loaded and updated justbefore mechanical completion and finalhandover of the total plant to Cabot.
Tight schedules met
Good cooperation between all involvedteams guaranteed that an ambitiousschedule of just 15 months up to mechan-ical completion could be met – althoughparallel ongoing process developmentand resulting improvements were simul-taneously integrated in work on site. De-spite all this, Siemens Axiva handed overthe completed plant at the end of April2002 – one week earlier than planned.
ect, with all its challenges, successfully.”After mechanical completion and han-dover of the plant in April 2002, the first“real” aerogel was produced at the semi-works Plant in Frankfurt in September2002. Cabot’s goal now is to gather experi-ence with the semi-works plant and to fur-ther optimize the process. In the mean-time, Cabot is planning a large-scale plantwith a capacity of 10,000 tons a year – andafter successful commissioning of the se-mi-works plant, Siemens Axiva has a goodchance of winning this contract. ■
Dr. Jürgen Hess (Key Account Cabot),Siemens Axiva FrankfurtE-Mail: [email protected]
8 CASE STUDY
Siemens Axiva made a major contribu-tion to all stages of the project – fromprocess development right to construc-tion – and is rightly very proud of the newplant. Moreover, Siemens was able toprove once again that close networking ofknow-how in process technology and inengineering and plant construction atSiemens Axiva with Siemens automationand solution concepts is an enormoustime and cost advantage.
The right way
The plant’s fast and problem-free comple-tion greatly impressed Torsten Lahrs ofCabot: “Because process development,plant construction, and configuration ofthe control system all came from the samesource, so to speak, communication be-tween the teams involved was exemplary.And the immense know-how of the engi-neering staff on site and in process devel-opment enabled us to complete the proj-
A new drying process makes industry-scale production of aerogels feasible
process news 2/2003
Aerogels
Siemens Axiva
The Automation and Drives (A&D)
Division of Siemens has acquired
Siemens Axiva to strengthen its
process engineering expertise for
the process industry especially with
respect to chemical and pharma-
ceutical processes. Moreover the
Siemens Axiva know-how will
improve the customer benefit of
A&D products, systems and serv-
ices and make Siemens more
attractive for customers in these
industries. The portfolio encom-
passes services from integrated
technology and process develop-
ment to so-called first-of-its-kind
plants. These plants require specific
expertise in developing a suitable
production process for laboratory
substance and up-scaling of the
process for production.
9
The secret of aerogels islocked inside: a porosity
of 95 percent and amedium pore size of
about 10 nanometersmake aerogels supreme
insulators
Aerogels can consist of practically anymetal oxide or mixtures of metaloxides, polymers, carbon, or variousother materials. At Cabot in Frankfurt,silica is used as the framework.
Aerogels belong to the family ofnanoporous solids – an aerogel’s typicalpore size is about 10 nanometers andthese pores make up about 95 percentof the material volume. This basic dataindicates what to expect from aerogels:They have extraordinarily good soundand heat insulation properties (aboutsix times better that polystyrene foam)and can therefore be used as insulatingmaterial. One area of application is asinsulation for engine compartmentsand vehicle doors in automobiles, andthey have various uses in the buildingindustry. Because aerogels are translu-cent – meaning that they allow passage
of some light – they open up totallynew architectural possibilities. It isconceivable, for example, to fill insu-lating windows with aerogels to createtranslucent facades while providingvery good heat insulation.
Although aerogels were describedas early as 1935, they could not bemanufactured on an industrial scaleuntil Siemens Axiva developed a manu-facturing process. This was mainly dueto the fact that aerogels had to bedried under supercritical conditions. Itwas not until Siemens Axiva’s develop-ment of the new process, whichallowed aerogels to be manufacturedwith conventional drying processes,that the road was clear for industrialproduction.
To improve the mechanical proper-ties of the aerogels, Siemens Axiva also
developed a special forming process toproduce monodisperse and sphericalaerogels. With the help of computer-aided simulation tools, Siemens Axivamanaged to develop a special patentedmixing nozzle, which can create silicagel particles with a narrow distributionof particle sizes, extremely good flowproperties, and a very high resistanceto abrasion.
Cab
otBlack is still the Cabot Corporation’sfavorite color. That’s because indus-trial carbon black, which is used as acoloring and filling material, has beenthe U.S. company’s most importantproduct for more than 100 years. Theother two main business fields of theCabot Corporation are the productionof performance materials, such astantalum and cesium, and fumedmetal oxides, especially silica andaluminum oxide. However, Cabot isrelying more and more on specialty
chemicals and spin-off products thathave developed from the main busi-ness, including ink for printers andnanogels. The first product of thecompany’s nanogels division isaerogel, which Cabot will produce inFrankfurt.
Cabot has ambitious goals for thefuture. The company not only wantsto consolidate and expand its mainarea of business – where theemphasis is mainly on the optimiza-tion of production and improvement
of product properties – but also tocontinue developing specialty chemi-cals and spin-off products to open upand exploit new market opportuni-ties. To achieve these goals thecompany is relying less on acquisi-tions than on expanding its ownknow-how, as Kenneth Burnes,Cabot’s president and CEO, stresses:“We work hard to improve our opera-tions and to develop our technologiesfor new market opportunities –successfully.”
Industrial production of aerogel: Translucent revolution
process news 2/2003
Big (not only) in black: Cabot is ready to conquer new markets
process news 2/2003
10Specialty Chemicals
CASE STUDY
Combining S88.01 standards with a diverse team of industry expertsallowed Cytec Industries’ Mobileplant to achieve its expectations ofincreasing production while usingtheir existing equipment. Only twodays after modernization wascompleted, the plant was delivering40 percent more product at higherqualities at lower handling, stockingand off site disposal costs. Betterprocess control helps Cytec in tuningproduction and their products to theircustomers’ needs.
C ytec, a specialty chemicals and ma-terials technology company, servesmarkets that include aerospace,
plastics, industrial coatings, mining, andwater treatment. The company postedsales in 2001 of $1.4 billion. Commitmentto the customer, superior technology andoperational excellence is paving the wayfor Cytec Industries to achieve aggressivegrowth targets, amidst the backdrop of aglobal economic slump.
The company’s significant water treat-ing sales volume growth was supportedby control modernization and expansion
at plants in Bradford, England, and Mo-bile, Alabama, USA. As a result of the workdescribed in this article, the Mobile plantis now the largest producer worldwide ofemulsion polyacrylamides. These prod-ucts are used predominantly in the watertreatment and mining industries.
S-88.01 standards make expansionaffordable
Cytec’s goal was to increase the facility’soutput utilizing mostly existing equip-ment by maximizing process efficienciesand reducing waste. Adherence to the S-88.01 standard for batch recipe manage-ment would be a critical part of this newventure. The Instrumentation, Systems &Automation Society’s (ISA) S88.01 BatchControl Standard was drafted to definestandards and recommended practices forthe design and specification of batch con-trol systems as used in the process controlindustries. The standard defines a consis-tent data structure for batch control lan-guage to simplify programming, configu-ration, and communication between vari-ous system components within a controlsystem’s architecture.
Cytec’ implemented the S88.01 stan-dard by employing Siemens’ ProcessSuiteBatch Manager. Installed by expandingthe existing APACS+ system, the graphical
Cytec Industries increasedoutput with Batch Manager
Batch DoneRight
process news 2/2003
11
software tool conforms to S88.01 con-ventions for process modeling to definerecipes as equipment-independent gener-ic processing and transfer functions.Configuration is broken down into dis-crete, repeatable modules, including units,phases, and operations. The resultantmodules are then used to construct andmanage recipes. Editing of recipes, chang-ing sequences and the implementation ofnew products can be done by process en-gineers without the need for program-ming.
Batch done right
Volume growth and market share penetra-tion resulted in very high plant demand. ASteering committee of Cytec, Avid andSiemens personnel was formed in ad-vance to make and monitor a plan thatwould ensure a smooth transition to the
new system. As a result, the plant was re-fitted with the Batch Manager systemcausing only minimal production outagesusing a series of short partial shutdownsduring a period of only one week. The on-ly major physical changes to the Mobileplant were an expanded tank farm forthe higher volume, a new central controlroom, and the instruments, controls andapplication servers needed for batch con-trol. In all, there are over 2200 I/O pointsthroughout the facility’s multiple produc-tion lines.
The precision of S88.01-based controlin Cytec’s emulsion polyacrylamide pro-
cess was impressive. Production of poly-acrylamide emulsions requires the addi-tion of precise amounts of materials. Thecontrol scheme for this reaction decideshow to initiate the reaction, how to controlit during the reaction, and when and howto end the reaction. The exact control ofthe reaction rate in this exothermic stepgives added control over the properties ofthe polymer that is being formed. Im-proved reactor control has given rise tonew specialty products to meet selectedcustomer needs.
When an operator chooses a recipe, theSiemens process automation system willautomatically initiate and manage the en-tire control scenario. Operators can selectwhich equipment to use dynamically; i.e.when it is needed, and a list of availableand appropriate equipment is provided.Before proceeding with a reaction, the
computer simply asks the operator “Areyou ready to react?” so that the operator isnotified, and can cross check that coolantis available to control the reaction. Eventhe equipment wash steps are executedper their own ‘recipe’. Required operatoractions (samples, „Is the reactor reallyclean?“ etc.) are included as steps in therecipe and are prompted by the BatchManager.
Numbers tell the tale
As anticipated, Cytec soon realized thatthe standardized approach not only re-duced complexity but also facilitated the
entire automation process. The team ap-proach and using S88 resulted in substan-tially reduced project costs. An independ-ent auditor used by Cytec to review capitalprojects concluded, based on their exten-sive database, that this project was carriedout at approximately 20 percent less thanthey would have estimated for a project ofthis scope.
Although transfers to a new systemusually produce hiccups for a project ofthis scope, Cytec began to see greater effi-ciency in production after the second dayof operation. Within weeks of the BatchManager implementation and tuning, theplant had demonstrated a projected 40percent capacity increase. Equally impres-sive are the quality results. The “percentfirst time right” metric has increased fromaround 90 to over 98 percent. Besides be-ing integral to customer satisfaction, the
increased quality also has important costreduction effects. Material handling, re-work, and off site disposal are more thanhalved, and there is far less potential forspills. The speed at which Cytec couldprocess batches for its 50 different prod-ucts, together with lack of off-grade mate-rial, has also allowed it to greatly limit in-ventories. These impressive achievementsare proof enough to Cytec that this ap-proach can serve as a blueprint for its oth-er batch facilities around the world. ■
Doug Child, Spring HouseE-Mail: [email protected]
Their new process control system helped Cytec achieveimpressive process improvements
Cytec’s Mobile plant produces polyacrylamidesused for example in water treatment
Cyt
ec
Cyt
ec
process news 2/2003
12Process Analytics
ACHEMA NEWS
W ith the FT-ICR (Fourier Transform-Ion Cyclotron Resonance) mass spec-trometer Quantra, Siemens has de-
veloped a high-resolution analyzer for onlineapplications, which is unique in the world. Ex-tremely small, mobile, robust, and – cost effi-cient in design, the device is made specificallyfor demanding applications. From the deter-mination of gas components in fermentersand catalyzers in the chemical and pharma-ceutical industry, to residual gas analysis insemiconductor production, the ICR technolo-gy provides a very high mass resolution sothat even compositions with almost identicalmass can be identified reliably. The informa-tion quality and thus the accuracy of themeasurement are much higher than in com-parable systems.
Quantra has been designed for use in aharsh process environment, for short analysistimes (about 800 milliseconds), and for low-maintenance operation. The integrated vacu-um system (Ion Getter Pump), for example,has no moving parts, is maintenance-free,
Innovations in process analytics at Achema
TotalAnalyticsSolutions
The wide Siemens product range offers everything formodern process analytics, from stand-alone analyzers tocomprehensive solutions. The Siemens portfolio alsoincludes customized components for mass spectrometry,process gas chromatography, and NIR spectrometry. Theproducts can be used in many different industries to imple-ment applications more quickly, flexibly, efficiently and/orcost effectively. At Achema Siemens will be presenting bothnew developments and proven technologies.
process news 2/2003
13
and has an expected service life of at leastfive years. The system can be kept contin-uously under vacuum (10-10 Torr) withoutan external vacuum pump and is there-fore ready for use almost any time. It is ex-ceptionally easy to handle and is ready foroperation after only a few minutes afterset-up.
The mass spectrometer is extremelyflexible and can be used at different pointsin the process. Unlike with large FT massspectrometer systems, no supraconduct-ing magnets are required, but only a per-manent magnet (1 Tesla). This means thatQuantra requires much less space thanconventional FT mass spectrometers. Theomission of a cooling system with liquidgases saves additional space – and, moreimportantly, a large portion of the operat-ing costs.
With Quantra it is now possible to ben-efit from the advantages of mass spectom-etry at reasonable costs.
Explosion-proof MicroSAM
Siemens is constantly creating technologi-cal innovations in the field of process gaschromatography – the first process gaschromatograph with capillary columns,and valveless live column switching, forexample. The latest innovation in thisfield measures just 25 centimeters in di-ameter and 23 centimeters in height andis an extremely powerful, explosion-proofprocess gas chromatograph. The smalleston-line process gas chromatograph todate from Siemens goes by the name ofMicroSAM. Using the latest silicon-based
micro-machining techniques results inminiature size while at the same time in-creasing power and versatility.
MicroSAM’s explosion-proof enclosurecontains everything that is necessary forseparating and detecting the measuredsample components. The valveless live in-jection has a flexible injection volume,and the valveless and maintenance-freecolumn switching can be further opti-mized with electronic pressure control.Multiple parallel micro-detectors give ac-curate measuring results. MicroSAM usesa thermal conductivity detector array inte-grated on silicon to measure all columnand vent flows as well as the injectionpeak itself. Several MicroSAMs can be con-nected in parallel to analyze multiple sam-ple flows. Redundant solutions can also becreated with little effort. MicroSAM takesup very little space in the analysis contain-er and because it requires just one gassupply line and little electrical energy andclimatization, operating costs remain low.The use of standardized, quickly replace-able analyzer modules and the mainte-nance-free column circuit also minimizemaintenance, failure times, and servicecosts.
Rugged workhorse for close-to-process analysis
Sinis A, the NIR (Near Infrared) spectrom-eter based on AOTF (Acousto-Optic Tun-able Filter) technology from Siemens, canbe used in various applications thanks tothe monochromator which operates with-out moving parts, a high light intensity,
and the possibility of transmission and re-flection measurement. With Sinis A it ispossible to determine the concentrationor quality properties of one or severalcomponents, and also the physical proper-ties of a sample (solid, liquid, or slurry).In addition, sum parameters can be deter-mined from the signals of several singlecomponents.
Polychromatic light is electronicallysplit up into different wavelengths with-out moving parts; this makes the deviceinsensitive to vibration and reduces main-tenance requirements. With IP54/65 highwater and dust protection, an operatingtemperature range of –20°C to +50°C, andoptional explosion-proof design the de-vice also meets other important require-ments for industrial use. Thanks to thehigh light intensity, glass fiber optics canalso be used, allowing measuring point inthe process and spectrometer to be sever-al hundred meters apart.
Typical applications for Sinis A includemonitoring the water content of sub-stances or several components in distilla-tion processes in the chemical industry,process solutions in paper manufacture,or production processes in the pharma-ceutical industry. In the food and bever-age industry, carbohydrate and fat con-tents can be determined as single valuesand total parameters. ■
Hartmut Oesten, KarlsruheE-Mail: [email protected]
The compact, low-maintenanceand high-performance Quantramass spectrometer
MicroSAM is a complete, explosion-proofprocess gas chromatograph
The rugged Sinis A spectrometer
process news 2/2003
14Life Science
CASE STUDY
S chering-Plough is a worldwide re-search based pharmaceutical com-pany. At their production site in
Avondale, over 400 fulltime employees aremanufacturing active pharmaceutical in-gredients. Their production facility inAvondale is made up of manufacturingcells ranging from a small pilot facility tolarge bulk production.
Standardization ensures smoothupgrades
Schering-Plough decided at an early stageto standardize on control equipment fromSiemens and have reaped the benefit of awell defined upgrade strategy ever since.All production facilities are now equippedwith technology based on Simatic and theTotally Integrated Automation conceptfrom Siemens. For several years, Scher-ing-Plough has cooperated closely withSiemens in upgrading and improving sev-eral units in Avondale. “We have betweenfour and eight people constantly on site,doing minor modifications and support-ing Schering-Plough in the validation anddocumentation aspects of their process-es”, says Eamonn Nally, Siemens manager
Siemens Ireland is a reliable partner in upgradingSchering-Plough's multi purpose facility
A Winning TeamSince Schering-Plough decided to upgrade the control system in theirprimary production unit in Avondale, Ireland, Siemens and Schering-Plough have been working closely together at improving plant perform-ance and ensuring FDA compliance. Multiple projects have already beenexecuted, including a new water-for-production unit and the upgrade ofan existing SCADA system. Moreover, Siemens is constantly supportingSchering-Plough in the validation and documentation process. Theexpert knowledge Siemens team ensures the long-term performance ofall improvements and has become an important success factor for themodernization projects at the Avondale site.
Simatic PCS 7Operator Stations
controlling bulkproduction
Simatic PCS 7 and Batch flexible at Schering-Plough in Singapore
A new production line at Schering-Ploughin Singapore uses only the latest technol-ogy for packing a highly effective drug fortreating hepatitis C. The active ingredientand the solvent are packed in a dual-chamber cartridge system. VETTER inRavensburg suplied the entire processingequipment of the new fully automatedproduction plant in Singapore. More than25 years of experience with complexaseptic production processes in close co-operation with the pharmaceutical indus-try recommended the company and theirpartners for this project.
The Simatic PCS 7 process control sys-tem comfortably and reliably controls theproduction of the solution that will laterbe packaged in the dual-chamber car-tridges V-LK®. VETTER put the job of au-tomating this plant in the hands of the ssgstarkstrom systeme GmbH in Freiburg.The heart of the production line is thecompounding system where the active in-gredient is prepared. The visualizationand automation system must be able toprocess several batches simultaneouslyand to document the production process.The batch processes for manufacturingthe dissolved active ingredient can becontrolled comfortably with Batch flexi-ble, allowing for processing complex tasksflexibly with alternating control routines.
The project was started in August2001 and preliminary commissioning wascompleted in December 2001 in Ger-many. The plant went into operation inSingapore in May 2002 and was handedover to the operators at the end of 2002.Both VETTER and Schering-Plough bene-fited especially from the experience of thessg team who made completing the proj-ect in such a short time possible while stillmeeting the customer’s requirements forplant availability and productivity.
at the Avondale site. “What is special onthis site is that it is not a one-time commit-ment for a single project, but a long-termpartnership where both Siemens andSchering-Plough can benefit enormouslyfrom sharing their expertise.”
Protecting investments while usingmodern technology
One recent project for Siemens and Scher-ing-Plough was the system upgrade forthe large bulk Production Cell P5. Com-missioning of P5 was first completed in1994 with a base control layer of TI con-trollers and a SCADA system of Tistar.When Schering-Plough decided to up-grade this system in 1998, a fundamentalreview of control strategy was carriedout on site.
After extensive research, Schering-Plough chose Simatic PCS Operator Sta-tions as the new system front-end. Accord-ing to Karl Lawler, Systems Engineer atSchering-Plough, “Siemens offered a welldefined upgrade strategy from Tistar toPCS. That way, we were able to protect ourinitial investment in PLC code. Moreover,this proved to us that Siemens was com-mitted to long term support of both itsclient base and automation platforms –and so we were investing in technology forthe future.”
The upgrade strategy was to install thenew front-end in parallel with the existingTistar system and to fully validate the new
process news 2/2003
15
PCS front end with reference to the opera-tional system. This also had the advantagethat plant operators had the opportunityto become very familiar with the new sys-tem before switch over.
No loss in production during changeover
During the entire change-over no loss ofproduction occurred, due to the extensiveup front planning by the Siemens ProjectTeam led by David Mahon. “We designedthe new system having the requirementsof the changeover in mind from day one.This meant that we had a very high degreeof confidence that no production timewould be lost on changeover.”
In the meantime, other projects havebeen completed. A new water-for-produc-tion system was installed with controllersfrom the Simatic S7-400 range, andSiemens also replaced the site boiler con-trol system with a new Simatic S7-400Hcontroller. In order to ensure future com-pliance with the most stringent regula-tions from the Food and Drug Adminis-tration (FDA), Schering-Plough have be-gun a fundamental review of the controland validation strategy for the entire site.This involves carrying out a critical analy-sis of all systems with a view to harmoniz-ing data handling in terms of storage, in-terface and security. The in-depth knowl-edge of the on site Siemens engineeringteam of all the manufacturing cells inAvondale means that their input into theprocess is critical to the long term successof the initiative. Once complete the Avon-dale site will be well positioned forgrowth in the future. ■
Owen Bonner, DublinE-Mail: [email protected]
process news 2/2003
16Level Monitoring
ACHEMA NEWS
W ith Levelwatch.com users canaccess bulk material levels atanytime, from anywhere, using
the Internet. By logging into a secure, cus-tomized web site, it is possible to view lev-el data and respond to changing raw ma-terial supplies. It is ideal for monitoringremote storage silos, bins and tanks hold-ing virtually any bulk material, includinggrain, petroleum, specialty chemicals,plastic pellets, aggregates, cement, pulp,and many other bulk solids or liquids.
At the remote site, reliable instrumentsfrom Siemens take the level readings. ALevelwatch.com unit connects this fielddata via landline, wireless modem, orsatellite to a secure web site that is staffedcontinuously. The system monitors level
status, tracks trends, and sends alarms di-rectly to designated personnel by any com-bination of phone, fax, pager, or e-mail.
Multiple benefits
This information can be used for businessdecisions and help to streamline businesssupply chains. Vendors of raw materialscan use Levelwatch.com to provide a val-
ue-added inventory management service,building a business partnership withclients beyond that of a regular supplier.By monitoring customers’ material levels,they can anticipate demand and optimizedelivery schedules. Manufacturers whorely on timely deliveries can use it to en-sure the supply of raw materials for con-tinuous production, without running out
Siemens introduces remote monitoring concept viaInternet and new monitoring devices
A New LevelThe Achema, held every two years in Frankfurt/Main, Germany, is one of themost important and biggest fair for the chemical and petrochemical industry.Siemens will present several new solutions and services – especially for contin-uous level monitoring. The Internet based Levelwatch.com service for moni-toring distributed or remote silos and tanks and two new monitoring deviceswill be among the highlights of this year’s presentation at the Achema.
17
or requiring emergency deliveries. Re-mote level monitoring reduces costs andsaves staff time traveling to remote sites.
A broad variety of Siemens level moni-toring devices are fully compatible withLevelwatch.com – just like the two new ca-pacitance technology devices for monitor-ing levels in conductive or non-conductivematerials that will be introduced at theAchema fair.
High accuracy at a reasonable price
The new Sitrans LC 300 is a cost-effectiveinstrument for level measurement in highaccuracy applications such as the process-ing of food and beverages, pharmaceuti-cals, detergents and pet food. It performsin liquids, bulk solids and slurries, includ-ing viscous media, even in challenging en-vironments involving vapor and dust.
Sitrans LC 300 combines high accuracyand reliability with low maintenance andease of installation. The unique inverse-frequency approach to capacitance tech-nology provides high resolution and long-term stability. The patented Active-Shieldtechnology protects the measurementfrom the effects of moisture, vapors,foam, temperature or pressure variations,and material build-up. Its advanced elec-tronics provide for simple calibration andits integrated local display make on-siteinstallation and set-up easy. The 2-wiretransmitter complies with Namur NE 43for current signaling.
Modular construction features a fullrange of NPT, BSPT, and JIS connectionsand DIN and ANSI flanges, as well as cor-rosion-resistant PFA and 316L stainlesssteel wetted parts, to suit virtually any ap-plication.
Mastering demanding tasks: Sitrans LC 500
The new Sitrans LC 500 is a high perform-ance field instrument that provides reli-able continuous level and interface meas-urement, even in the critical conditionsoften found in the chemical and hydrocar-bon processing industries.
It has been designed for extreme condi-tions characteristic of high-pressure coa-lescers, fractional distillation columns, cat-alytic crackers, glycol regenerators, heatertreaters, gas and oil tankers, F.P.S.O. shipsand LNG processing plants.
The smart, 2-wire transmitter has HART®communications for remote commission-ing and inspection. Its advanced electron-ics provide for one-step calibration and lo-cal display for easy on-site installation andset-up. One-point calibration makes set-up possible without shutting down theproduction process. Full-function diag-nostics comply with NAMUR NE 43 forboth local and remote diagnostics, show-ing all the relevant variables at the sameinstant.
The patented Active-Shield technologyprotects the measurement from the ef-
fects of moisture, vapors, foam, materialbuild-up, and temperature or pressurevariations. The unique probe design has ahigh integrity seal, which allows for reli-able use in high pressure/high tempera-ture conditions as well as in high pres-sure/low temperature conditions. The PFAprobe-insulating sleeve is chemically re-sistant. This special insulated probe de-sign prevents “cold flow of plastic” oftenassociated with competitors’ devices, en-suring stable measurement without theneed for frequent re-calibration. The in-strument is effective in temperaturesfrom -200 to 400 degrees Celsius (-328 to752 degrees Fahrenheit) and pressuresfrom full vacuum to 525 bar (7665 psi).Sitrans LC 500 is approved for hazardousconditions, and has Lloyd’s Register ap-proval for use in marine applications.
Sitrans LC 500 offers an auxiliary out-put and a solid state switch, enabling theinstrument to perform the additionalfunction of a level controller when theseare connected to a relay that activates apump. Modular construction features a fullrange of probe options and process con-nections, as well as customized configura-tions, to suit virtually any application. ■
Janet Wile, PeterboroughE-Mail: [email protected]
process news 2/2003
process news 2/2003
18Drive Technology
ACHEMA NEWS
Physical-Technical Institute (PTB) or byDeutsche Montan Technologie GmbH (DMT,a renowned technology service providerin the fields of raw materials, safety, andinfrastructure).
Frequency converters
The chemical industry offers many areasof application for converters: pumps andfans, mixer drives in connection with off-set shaft gearboxes, agitators in potential-ly explosive areas, extruders with hightorque requirements, or foil processingmachines requiring the synchronizedrunning of several drives. The Micromas-ter frequency converters combine maxi-mum technical sophistication with func-tional versatility and are designed to meetthe special requirements of the chemicalindustry. The Micromaster 440, for exam-ple, is designed especially for those appli-cations that demand greater dynamic re-sponse than normal. The vector controlensures a uniformly high drive qualityeven in the case of sudden load changes.In combination with the torque controland the encoder module, synchronizedmultimotor applications can also be con-trolled easily. With LC output filters, mo-tors in explosion hazardous areas can beoperated from up to 300 meters away. Theclass A limit values (according to EN55011) are also satisfied with unshieldedlines up to a distance of 200 meters, andall important protection and overloadfunctions are integrated as standardequipment. All devices in the Micromasterseries meet the requirements of the EULow Voltage Directive as well as having theCE mark and UL and CUL certification. AllSiemens standard drives with the Profibusoption are also integrated into Totally In-tegrated Automation (TIA). TIA’s use ofuniform communication, identical config-uration, and common data storage resultsin a savings potential of up to 30 percent.
Even more powerful
Siemens naturally also offers drive solu-tions that have a higher power range(more than 10 Megawatt) and are wellsuited for process applications. ■
Drive solutions for the chemical industry
The Safer SideNothing works in the process industry without electromechanical drives. Thedesire for cost-effective, reliable, and above all comprehensive drive solutions isa prime concern. Siemens Automation and Drives offers drive solutions that areadapted to the special requirements of the chemical industry as well as solu-tions for distributed drive technology. In addition to a full range of low-voltagemotors, frequency converters meeting NAMUR standards and offering PFIVprotection are available.
Erwin Buchert, NurembergE-Mail: [email protected]
S iemens low-voltage drives cover thepower range from 0.06 to 1,000 Kilo-watt. Economy motors of efficiency
class EFF1 and EFF2, gear motors, explo-sion-proof motors, motors meeting NEMAspecifications, combustion motors, andindustry- and customer-specific motorsare available depending on requirements.
The potentially explosive and danger-ous areas of the chemical industry in par-ticular demand the use of specially pro-tected drives. The explosion-proof motors
from Siemens are protected from both gasand dust explosions. The full EEx motorrange includes a complete cast-iron seriesin the versions• “increased safety” – EEx e II T1–T3• explosion-proof enclosure –
EEx de IIC T1–T4• non-sparking – EEx nA, Ex nA• dust explosion proof for Zone 21 and 22• optional VIK versionAll explosion-proof Siemens motors havebeen tested and certified by the Federal
process news 2/2003
Until now there has been no opti-mum solution for automation withPCS 7 for the plants with complex
and extensive tank farms because apartfrom the tank automation aspect, materialtransport automation is a key task. PCS 7had no standardized solution for this.
Siemens has previously used this func-tion only in connection with the Braumatcontrol system. Now that experience hasbeen transferred to the independent soft-ware package Route Control Systems (RCS),which can be used in various industriesand is totally integrated into PCS 7.
RCS is designed for manual and auto-matic control of up to 300 material trans-ports. The routes can be configured veryeasily to considerably simplify engineer-ing and implementation. In addition, RCSoffers simple, standardized control of theprocess elements capable of diagnostics
so that additional information can be dis-played or provided in the event of a fault.
Steady improvement
Not long ago, the PCS 7 Batch system wasdrastically improved and now additionalenhancements are under way. A stan-dardized API interface makes integrationinto the World of IT easy. That way, errorsources for the user are eliminated andthe system becomes even more robust.Moreover, the system now offers inter-faces for the integration of S5, Telepermand third party controllers. Features forattributing equipment-independent recipesto sub-plants were also enhanced.
Simatic PDM is the central tool for engi-neering, programming and commission-ing of intelligent process devices. It willhave more features and will be further in-tegrated into PCS 7 engineering in the fu-
Alberto Pelegri, KarlsruheE-Mail: [email protected]
ture. Device-specific parameters, for ex-ample, are now integrated into the newProcess Object display mode of PCS 7.Modifications can be made directly in thismode. PDM will also become part of PCS 7Audit Trail so that parameter modifica-tions of devices can be monitored. Addi-tional improvements for PDM that are cur-rently in the planning phase include inte-gration into the Simatic Logon Serviceand extended diagnostic features. ■
Simatic PCS 7 further expands its scope of functions
Even More PCS 7In the current Simatic PCS 7 Version 6.0, Siemens has already considerablyextended the scope of functions of the process control system, increased thescalability, further enhanced vertical integration, and thoroughly improved theengineering and batch system. In the automation sector, however, standingstill is synonymous with moving backward, so new developments are alwayscontinuing in various directions. A new route control system for PCS 7 iscurrently being implemented. Moreover, new features for Simatic Batch andSimatic PDM are being developed and integrated into PCS 7.
19ACHEMA NEWSProcess Control Technology
PCS 7 – Training for successSitrain is the training partner for
Simatic PCS 7 and offers courses for
engineers, systems integrators, and
planning, operating, and service
personnel. Implementation and
training on the process automation
of a plant, right up to the operator
level, is done virtually, using exam-
ples and exercises.
Further information about the
range of courses is available at:
www.siemens.de/sitrain
Keyword: PCS 7
process news 2/2003
20 CASE STUDY
Siemens was responsible for supplyingthe hardware and the software engineer-ing for this project. Since the polymeriza-tion pilot plant was still being used, theconversion had to be done quickly. Onlyvery short shutdown phases could be usedfor the migration work – a great challengefor the executing engineers. Thanks toperfect preparation and planning and ex-tensive testing of the user software in ad-
vance the conversion proceeded exactlyaccording to plan.
The tasks of the old Teleperm M sys-tems were changed over to the new systemstep by step combining several AS215 onone PCS 7 automation system. Simatic ET200M devices were installed at the nowfree slots of the Teleperm M controllers.The ET 200M communicate with the con-trol system via Profibus. The wiring up tothe terminal strip could therefore be re-tained. Only the connections from the ter-minal board to the ET 200M had to be re-wired.
Great potential for the future
The results are absolutely convincing inWacker’s opinion, “With its high availabil-ity PCS7 is exactly the right process con-trol system for the requirements in thepolymerization center” Ferdinand Bauer-egger, engineer at Wacker Chemie, praisesthe new system. The flexible and open TIAconcept is bound to see the PCS 7 estab-lishing itself in other areas of the plant. ■
Alois Brandmaier, BurghausenE-Mail: [email protected]
Ferdinand Baueregger is very satisfiedwith the smooth migration fromTeleperm M to Simatic PCS 7
Wac
ker
WPS emerged from a Joint Ven-ture of Wacker Chemie GmbH,Burghausen and Air Products
and Chemicals Inc in Allentown, Pennsyl-vania. The polymers that are produced attwo sites in Calvert City, USA and the com-pany headquarters in Burghausen are ap-plied mainly in the building, adhesivesand textile industries but also as impor-tant ingredients in paints and varnishes.
The heart of the company is the poly-merization pilot plant where all productlines of WPS are developed. This centralplant is equipped with all the latest tech-nology – and the automation technologymust meet the highest demands. For thisreason one sub-plant was already convert-ed from Teleperm M (TPM) to PCS 7 in apilot project in 1996.
Migration completed in short time
In autumn 2002 Wacker decided to makea clean sweep and completely replace theexisting process control systems TPMAS215, AS230 and OS525 with SimaticPCS 7. Siemens was WPS’s first choice forthis project because PCS 7 had alreadybrought excellent results in other parts ofthe plant. Besides, Siemens has been of-fering made-to-measure migration solu-tions for years and therefore has the nec-essary know-how to guarantee a trouble-free conversion.
Migration project from Teleperm Mto PCS 7 at Wacker
EconomicInnovationWacker Polymer Systems (WPS) is one of theworld’s leading manufacturers of redispersiblepowders and vinyl-acetate-ethylene dispersions.The company, located in Burghausen, has updatedits automation technology and converted the poly-merization pilot plant from Teleperm M to SimaticPCS 7. The migration of the plant was completedwithout any problems and Wacker is alreadyconsidering follow-up projects with Simatic PCS 7.
Chemical Industry
process news 2/2003
21CASE STUDY
U ltramat and Oxymat analyzers areno strangers to the Dow staff inStade. The analyzers have been in
use there for quite some time (as they arein almost all the other locations of this in-ternationally active company), but in thepast they have usually been planned, inte-grated into the production system, andcommissioned by Dow itself. For this proj-ect, however, a bottleneck in resources ledthe company to search for a suitable exter-nal service provider. Thanks to extensiveexperience with the construction and com-missioning of analysis systems, Siemenswas once again well positioned to win thisorder.
On-site work included the installationof measuring systems in the outdooranalysis cabinets as well as completely
equipping an analysis house built by thecustomer.
Complex media well under control
Every analysis system consists of the pri-mary sample conditioner at the removalpoint, the secondary sample conditionerin the analysis house or cabinet, and theactual analyzer, which includes all thenecessary safety-oriented shutdown de-vices (according to the LOPA study and SIL61508). To achieve maximum possibleavailability and production reliability, allanalysis systems are redundant.
“We use the new systems mainly foranalyzing gas streams contaminated bysolids,” explains Ralf Schade, who is re-sponsible for process analytics at theStade factory. “We have to prevent lines,
sample conditioning components, and theanalyzer itself from becoming blocked,and we have to have suitable measuresready to clear such blockages quickly ifthey do occur.”
Standards for further projects
The Siemens analysis systems had alreadysatisfied the detailed specifications of DowGermany during acceptance testing at theSystem House in Karlsruhe. They were in-stalled on schedule under the direction ofa supervisor and were put into operationwithout any problems. “With this first in-stallation,” says Ralf Schade, “Siemens hasset a high standard for future projects.” ■
Siemens installs analysis systems at Dow Stade
Comprehensive SolutionDow Germany contracted with the Siemens System House in Karlsruhe to outfita production plant in Stade, Lower Saxony, with analysis systems. Siemens notonly supplied the equipment but also provided complete installation andcommissioning of the systems on site.
Chemical Industry
Herbert Rösinger, KarlsruheE-Mail: [email protected]
Dow in Stade is highly satisfied not onlywith the analyzers from Siemens but alsowith the performance of the Siemensproject team
process news 2/2003
22Process Control Technology
TECHNOLOGY
Mr. Dietz, why exactly is your laboratoryinterested in the FF and Profibus fieldbussystems?Manfred Dietz: There are basically twofieldbus systems which NAMUR classifiesas suitable for process technology, andthose are the FF system from the FieldbusFoundation and Profibus PA. That’s whyour lab is mainly concerned with thesetwo systems.
You stress the PA after Profibus.Manfred Dietz: That is a very importantpoint. In terms of functionality, process-technical suitability, and so on, you can re-ally only compare Profibus PA and FF be-cause Profibus with Profibus DP and Profi-drive have many more features than FFand PA. This is obvious just from the factthat every FF system also has an interfaceto Profibus systems to cover such func-tions as drive control, for example. That’snot possible with FF alone. Profibus withDP has the solution for this.
And which system is better?Manfred Dietz: That’s hard to say off-hand. If I’m looking for a solution with
which I “only” want to measure and regu-late, FF is, if you will, the more special-ized system that has more functions to of-fer in this respect. This, of course, meansthat FF is very complex and requires agreat deal of specialized technical knowl-edge. Profibus, in contrast, is more of an
“all-rounder”; it covers many areas of au-tomation technology, from drive controlthrough low-voltage switchgear up to the
process level with Profi-bus PA. In addition, itshandling is simpler, sothe technician or mainte-nance mechanic can findhis or her way around the system more quickly.However, for us here atHöchst there is anotherimportant point in favorof Profibus PA. Here, fu-ture fieldbus technologywill be applied above allin the modernization of
old plants. Profibus has a clear advantagehere because migration and moderniza-tion solutions are available for this sys-tem; FF lacks this capability.
Your test lab has recently installed a com-plete Simatic PCS 7 system, including inte-
Comparison of fieldbus and control systems at Infraserv Höchst
”We Too Can LearnFrom Siemens”Infraserv Höchst Technik GmbH & Co. KG, in Frankfurt, is the leading maintenanceservice provider for technical process systems and subsystems in the Rhine/Mainregion and is a key resource when questions arise during the life cycle of thesesystems. One of the fields of activity of Infraserv Höchst Technik is the EMR Compe-tence Center of the Interessengemeinschaft Regelwerke Technik (IGR). The task of theEMR Competence Center is the preservation and further development of expertise inthe field of EMR and automation technology, as well as the organization of workteams and projects. The test lab at Infraserv Höchst Technik tests field devices,fieldbus systems, and control systems for the IGR and examines new technologies fortheir suitability for use in process-technical systems. In addition to two complete multi-vendor systems for the two fieldbus systems, FF (Fieldbus Foundation) and ProfibusPA, a complete Simatic PCS 7 setup with integrated fail-safe technology has recentlybeen added to the lab equipment. ProcessNews spoke to Manfred Dietz, head of thetest laboratory, about his experience with Profibus and PCS 7.
”As far as thefunctional scope isconcerned, PCS7 –especially with theintegrated safetytechnology – iscertainly uniqueat present.”
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23
grated fail-safe technology. What is youropinion of this technology?Manfred Dietz: As far as the functionalscope is concerned, PCS 7 – especially withthe integrated safety technology – is cer-tainly unique at present. I know of no oth-er system that offers as many possibilities.
What does Siemens need to work on to en-sure that PCS 7 stays successful in processtechnology?Manfred Dietz: PCS 7 is a very powerfulsystem – and that power has usually comeat the cost of user friendliness. And at thefield level, with Profibus PA, the systemhas not yet exploited its full potential, inmy opinion. We as users would like to seea simple, process-oriented I/O system forProfibus PA with which we can addresssensors and actuators in the field. There isno solution in sight for this task yet – notfor FF either, as it happens. All in all, I as-sess the chances of PCS7 very positively.In my opinion, the trend is clearly moving
toward integrated safety technology – andhere Siemens has a very good solution onoffer with the fail-safe and high-availabili-ty AS, as well as the integrated fail-safemodules.
Siemens has been very committed toprocess automation in recent years. As aleading company in the manufacturingindustry, Siemens has a lot of catching upto do in process automation. Where doyou see Siemens today? Has the companyunderstood the priorities in the processindustry?Manfred Dietz: Of course I can’t speak forthe whole process industry, but I do thinkthat providing our laboratory with thePCS7 system shows that Siemens seesclose cooperation with the process indus-try as very important, and that the compa-ny is willing to adapt to our sometimesvery special requirements. We too canlearn from Siemens. Sometimes in theprocess industry one has the tendency to
look no further than oneself and one’s owntechnologies. At the same time, however,other industries are coming up with inno-vations that are extremely interesting forprocess technology. As a market leader inautomation technology, Siemens is one ofthe few companies in Europe that con-sciously and actively helps to shape futuretrends. We can only benefit when such aninnovative company shows a commitmentto the process industry.
Thank you for talking to us.
Holger Rachut, KarlsruheE-Mail: [email protected]
Profibus PA and Simatic PCS7 in the test labat Infraserv Höchst Technik
The landmark of the Höchst Industry Park is the prominenttechnical administration building of the former Hoechst AGplant. It was built under the direction of architect Peter Behrensbetween 1920 and 1924
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©In
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Höc
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O ver its almost 80-year history, JosefMeissner GmbH & Co. in Colognehas become a renowned global
partner for the design, engineering, andconstruction of plants for manufacturingexplosives, nitroaromatics, formaldehydeand cellulose derivates, and more recentlyother cellulose-based products. TodayMeissner employs a permanent staff of 65and has installed more than 450 plants forleading companies all over the world. Theexperience gained through these installa-tions was a major reason why the Egyptianmanufacturer Egycel decided to place theorder for the construction of a new pro-duction plant for carboxymethylcellulose(CMC) with Josef Meissner GmbH & Co.CMC is a water-soluble cellulose etherused in the building, ceramics, textile, andcosmetics industries, as well as in oil andgas exploration. The most importantphase in the manufacturing process is themultistage batch process of alkalizationand etherification, whereby importantproduct properties can be “set” individu-ally, causing various effects on the subse-quent process steps. This demands maxi-mum flexibility from the entire system,especially the process control system.
Flexible, expandable, comfortable
The new control system was to be readilyexpandable, was to allow the rapid imple-mentation of process-technical functionsat both the controller and the operatorlevel, and was to offer easy recipe man-agement. Meissner soon decided in favor
process news 2/2003
of the Simatic PCS 7 process control sys-tem with the Simatic WinCC process visu-alization system from Siemens and a re-dundant solution made up of two OSservers and four OS clients. Twenty-onedistributed I/O stations (primarily ET200M) transmit process data from approx-imately one thousand process control ele-ments in the field via Profibus in fiber op-tic cable technology to the control sys-tem’s two Simatic S7-416 controllers. Inorder to complete the first PCS 7 project inthe planned period, Siemens was involvedfrom the start and supported the plantbuilder from the ordering through train-ing and the set-up of the client/server ar-chitecture right up to final signal andfunction testing in Cologne. As a result,the entire installation was ready to becommissioned on site in just six weeks.
Installation in record time
The premiere was a huge success forMeissner. With the new process controlsystem installed in record time, Egycel,the end customer, is now able to managediverse processes (with a total of 13,000WinCC variables) much more easily andmore reliably than ever before. The vari-ous process data can be visualized clearlyand a consistently high quality can be eas-ily documented. ■
Reinhard Stader, CologneE-Mail: [email protected]
Egyc
el
The Simatic PCS 7 controls thecomplex multistage etherification
24Chemical Industry
CASE STUDY
Simatic PCS 7 in CMC production
Premiere in EgyptA company from Cologne, Germany has set up a plantfor manufacturing cellulose products from scratch nearCairo. This was the first large-scale project with theSimatic PCS 7 process control system for Josef MeissnerGmbH & Co., which installed the system. Thanks toextensive support from Siemens, the project wentexactly according to plan. The end customer, Egycel,now benefits from increased process reliability andproduct quality.
process news 2/2003
25CASE STUDY
Siemens has recently completedFactory Acceptance Testing for batchprocess control and production infor-mation systems for the Akzo NobelSurface Chemistry Pte Ltd Quat Plantcurrently under construction onJurong Island in Singapore. SiemensSingapore has worked closely withAkzo Engineering in the Netherlandsand local EPC contractor, SembCorpEngineers & Constructors, to designand build the system.
A kzo chose Siemens Singapore forthis project because of their satis-faction with the PCS 7 system at
Akzo’s site in Malaysia. At the plant au-tomation level, the PCS 7 process controlsystem is used with a tightly integratedFailsafe/High Availability safety system.Adoption of a remote I/O concept withmaximum utilization of Intrinsically Safestandard and failsafe I/O cards minimizessystem hardware and site installationcosts. To ensure system reliability andhigh availability, redundancy has beenprovided at all levels of the system includ-ing field communications, CPU’s, systemcommunications and servers.
Integrated data management
At the operator interface level, redundantservers and an engineering station are al-so used as operator stations. Recipe man-agement and batch control have been im-plemented with the Batch flexible soft-ware. All operator stations are also batchclients so that the plant can be operatedfrom any operator station.
At the Plant Information system level, adedicated server running the MISLightsoftware has been used to collect processdata and batch records and to store otherexternal plant data such as material stocklevels, material movements and laborato-ry data. This external information is en-tered via a customized production data-base user interface built on the Simatic ITplatform. This application provides nu-merous customized data entry forms andreports in a fully user access controlledenvironment.
The next phase of the project involvesinstalling the Engineering & Operator sta-tions with the CPU cabinet and MIS serverin a temporary site office to allow operatortraining on the actual control system. ThePCS 7 software has already been config-ured with in-built plant simulations anddedicated operator screens to control sim-ulated field devices and thus will facilitate
Integrated process controland data managementsystem at Akzo Nobel in Singapore
A DatabaseforProduction
Chemical Industry
Abram Ziegelaar, SingaporeE-Mail: [email protected]
the training. Final installation and Site Ac-ceptance Testing is scheduled for July ’03with plant startup in September ’03.
Excellent cooperation
Akzo’s plant manager Mark Hutchinson isvery satisfied with the progress of theproject so far. “It was a pleasure to workclosely with the Siemens team recentlyduring the testing phase of this project.We are looking forward to seeing the fin-ished PCS 7 system up and running at ournew facility in July managing our fairlycomplex batch production process, andwe anticipate that the production data-base will be an extremely powerful tool inproviding management information andreporting for our plant”. ■
process news 2/2003
26Service and Support
TRENDS
For protecting investments over thelong term, Siemens creates a system-atic, made-to-measure plan for plant
maintenance in cooperation with the cus-tomer. The service contract guaranteesthe owner fast, competent assistance, andthe customer-specific maintenance con-tract makes a major contribution to theachievement of optimum plant availabili-ty. Greater productivity and higher qualitycan be achieved at lower costs by optimiz-ing the production process.
Siemens specialists are on hand for allindustries and systems in the case of per-sonnel shortages, tight deadlines, or lackof know-how. Online support offers nu-merous tricks and tips in addition to ex-tensive information about products andsystems. It is also possible to downloadmanuals and firmware. The product andsystem experts from technical supportprovide 24-hour consulting. The world-
wide spare-parts logistics system guaran-tees short plant downtimes, and a globalnetwork of repair facilities enables imme-diate support in the event of damage.
The many faces of modernization
The professional modernization of a plant– whether to increase productivity or re-duce costs – is often a better alternative toinvestment in new facilities. A retrofit isfrequently the best way to protect an in-vestment. A feasibility study reveals theopportunities and risks of modernizationin advance.
In the implementation of moderniza-tion measures, Siemens either takes onthe complete project management and ex-ecution or advises the customer on theconception, configuration check, softwareengineering, installation, and assembly.Siemens also offers tailor-made financingoptions. Various simulation tools that
provide a virtual representation of theprocess are used to reduce commission-ing times. The program function is testedand potential for optimization examined.Professional support is also provided formigration from an existing control systemto the Simatic PCS 7 process control sys-tem, and for retrospective validation orproper disposal of plants at the end oftheir life cycle. ■
Carsten Köhler, KarlsruheE-Mail: [email protected]
Planning & Design
ProjectEngineering
& Development
Installation &
CommissioningOperation &
MaintenanceModernization
Services for operation,maintenance, and modernization
Time is MoneyIn order to use available resources efficientlyand effectively and to achieve a maximumreturn on investment, plants must be inproduction around the clock where possible.Siemens supports its customers in opti-mizing the productivity of their processeswith customized services such as worldwidespare-parts logistics, maintenance plans orsupport specially adapted to each plant, andassistance with modernization and systemmigration.
Maintenance Plan
Service (contract)
Maintenance (contract)
Software Update
Optimization
Personnel Support
Online Support
Technical Support
Spare Parts
Repairs
Revalidation
Field Trials
Retrofit
Feasibility Study
Financing
Survey of I/O Signals
Expansion
Online Support
Technical Support
Conception
Configuration Check
Configuration
Software Engineering
Optimization
Installation and Assembly
Migration
SW Update
Simulation
Field Trials
Certification
Training
Project Management
Retrospective Validation Support
Dismantling and Disposal
Integrated Information andSolutions Portals: New IndustryPortals Go OnlinePharmaceuticals and automotive are the first to go online, other in-dustries will follow suit: Siemens has created dedicated Internetportals for several industries that are tailor-made to meet the spe-cific demands of the respective industry.
www.siemens.com/automotive
www.siemens.com/pharma
www.siemens.com/paper
www.siemens.com/oil-gas
All solutions, products and services covering the entire lifecycle ofa plant are blended into an interdisciplinary, industry-specificportfolio. Solutions including automation and power supply tech-nology as well as offers from logistics or financial support areavailable at a single glance. Moreover, all-in-one packages that aredesigned for the specific processes in the respective industry arepresented together with case studies for real-world applications.Additionally, the site contains links to the A&D mall or to productsites so that the user can get more information on the topic. Thatway, specific plant solutions can be developed faster and more eas-ily. Industry portals therefore help to increase overall productvity.
Right now the portals for the automotive, pharmaceutical, paperand oil & gas industries are already online. Food & beverage, glass,chemicals, metals & mining and water will follow by the end of 2004.
infoinfoDo you want to know more about the Siemens Automation andDrives systems and solutions for the process industry? Simply visitour information portal on the Internet:
www.siemens.com/processautomation
onlineonline
e-business
Visit
www.siemens.com/processnewsHere you can download the current issue and past issues of Processnews in PDF format, and search directly for articles about specifictopics, technologies or systems in the Reference Center.
e-business
process news 2-03PublisherSiemens Aktiengesellschaft,Automation and Drives Division (A&D), Gleiwitzer Str. 555, 90475 Nuremberg
www.siemens.com/automation
Group Executive Management Helmut Gierse, Anton S. Huber, Alfred Ötsch
Responsible for ContentPeter Miodek
Responsible for Technical ContentCornelia Dürrfeld
ConceptChristian Leifels
EditorCornelia Dürrfeld, Siemens AG, A&D SP A ISDSiemensallee 84, 76187 Karlsruhe, GermanyTel.: +49 (0)7 21/5 95-25 91Fax: +49 (0)7 21/5 95-63 [email protected]
Editorial CommitteeRichard Ahearne, William Dalton, Dr. Michael Gilluck,Achim Heim, Walter Huber, Michael Lang, Harald Mag,Yves Masson, Hartmut Oesten, Rolf Panzke, Manfred Schirner, Detlef Seidel, Roland Wieser, Deborah Wolin
Publishing HousePublicis KommunikationsAgentur GmbH, GWACorporate Publishing ZeitschriftenPostfach 3240, 91050 Erlangen, GermanyTel.: +49 (0) 91 31/7-2 73 91Fax: +49 (0) 91 31/7-2 45 40
From June 2nd 2003 different phone and fax number:Tel.: +49 (0) 91 31/91 92-5 01Fax: +49 (0) 91 31/91 92-5 96
Editorial Staff: Dr. Beate Bellinghausen (Editor in Chief), Robert Engelhardt, Dorit Gunia, Christoph Manegold,Kerstin Purucker
Layout: Axel Kornemann, Reinhard Sorger, Jürgen Streitenberger, Werner Völkl
Copy Editors: Regina Severing, Olaf Wolff (Editor in Chief), Sabine Zingelmann
Jobnumber 004900 RPE32
DTP: Doess, Nuremberg
Print: Stürtz AG, Würzburg
Circulation: 28,000
© 2003 by Siemens Aktiengesellschaft Munich und Berlin
All rights reserved by the publisher.
ISSN 1430 2292
The following products are registered trademarks of Siemens AG:SIMATIC, SIPART, SIPAN, SITRANS, TELEPERM, TOTALLY INTEGRATED AUTOMATION, OXYMAT, ULTRAMAT
If trademarks, trade names, technical solutions or similar are not listed above, this does not imply that they are not registered.
Order No.: E20001-M6203-B100-X7600
27DIALOGUE
As one of the biggest crude oil processors in Germany, Shell & DEA Oil GmbH is setting a benchmarkwith the modernization of its refinery in Heide – with the automation platform Totally Integrated Auto-mation (TIA). Also included: the SIMATIC® PCS 7 open process control system with integrated fail-safeand fieldbus technology. The openness of the system makes it easy to link MES applications for processoptimization. The result: a maximum yield of high-quality, environmentally friendly fuels which willmeet the market demands of both present and future while minimizing energy and personnel require-ments. In other words, lower life cycle costs and higher product quality. And that is why the Heidefacility is one of the leading European refineries. Would you like more information on TIA? Just fax us:0 08 00/74 62 84 27 with reference AD/Z843.
Shell & DEA Oil is setting new standardsin safety and efficiency:TIA ensures optimized processes.
www.totally-integrated-automation.com
totally integrated