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D i a l o g u e

Jacky Chan Sr. Vice President Industry Sector Industry Automation/Drive Technologies

Editorial BoardDieter BroecklHartmut KlockerMabel ChinMarie Princess Nuevo Caraan

Technical WritersStephen BurkeColin OngJorey Guzman

Guest WritersDavid Ong, Excel MarcoEdwin Ng, Winston Engineering

PublisherSiemens Pte. Ltd.60 MacPherson RoadSingapore 348615

ConceptMarie Princess Nuevo Caraan

Regional Support and CoordinationIA/DT GC Regional Support & Coordination Group Erlangen, Germany

Publishing HousePublicis KommunikationsAgentur GmbH, GWACorporate PublishingP.O. Box 3240, D-91050 Erlangen, GermanyTelephone +49 (0) 91 31/91 92-527Telefax +49 (0) 91 31/91 [email protected]

Ideas Singapore is published twice a year

Title: Siemens AG

Circulation: 2,000

©2008 by Siemens Aktiengesellschaft Munich and Berlin

All rights reserved by the publisher.

The following products are registered trademarks of Siemens AGSIMATIC, SCALANCE,TOTALLY INTEGRATED AUTOMATION, SIMOCODE, PCS 7, ROBICON, SITRAIN, WINCC, SIMATIC PANEL PC, SINEMA, SIMATIC TELESERVICE, STEP 7

If trademarks, technical solutions or similar products are not included in the list, it does not imply that they are not protected. The information provided in this magazine contains merely general descriptions or characteristics of performance which, in case of actual use, do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed upon in the term of contract.

Printed in Singapore

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IEC 61511 in Practice

Process Safety WorkshopDate: Feb/March 2010 5 days 9AM – 5PM

To request for more information, please email us at [email protected]

First OilIntegrated Control and Safety Systems

The Magazine for Automation in Manufacturing Industries

Number 1, 2008

ideassingapore

.The Magazine for Industrial Innovations

MICA (P) 045/11/2007 Issue 09/09

3 ideas singapore | 2009

Safety Performance in every plant is required 24/7 round the clock.

In the process industries, it is common to find hazardous processes. These hazards may arise from raw materials and products being toxic, flammable, or even potentially explo-sive. Alternatively the process itself may be hazardous-involving high pressures, tempe-ratures, or exothermic reactions. Any of these hazards, if not properly addressed, could lead to fatalities.

Another important factor when dealing with hazardous processes is the safety of person-nel, plant equipment and the environment without compromising the production pro-cess through false trips.

In order to achieve this combination of safety and fault tolerance, a reliable Safety In-strumented System (SIS) is required in the process industry. A system which can bring the plant to a safe state at its highest availability requirements.

Comprehensive range of Safety Instrumented products and servicesSafety Integrated for Process Automation provides a comprehensive range of products and services for fail-safe and fault-tolerant applications in the process industry. Compo-nents from the Safety Integrated range are combined in a Safety Instrumented System capable of reacting rapidly to trip conditions to bring the plant to a safe state. All the principal components of a typical Safety Instrumented System are available from Sie-mens including fail-safe instrumentation, fail-safe and fault-tolerant control, up to the actuators.

Completely integrated in the standard automationThe SIMATIC S7-400FH controller with its matching I/O (Input/Output modular periphe-rals) offers a maximum degree of safety, fault-tolerance and availability for your applica-tions. From a fail-safe transmitter on PROFIBUS at the field-level, up to the SIMATIC PCS 7 process control system: with our offering you can implement efficient and flexible so-lutions for automation and safety applications in a totally integrated complete system.

Read on to know more.

Dear readers,

The Editors

N o t e f r o m t h e E d i t o r s

i d e a s s i n g a p o r e | 0 9 - 0 9C o n t e n t s

Cover

First OIl04 IntegratedControlandSafety

Systems

News

FPSO on Espirito santo06 SBMoffshoreannouncesFirst

OilonFPSOEspiritoSanto

Technology

08 OneCommonAutomationNetwork

12 SafeIn.SafeThrough.SafeOut.

14 Clamp-onLeakDetectionandPipelineManagementSolutions

Training

22 Sitrain-TrainingforAutomation&IndustrialSolutions

Products

16 30,000thSIMATICPCS7automationsystemleavesthefactory

Cover - ICSS

Page4

Siem

ens

AG

One Common Automation Network

Page08

Siem

ens

AG

17 Perfectinteractionbetweenmicro-controller,HMIpanels,andengineering

18 SINAMICSG120-EnergySavingSafeandCommunication-CapableFrequencyInverter

20 ExclusivelytoSiemens

21 GrowingThroughAutomation

SIMATIC S7-1200

Page17

Siem

ens

AG

Safety never takes a holiday!


Integrated Control and SafetyToday, many users are finding logical reasons to ju-stify using similar systems for control and safety functions, such as reducing the problems associa-ted with different programming procedures, langu-ages, installation requirements, and maintenance. There is always the risk that these different proce-dures might contribute to human error and possible safety problems. The financial benefits of using si-milar systems are also clear; reduced hardware, configuration, training, and inventory costs result from the reduced range and quantity of equipment that is required. In addition the burden of different service and support help associated with disparate systems is removed. The integration between con-trol and safety systems may be categorized into three levels:

Interfaced•The Basic Process Control Systems (BPCS) and the Safety Instrumented System (SIS) are based on dif-ferent hardware, and are connected together by a gateway for data exchange. The two systems use separate engineering tools.

Integrated•The BPCS and the Safety Instrumented System are based on different hardware, but have a uniform communication system and use a common engi-neering tool.

Common•The BPCS and the Safety Instrumented System are combined in the process control system. They use common hardware (controller, fieldbus, I/O). Stan-dard and safety related programs are executed in parallel and independent of each other.

Safety Integrated for Process Automation from Sie-mens allows the best possible type of integration of the Safety Instrumented System into the process control system. With this common integration, the basic process control system (BPCS) and the Safety Instrumented System are based on common hard-ware.

Integrated Control and Safety Systems

Siemens Integration of Control and Safety Systems

In the recent past, many users have kept the process control systems completely inde-pendent from their safety shutdown sy-stems. Controllers used for SIS require ex-tensive diagnostics necessary for TUV safety certification not available in process control systems. This meant users had no choice other than to use dedicated systems for con-trol and safety. Necessarily this involved the application of different programming lan-guages & procedures, training, installation and maintenance requirements as well as in-creased inventory costs due to wider range of spare parts needed. Now Siemens Safety Integrated for Process Automation allows the implementation of a truly Integrated Control a n d Safety System solution.


BPCS SIS

BPCS

BPCS

SIS

SIS

Gateway

ES ESOS

ES OS

ES OS

Interfaced

Integrated

Common

Integration levels of the Safety Instrumented System in the process control system

Many advantages of Safety Integrated can also be in-tegrated into any open process control system using standardized communication over PROFIBUS. These include:

Processing of standard and safety functions in one •S7-400H controller

Standard communication and safety-related com-•munication between controller and distributed I/O over PROFIBUS and PROFIsafe instead of a se-parate safety bus

Mixed operation of standard and safety-related I/O •modules in remote I/O stations of the ET 200M and ET 200S systems

However, the maximum potential of Safety Integrated can only be utilized through the unique combination with the universal SIMATIC PCS 7 process control sy-stem from Siemens. You then profit from further ad-vantages such as:

One engineering system for basic process control •and safety-related applications

Homogenous integration of the safety technology •into the automation system of SIMATIC PCS 7

Integration of the safety-related applications into •the convenient process visualization on the SIMA-TIC PCS 7 operator station

Automatic consideration of safety-related fault mes-•sages in the process visualization, with time stamping

Uniform data management for basic process control •and safety-related automation, including process visualization and diagnostics, therefore no com-plex data management between BPCS and SIS

Integration of safety-related hardware into the SI-•MATIC PCS 7 asset management for diagnostics and preventive maintenance

ConclusionThe new integrated safety concept from Siemens ena-bles programming of safety functions in the same graphical environment used to configure non-safety functions, but in distinctly different organizational units within the project. Safety functions are also co-lour-coded so that they are readily distinguishable from non-safety functions. This allows safety func-tions to be designed, reviewed, commissioned and locked in, while non-safety related code can be edited without restriction.

Siemens’ solutions allow the company to offer any of the three levels of integration, depending on users’ preferences. All three configurations are certified by TÜV for up to SIL 3 applications.

infocontact

www.siemens.com/[email protected]


C o v e r I n t e g r a t e d C o n t r o l a n d S a f e t y S y s t e m s ( I C S S )

of gas for injection or export. It is the deepest moored FPSOof the SBMfleet and thefirst turretmoored FPSO in the world using steel catenary ris-ersforfluidtransfer.Allprojectactivitiesincludingengineering, procurement, project management, construction supervision and commissioning were performed using in-house personnel from the SBM Offshore Group. SBM Offshore in joint venture with MISC will also operate the unit offshore Brazil.

The lease and operate contract was signed in No-vember 2006, the converted FPSO arrived in Bra-zil inDecember 2008 andfirst oil productionwasachieved less than two weeks after successful hook-up of the last steel catenary riser.

SBM Offshore N.V. announced that the FPSO Espirito Santo, located in the BC-10 deep water fielddevelopmentintheCamposBasinoffshoreBrazil, has achieved first oil production on 13July 2009. The FPSO is chartered by the BC-10 Joint Venture, which is operated by Shell with ONGC Campos Ltda. and Petróleo Brasilieiro S.A. (Petrobras) as co-venturers, from SBM Offshore injointventurewithMISC,underafifteenyearlease and operate contract.

The FPSO is moored in 1,789 metres of water depth and is designed to process 100,000 bar-rels of oil per day with gravity ranging from 16º API to 42º API, and to treat up to 45 MMSCFD

SBM Offshore Announces First Oil on FPSO Espirito Santo

Tony Mace, CEO of SBM Offshore: “Last month has been a very intensive period for the Company in which we have seen the conclusion of three years of hard work with the completion and start up of three major floatingproductionunitsrepresentingadesignpro-cess capacity of 260,000 barrels of oil per day.

Production commenced on the FPSO Espirito Santo in Brazil and on the Thunder Hawk Semi in the Gulf of Mexico, which are both substantial assets in SBM Off-shore’sleasefleetofseventeenunits.Intheturnkeysegment we completed delivery and commenced pro-duction on the FPSO Frade in Brazil and will operate that unit for another three years as well.”

N e w s F P S O o n E s p i r i t o S a n t o

6 ideas singapore | 2008 7 ideas singapore | 2008

Siemens congratulates its safety specialist partner, Excel Marco for the successful delivery of the facility wide integrated control and safety systems (ICSS) using SIMATIC PCS 7 for the FPSO Espirito Santo Project.

In Photo: Siemens standard and safety-related automation system components for ICSS

Be safety smart right from the start.

SIMATICPCS7 - the single solution for Integrated Control and Safety Systems

Join our Siemens challenge. Be safety-smart and stand to win an Ez-link card worth $10.

Log on to www.siemens.com.sg/safety-smart today.

For Questions and Inquiries, please email us at [email protected]. *Terms and conditions apply.

P r o d u c t P r o m o t i o n s

One Common Automation Network

The introduction of “functional safety“ takes account of the increasing complexity of production processes and the demand for cost optimiza-tion. Today, safety-related control and bus systems are the state of the art. They permit miscellaneous system architectures and offer various benefits to manufacturers, integrators, and users. But only a holistic con-sideration shows its real potential.

Fusion of Safety Technology and Standard Automation

but also to improve flexibility in the planning and implemen-tation of a machine or the production process, and to bring about greater availability in operation. What is the use of ri-gid safety equipment and shutdown mechanisms if in practi-ce they are bridged to increase cycle times or to set up a ma-chine? A modern safety concept can be adapted to the production process and handling of a machine. Safe automa-tion systems allow for quick and inexpensive implementation of new safety functions that support, not hinder, mainte-nance, commissioning, and service.

To implement the safety functions, safe I/O components or field devices need only be placed where they are required for reading safety-related signals and for the safe disconnection or shutdown of actuators. The assignment of sensors and ac-tuators in accordance with specified safety functions is no longer hard-wired, but is set flexibly by programming or pa-rameterization in the safety control. This allows the easy im-plementation of selective shutdown actions depending on the active operating mode, position, or safety requirement. In the event of a plant modification, a retrofit, or an expansi-on, the safety concept can be quickly adapted to the machi-ne concept through programmed or parameterized safety functions.

Drives and motors play a key role in the new safety technolo-gy. Until now, disconnection of the power supply has been the only possible measure for safe shutdown. As a result, ho-wever, the restart could be correspondingly difficult because of the resulting undefined machine or system state. Today, safety functions that are controllable via the fieldbus and in-tegrated into the drive controls enable a much more flexible approach through the use of various stop and monitoring functions, such as safe standstill or safely limited speed,

State of the artThe rapid pace of development in automation technology has led to great strides in efficiency and flexibility through micro-controllers, software, and fieldbus technology. Until recently, safety-oriented automation technology was greatly limited in the use of such innovations by its dependence on established standards. Until 10 years ago, the use of safety-related con-trols would have been almost unthinkable in many areas of the manufacturing industry. However, because the new tech-nologies had been proven in millions of installations, the rea-diness to include them in standards grew steadily. This re-thinking was supported by IEC 61508, the international basic standard for functional safety. It describes measures for fault detection and fault management, along with the steps re-quired for systematic development that also address the needs of secure communication. With it, nothing more stood in the way of the development of fail-safe automation and bus systems.

Regardless of whether a proprietary or protocol-based safety bus is used, data is exchanged between the safety-related controller and fail-safe I/O devices in accordance with the re-quirements of functional safety. In this way, all expected communication errors such as data loss, duplication, and fal-sification of message frames are recognized and overcome in interaction with the secure components.

From the fieldbus to the safe automation networkSafety-related bus systems make the distributed automation of safety functions possible while providing users with the benefits and optimization capabilities of standard automati-on, including those for safety. This is not just to reduce the wiring, the number of components, and the need for space,

T e c h n o l o g y S a f e t y I n t e g r a t e d

PROFIsafe is the first safety pro-tocol that has been developed and certified according to IEC61508. The profile permits thesimultaneous transfer of standard and safety-oriented data via one fieldbussystem.Asthefirstopenfieldbuses, Profibus and Profinetcombine standard and safety-re-lated automation technology and thereby offer users vast rationa-lization potential and numerous new functions, including safety features.

Safety-related data

Standard data

Standard data

PROFIsafe layer

PROFIsafe layer

Safety-related data

Standard bus protocol Standard bus protocol

PROFIBUS


infocontact


HMI

Standard and fail-safe controller

Control level

Field level

Sensor/Actuator level

System Architecture 3: A common bus system in combination with an integrated automation system offers the greatest savings potential for hardware and installation and also simplifies safety and standard engineering

without having to deenergize or to switch the machine off.

Intelligent sensors such as laser scanners are optimally suited for the safe drives: Initially, only a production slowdown and warning are triggered when persons ap-proach; shutdown occurs only when they enter the pro-tective zone. Similarly, for moving machinery or machi-ne parts, functions can be triggered safely, depending on their location or position.

The integration of these functions permits improved co-ordination of standard and safety components and thus simplified handling as well as flexible safety functions. Via the bus interface, process states and integrated dia-gnostics of field devices can be supplied directly to the visualization and engineering system for display, and thus they support commissioning, maintenance, and operation, in contrast to conventional safety relays with fixed wiring.

Safe networkingDistributed intelligence is unlimited if the controllers support safety-oriented data exchange via the network. This not only applies to large or modular machines. Sa-fety features are often not restricted to the effective zone of a machine control, but can extend to the pro-duction system, in whole or in part. For this, the con-trols must be capable of exchanging safety-oriented fail-safe signals over the network.

System architecturesFail-safe controllers and bus systems offer different ways of achieving safety in automation. Safe communi-cation plays an important role as to whether safety-rela-ted data can be transferred only on a proprietary bus system, or also via the standard bus system. The con-ventional version is the strict physical separation of sa-fety from standard automation. Innovative versions, however, integrate the safety system in the automation system. This can range from a shared network to an au-tomation system that is designed entirely for safety. Re-gardless of the distribution of intelligence to a central or distributed control system, it is possible to distingu-ish between three graduated system architectures. The-se architectures provide various advantages for manuf-acturers, integrators, and operators of machinery.

Separation of safety-related and standard automationSimilarly to traditional safety relay technology, safety-related and standard components are installed separa-tely, both functionally and structurally. The independent controllers and their I/O devices are each assigned to a separate bus system.

The advantages of this version lie in the functional and structural separation of safety and in the vendor-inde-pendent choice of safety and standard systems. Both systems can be handled independently of each other.

communication facilitates the engineering of safety and the coordination between standard and safety func-tions, including diagnostics and visualization.

Users are spared all the disadvantages of the coexis-tence of two different technologies, such as special trai-ning, additional installations, spare parts management, integration problems, different engineering, etc.

A safe investmentBesides all the structurally oriented decision-making cri-teria mentioned above, a further point should be menti-oned: It is important for users that their investment is made in a future-proof automation and network tech-nology. Here, protocol-based safety buses can be the right choice, because due to the “Black Channel” princi-ple, they do not restrict automation. Technical develop-ments, such as Ethernet, WLAN, etc., can also be used for safe automation.

The current changes in the standards situation have caused many machinery manufacturers and operators to review their previous safety concept. A reorientation toward an intelligent concept can introduce them to new market opportunities and secure existing competi-tive advantages.

In this architecture, the physical separation of safety and standard components is also possible, as is the in-dependent selection and handling of the safety and standard system. The use of a common network offers the advantage that the components, installation, and overhead of a separate bus system are no longer neces-sary. Likewise, interfaces for the exchange of shared si-gnals are not necessary if communication takes place over the existing bus interfaces. The use of a common bus system facilitates access to process signals and the diagnosis of distributed I/O devices.

One safety-related and standard automation systemThis architecture is based on the integration of safety in the automation system. Standard and safety automati-on are functionally separate. Both process and safety functions are executed on a single control unit. Fail-sa-fe and standard I/O modules can be operated jointly in the same structure, i.e. both in the stations as well as on the same bus system.

The use of a common network in combination with an integrated automation system with safety integrated of-fers the greatest potential for savings in hardware com-ponents, wiring, and installation space. The ability to operate standard automation and safety in combination on one bus node reduces the number of necessary dis-tributed stations, bus interfaces, and modules. Fail-safe modules are only used where they are necessary for monitoring and implementing safety features. Non-sa-fety-related signals such as control and operating si-gnals, etc. can be connected to standard modules.

A seamless engineering platform for standard and safe-ty automation with consistent data management and

System Architecture 2: The separation of automation and safety in a single bus system allows the vendor-independent choice of both systems with reduced overhead for communications.

HMI

Control level

Field level

Sensor/Actuator level

Standard

Controller

Fail-safe-

Controller

HMI

Standard

Controller

Fail-safe-

Controller

Control level

Field level

Sensor/ Actuator level

System Architecture 1: The standard separation of automation and safety offers a vendor-independent choice of the safety and standard system. Both systems can be handled independently of each other.


For the exchange of shared data, such as for diagnostic or process signals, associated interfaces must be availa-ble and the data must be processed accordingly.

Safety and standard automation on one busSafety and standard components are installed function-ally separately from each other. The independent con-trollers, I/O modules, and field devices are networked via a common bus system. This means that safe and non-safe input and output signals are transferred via a single bus line.

Safety Integrated is the consistent implementation of safety technology within Totally Integrated Au-tomation: Safety functions are directly integrated into the standard products and offer user-friendly and seamless integration in standard automation. This provides numerous advantages for machine manufacturers and plant operators, particularly in economic terms.

T e c h n o l o g y T u n n e l S y s t e m s

The most dangerous sections of highways and express-ways are tunnels, where accidents can have particular-ly disastrous consequences. Rescuing the injured and dealing with breakdowns is considerably more difficult than on the open road. Accidents, fires and excessive carbon monoxide values must be detected and dealt with quickly. Siemens offers an advanced traffic con-trol solutions and safety and information systems that optimize road safety.

Tunnel control centerThe centerpiece of tunnel control and safety

Existing tunnel control centers have usually been equipped with widely varying hardware and software designed to conform to local regulations and technical standards. Siemens has developed a control system that integrates a multitude of safety components and control models, enabling communication between pro-prietary developments and standard industry compon-ents. The system brings together traffic guidance and control equipment, safety technology, lighting, ventila-tion and power supply equipment, emissions measure-ment, and fire alarm and emergency call systems. Traf-fic can be controlled either automatically or by active operator intervention. If a fire alarm is activated, for example, the traffic lights at the tunnel entrance auto-matically switch to red and the tunnel is closed.

Reference ProjectsWith a length of 3,820 meters, the Nefise Akçelik tun-nel in Turkey is the country’s longest expressway tun-nel. Siemens provided the complete traffic control technology for the project, from a tunnel control cen-ter to traffic guidance systems, power distribution s y -stems, the lighting, ventilation and fire protection

Safe In. Safe Through. Safe Out.

Tunnel Systems from Siemens

A road in a tunnel can hardly be compared to normal roads. The roadway is narrower, the height is restricted and there is a distinct lack of daylight. Moreo-ver, the space for maneuvering to avoid other vehicles is usually limited. In spite of all this, the safety risk in tunnels is hardly any higher than on normal roads—as long as modern technical systems monitor all the important parameters, regulate the traffic and ensure a smooth flow of vehicles. This is where Siemens comes in as the ideal partner of choice.

equipment, radio systems and camera monitoring equipment with automatic event detection. The tunnel was constructed to cut travel time from one hour (along a 42-kilometer coastal road) to 15 minutes. Its state-of-the-art equipment makes the Nefise Akçelik tunnel one of the world’s most advanced tunnels. An automatic detection system identifies vehicles that have stopped or are moving in the wrong direction, pe-destrians, sudden changes in vehicle speed, congesti-on, extraneous objects on the roadway or smoke, and immediately triggers the alarm systems accordingly. The system also analyzes a multitude of data – such as an increase in the carbon monoxide level, impaired vi-sibility or changes outside the tunnel – and automati-cally activates defined operating plans to respond to each situation. To ensure a comfortable and safe jour-ney, lighting can be adapted to tunnel conditions and the ventilation system can be controlled. A wireless communication system enables contact with various public services from within the Nefise Akçelik tunnel. For example, drivers’ attention is quickly drawn to spe-cial situations in the tunnel via radio transmitters, pro-viding them with safety and warning information by messages or variable-message signs. General an-nouncements can also be made through 252 loudspea-kers in the tunnel. The automation system ensures that the ventilation, lighting and traffic control systems function quickly and reliably in case of a fire. A total of 84 jet fans have been installed and, about every 100 meters, foam fire extinguishers have been provided, along with fire closets, including dry-type fire extingu-ishers. An additional, water-type fire extinguishing sy-stem is supplied from a tank with a capacity of 370 cu-bic meters that is automatically constantly monitored. The tank is kept filled at maximum level by diesel and jockey pumps.

Sitraffic ITCC (International TunnelControl Center) is a modular tunnel control system based on standard com-ponents and developed by Siemens. Its control modules and communica-tions interfaces can all be tailored to country-specificrequirements.Inaddi-tiontocontrolelementsfortraffic,thesystem includes operational control features for the tunnel’s lighting, ven-tilation, power supply, fire alarm sy-stems, harmful emissions testing, and emergency call services. In northern Turkey, in the country’s longest road tunnel(2.3miles),NefiseAkcelik,Sie-mens supplied the entire power supply, lighting, and ventilation technology as well as the security, sensor and com-munication systems. The centerpiece of thesystemis theSitraffic ITCCtun-nel control center, which oversees and manages the operational and traffictechnology as well as the exterior sy-stems for the tunnel.


T e c h n o l o g y C l a m p - o n L e a k D e t e c t i o n a n d P i p e l i n e M a n a g e m e n t S o l u t i o n s

Whether customers are looking for increased pipeline control, protection against theft or are under regulato-ry constraints, Siemens SITRANS FUH1010 clamp-on ultrasonic leak detection system is the answer, offe-ring four distinct benefits:

Extreme sensitivity•High accuracy•Proven reliability•Continuous robustness•

SensitiveThe leak detection system from Siemens is based on the normalized volume balance technology. Combine this with temperature and pressure computation mo-dels, continuous Reynolds number flow profile com-pensation and sonic signature liquid density and visco-sity identification and the result is an extremely sensitive solution. By means of alarm thresholds thatcan be set in accordance with user requirements to ac-commodate specific operating conditions, the leak de-tection system detects releases in real-time. If an im-balance between the inlet and outlet data is detected during any four integration periods (1, 5, 15 or 60 mi-nutes) an alarm is activated, calling for operator atten-tion. On the user-friendly display the operator can quickly and easily identify where a release is located. In addition, a visual trend line is shown, facilitating identification of very small releases that occur before the alarm thresholds are breached. Given the sensitivi-ty of the ultrasonic flow measurement technology, a leak detection system from Siemens also provides:

Product type and quality identification•Measurement under flow and no flow conditions•Bi-directionality •Pig passage alarm and tracking•

AccurateSince the SITRANS FUH1010 leak detection system is based on compensated balance technology, it provides very accurate estimation parameters for location, flow rate and total volume in the case of a product release. This accuracy allows an event to be located within +/-150 meters and enables recognition between a leak and other pipeline operations such as pump start-up. In addition, pigs or product changes can be easily re-cognized and tracked. While most leak detection provi-ders only offer the softwarepart of the system, Sie-mens also supplies the complete range of flow and temperature instrumentation that provides informati-on for the software to analyze. This not only providescustomers with a very accurate and integrated detec-tion solution, it also adds the benefit of one-stop-shopping.

ReliableThe proven and high reliability of the Siemens system lies in its ability to provide reliable decisions on the existence of a release. Several functionalities are in place to create this level of reliability:

Clamp-on Leak Detection and Pipeline Management Solutions

SITRANS F

With benefits that include sensitivity, accuracy, reliability and robustness, Siemens clamp-on ultrasonic leak detection systems offer customers a realtime solution for small and large product releases in installations ranging from oil pipelines to processing plants

To avoid false alarms, the system senses pipeline ap-•plication conditions, such as liquid aeration, emp-ty pipe, temperature changes, interface arrival, line packing and dynamically compensates the af-fected area until conditions improve

Multiple flow meters can be installed, allowing con-•tinuous line balancing measurement; even if one goes off line

Database stores system history for audits, trouble-•shooting purposes and performance analysis

Data communication options allow operators to •work on the system from a remote location

RobustSince Siemens leak detection solution has no moving parts to wear, and external sensors that do not require periodic cleaning, it is very robust. Operation is maintained despite liquid property changes such as in-ferred density, temperature and pressure. For this to properly work, the system gathers a wealth of infor-mation that is available to the operator by the push of a button: flow rate, batch size and location, scraper lo-cation, interface location, liquid API number, Reynolds number, site station diagnostics etc.

infocontact


The clamp-on differenceAs with any other clamp-on flow device from Sie-

mens, it is not necessary to cut the pipe or shut

down operations to install the flowmeters that are

so vital in leak detection systems; the sensors are

quickly and easily mounted on the outside of the

pipe, minimizing maintenance expenses and pre-

venting deposits from forming. The clamp-on de-

sign also eliminates the need to modify pipes or

interrupt the flow.

Key features at a glanceComplete software and hardware solution•

Real-time detection of small and large product •

releases

Easily accessible pipeline performance data•

Operation unaffected by changes in liquid •

properties

Easy system installation and optimization•


material transport and telecontrol systems. What is unique about these products is their common system base. Process automation, discrete control (high-speed logic), process sa-fety (SIS) and batch processes use the same hardware and software.

SIMATIC PCS 7 release 7.1 with a revamped modern user in-terface and many added functional features has been availa-ble since the beginning of 2009. The new “Advanced Process Library” provides a large number of pre-defined functions which all help significantly cut the cost of planning and engi-neering. Future developments will focus on optimizing the life cycle of plants. Users are set to gain even greater bene-fits in the future from the parallel process strategy in all pha-ses of the life cycle ranging from the planning and operating phase through to the refurbishment of a plant.

Siemens has recently shipped its 30,000th SIMATIC PCS 7. This successful automation system has been in-stalled in over 10,000 projects in all sectors of the pro-cess industry.

As in previous years, Siemens succeeded again last year in significantly increasing its market share in the field of DCS (Distributed Control Systems). A recent study carried out by ARC Advisory Group analysts has identified Siemens as number three on the global scale. SIMATIC PCS 7 uses all the benefits of the open system architecture provided by Totally Integrated Automation. This openness offers scope for widely diverse applications. In fact, SIMATIC PCS 7 ap-plications can be found right across the process indus-tries. The wide spectrum of applications ranges from pa-ckage units to large plants involving over 100,000 I/O (process signals). Seamless integration provides more than a conventional process control system: direct inte-gration of electrical infrastructure, route control for

30,000th SIMATIC PCS 7 automation system leaves the factory

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For demanding technological tasks, technology functions for counting, measuring, closed-loop control, and motion control are already integrated as standard. In addition, compared to the SIMA-TIC S7-200 predecessor model, the new micro-controller also has a faster processor and larger memory, which can be divided flexib-ly between program and application data.

The new SIMATIC Step 7 Basic engineering system provides inte-grated engineering for controllers and SIMATIC HMI Basic Panels. SIMATIC Step 7 Basic V10.5 with integrated WinCC Basic for visua-lization tasks supports the user with task-oriented and intuitive editors for a high degree of user-friendliness and efficiency in en-gineering. The coordinated solution of controller and engineering system can be expanded through a range of HMI Basic Panels with a high IP65 degree of protection and with integrated Profinet in-terface. The panels include 4 to 15-inch pixel-graphic displays with touch screen and tactile function keys. All panels consistently offer the same functionality regarding reporting, recipe manage-ment, and trend curve functions. The SIMATIC S7-1200 Micro-Controller is versatile and is suitable for both the efficient automa-tion of smaller machines and conveyor systems as well as distributed closed-loop control components in larger systems.

The SIMATIC S7-1200 Micro PLC (programmable logic controller) is a new modular controller for compact appli-cations in the lower performance range. In developing the controller and the software, particular emphasis was given to seamless integration and the ideal coordination of controller, HMI, and software.

The design of the new SIMATIC S7-1200 Micro-Controller is scalable and flexible. This makes it possible to fulfill au-tomation tasks with precision. The central module can be extended flexibly with input/output and communication modules. The “signal boards“ are a new feature. They are simply attached to the front of the CPU module and provi-de either two DI (digital input)/DO (digital output) inter-faces or one analog output. This allows a very compact design for applications with only a few signals. The new micro PLC can be expanded for serial communication with two communication modules, each with an RS232 or RS485 port.

The SIMATIC S7-1200 has an integrated Profinet interface for easy networking and communication between engi-nee ring system, controllers, and HMI; for example, for programming and CPU-to-CPU communication. The Sima-tic HMI Basic Panels for visualization are also connected via this interface. The CSM 1277 expansion module, an unmanaged 4-port Ethernet/Profinet switch, is available for networking multiple controllers or HMI devices.

Perfect interaction between micro-controller, HMI panels, and engineering

infocontact

www.automation.siemens.com/microsite/[email protected]

SIMATIC PCS 7 release 7.1 with a revamped modern user interface and many added functional features has been available since the beginning of 2009. The new “Advanced Process Library” provides a large number of pre-defined functions which all help signifi-cantly cut the cost of planning and engineering. Future developments will focus on optimizing the life cycle of plants. Users are set to gain even greater benefits in future from the parallel process strategy in all phases of the life cycle ranging from the planning and operating phase through to the refurbishment of a plant.

The new SIMATIC S7-1200 Micro-Controller from Siemens is characterized by its versatile and flexible setup concept, along with high performance and an extremely compact design. The new SIMATIC Step 7 Basic engineering system configures both the controller and the HMI (human-machine interface) Basic Panels. This ensures simple and rapid programming, networking, and commissioning.

P r o d u c t S I M A T I C P C S 7 P r o d u c t S I M A T I C S 7 1 2 0 0


The PM260 Power Module series further distinguishes itself as a result of a higher standard clock frequency and an integrated sinusoidal output filter.

Control Units Control Unit controls a motor using a range of different closed-loop control techniques. In addition to the closed-loop control, additional functions are available that can be adapted to the particular application by appropriately parameterizing them. info

contactwww.siemens.com/[email protected]

SINAMICS G120 Benefits at a GlanceModular, flexible and expandable

Future-oriented drive concept•

Easy maintenance and servicing•

Integrated safety functions

STO, SS1 and SLS functions integrated (unique worldwide)•

Low cost and less complex construction of drives in a safety-oriented, uniform •

automation and drive environment

Safety and protection for man and machine•

Communication via PROFIBUS and PROFINET •

Optimized engineering and configuration structures •

Totally Integrated Automation (TIA), consistency from SINAMICS through to •

the automation level

Energy-saving through energy recovery

Energy regeneration capable, approximately 100% regeneration feedback•

Saves energy and space•

Faster engineering, fast commissioning

SIZER and STARTER tools and data backup using the Basic Operator Panel •

(BOP) and MMC card

Globally certified•

In conformance with UL and CE, Safety Integrated (IEC 61508/SIL 2), SEMI F47-0706•

Power Module at a glancePM240

0.37 kW to 250kW •

3AC 380…480V, 47…63 Hz•

Increased air cooling by built-in fans•

Integrated brake chopper (up to 132 kW) •

PM250

7.5 kW to 75 kW •

3AC 380…480V, 47…63 Hz•

Energy regeneration into line supply •

A-type filter integrated, no line reactor required•

PM260

11 kW to 55 kW •

3AC 500…690V, 47…63 Hz•

Energy regeneration into line supply •

A-type filter integrated, no line reactor required•

Integrated sinusoidal filter•

Control Units at a glanceCU230P-2

for pump, fan and compressor•

V/f, FCC, Sensorless vector control•

Modbus RTU, CANopen, RS485(USS), PROFIBUS DP•

6DI, 3DO, 4AI, 2AO (all programmable)•

CU240x

RS485(USS), PROFIBUS DP, PROFINET•

Encoder interface •

V/f, FCC, torque control, Sensorless vector control•

Fail-safe for Safety integrated•

9DI, 3DO, 2AI, 2AO (all programmable)• 19 ideas singapore | 2008

SINAMICS covers a broad performance spectrum. Compo-nents that are finely graduated, with respect to one ano-ther, permit drive solutions that are perfectly tailored to the particular application to be cost-effectively and effici-ently realized.

The SINAMICS G120 drive inverters distinguish them-selves a result of their modular design (Power Module and Control Unit), as well as numerous innovative functions that they have in common – such as for safety technology (Safety Integrated), energy recovery and communication capability. With a wide range of versions in the power range 0.37 – 250 kW (0.5 – 400 HP) for G120, they are suitable for a broad range of drive solutions.

The Control Unit controls and monitors the Power Module and the connected motor in several operating modes that can be selected. It supports communications to a local control as well as to monitoring devices and equipment.

SINAMICS G120 - Energy Saving, Safe and Communication-Capable Frequency Inverter

Power Module PM240PM240 Power Module has an integrated braking chopper. Loads can dynamically brake using an external braking re-sistor. With the DC link capacitance, a sufficient control range is available to control the DC link voltage. This al-lows certain applications to be easily implemented.

These applications include, for example, kinetic buffering or using the kinetic energy of the load to implement a controlled stop when the power fails.

Power Module PM250 and PM260As a result of the innovative circuit concept, the kinetic energy of a load can be fed back into the line supply. With its regenerative feedback capability (energy recovery), the PM250 power module series offers enormous energy-saving potential. Regenerative energy is no longer con-verted into heat in a braking resistor.

For SINAMICS G120, several Control Units with different functionality are available. Siemens Industry extends the modular frequency inverter SINAMICS G120 by the basic con-trol Unit (CU240E) for standard applications and by the PRO-FINET Control Unit (CU240S PN-F) for PROFINET with Safety Integrated. This includes the specially designed versions with integrated functions for pump, fan and compressor applica-tions (CU230P-2).

The Sinamics G120 converter from Siemens now has a new Control Unit (CU) with a Profinet interface. This means that the Sinamics G120 converter series can also be used in complex automation architectures which require real-time Ethernet.


P r o d u c t S I N A M I C S G 1 2 0

Exclusively to SiemensWinston Engineering Corporation is a leading pump spe-cialist in Asia. Being the leader in their business operati-on, they recognized that Siemens is the right partner for their vision to extend, expand and explore. Winston is now the largest motor stockist in SouthEast Asia with good range motor families such as Siemens standard mo-tors and explosion proof motors.

With the high pumping requirements from various indus-tries such as pharmaceutical, oil and gas, water, chemical, semiconductor, marine and general manufacturing. Win-ston Engineering trust only Siemens for its motor require-ments since 2001.

“In hazardous areas such as those found in the oil indus-tries and in gas works, motors must meet the highest sa-fety standards - and you can always rely on Siemens ex-plosion-protected motors. With customized and advanced drive systems that are built to run extreme conditions. And besides, Siemens motors quality and reliability had been proven worldwide.” says Mr Henry Ong, Managing Director.

Siemens offer a seamless program for all requirements

with maximum security and the highest efficiency. For the explosion protection types “increased safety“ - “e“ (EEx e II), flameproof enclosure - “d“ (EEx de IIC) and non-sparking - “n“ (EEx nA, Ex nA ) for gas explosion protection. New additions to the series are the motors for dust explosion protection.

The Siemens Energy Saving motors also offer a signifi-cant impact on operating cost which account for 97% of life cycle cost of a motor, Significantly lower opera-ting costs, up to 45% less power losses, extended ser-vice life, and low maintenance. “Siemens powerful energy-saving motors can easily be integrated anywhere; they comply with all current in-ternational standards and cover more than 90% of all conceivable applications worldwide. With their alumi-num or cast-iron enclosures, frame sizes from 56 to 450 mm, outputs of between 0.06 and 1,000kW – Sie-mens rugged, energy-saving motors offer an excellent price-performance ratio and high operational reliabili-ty. “Mr. Ong ended.

One of the key objectives of a company is conti-nuous growth and this is more often than not achieved with increased productivity through automation of business and work process, unless one can invent commercially viable products from time to time. The Automation industry has been gaining momentum and blossoming large-ly because of three key factors. The sensing tech-nology providing more accurate and real-time measurement; the final element that activates equipments under control; and the logic solver comprising of smaller and faster microprocessors that takes instruction from carefully thought out application software.

All these work as an integral system to automate operations that would otherwise be carried out by people manually, thus reducing manpower and at the same time producing higher through-put and consistency tirelessly. This integral sy-stem has been the case for decades but what is changed today and still constantly changing is the processing speed, real-time response, size of system footprint, integration between different systems, networking capability, storage capacity, lower power consumption and the list goes on.

Today the automation industry applies the same principal but much more complex in every aspect in order to capitalize on technologies that are available in the market. Very often interfacing with sub-systems or other control systems are required to form a larger network of control sy-stems architecture. This results in greater need for integration capability to ensure that all these equipment work together in unison as desired.

An analogy will be like having an orchestra where all the musicians must play the symphony harmoniously.

This is where Systems Integration comes in, where specialization in one product is just not good enough. This is where linking systems to-gether is not a stop-gap temporary measure but where seamless integration of data where con-trol command transfers has to be executed like clockwork.

Growing Through Automationby David Ong, Excel Marco

I n s i g h t s P a r t n e r s h i p

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[email protected]

So, be it that when you have a group of talent musi-cians or a requirement to automate industrial pro-cesses or equipments, don’t forget to choose an equally talented orchestra conductor for the former and, don’t set up your automation project for failure, choose a qualified if not certified systems integrator. May we all enjoy greater level of automation and higher level of growth.

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[email protected]

Ideas Guest writer - David Ong , Managing Director of Excel Marco

ExcelMarcoisaSiemenscertifiedsolutionautomationpartner in Process Control System SIMATIC PCS 7 and PCS 7 Safety Specialist.

Siemens and Excel Marco jointly provides complete auto-mation solutions for Process Safety to the offshore FPSO (Floating Production Storage Off-loading) Oil and Gas ProductionPlatform,Jack-upDrillingRigs,OnshoreRefin-eryandPetrochemicalplantsintheAsiaPacificregion,Middle East and the South Americas.

From left to right: Siemens - Mr. Simon Lee, Sr. Sales Engineer; Ms. Mabel Chin, DGM Siemens I DT; Mr. Jacky Chan, SVP Siemens I IA/DT. Winston Engineering - Mr. Henry Ong, Managing Director; Mr. Collin Ong, General Manager; Mr. Edwin Ng, Senior Sales Engineer

I n B r i e f P a r t n e r s h i p


Course Description Pre-requisites Course duration

Schedule 2010

Simatic PLC

SIMATIC Step-by-Step

Provides a good foundation in Simatic Step7 software environment and skills to handle and maintain SIMATIC S7-300/400 PLC.

Background in Automation

3 days 11-13 Jan 03-05 Feb15-17 Mar 14-16 Apr10-12 May 02-04 Jun12-14 Jul 18-20 Aug06-08 Sep 20-22 Oct 17-19 Nov 08-10 Dec

SIMATIC S7 Programming 2

Directed at personnel engaged in project engineering tasks who will learn to structure and create advanced S7 programs in order to work efficiently with S7.


5 days 08-12 Feb 19-23 Apr07-11 Jun 23-27 Aug25-29 Oct 13-17 Dec

Simatic HMI

SIMATIC HMI Panels/ WinCC Flexible

Performing of a complete system configuration (graphics design, system integration etc.) Providing skills with the user management tool including security, access, alarms and messaging.

General Computer Knowledge

2 days 25-26 Jan 18-19 Feb25-26 Mar 07-08 Apr24-25 May 17-18 Jun22-23 Jul 12-13 Aug20-21 Sep 11-12 Oct25-26 Nov 01-02 Dec

SIMATIC WinCC Foundation course to provide participants with concepts of WinCC SCADA software.

General Computer Knowledge

3 days 18-20 Jan 22-24 Mar17-19 May 19-21 July13-15 Sept 22-24 Nov

Simatic NET

SIMATIC S7 Communications

Foundation course to provide participants with an understanding of networking and communication concept in SIMATIC S7 systems.


3 days Upon request

Certified PROFIBUS DP Engineer

Worldwide recognized training program that covers the technology, design and operation of PROFIBUS DP network.

None 3,5 days 22-25 Feb21-24 Jun04-07 Oct

Certified PROFIBUS PA Module

Fully concentrated on PROFIBUS PA. Only accessible for people who passed the Standard PROFIBUS Engineer Course.

Certified PROFIBUS Engineer

1,5 days 25-26 Feb24-25 Jun07-08 Oct

Simatic PCS7

SIMATIC PCS7 System Engineering

Defining a typical project and planning the system architecture. The participants build, test and debug a simple PCS7 process system.

Background in Automation

5 days 08-12 Mar 26-30 Jul

08-12 Nov

Drives/ Motion Control

Micromaster MM4 Drive

Provides basic technical knowledge for start-up and maintenance of Micromaster 440.

None 2 days 01-02 Feb 14-15 Jun18-19 Oct

MASTERDRIVES Service and Commissioning

The course is designed for Service and Commissioning personnel to configure the Masterdrive VC (Vector Control).

Basic knowledge in Drives

4 days 16-19 Mar06-09 Jul

01-04 Nov

SIMOREG DC-Master 6RA70

Basic electronics knowledge would be an advantage.Familiarity with DC drives.

Basic electronic knowledge & familiarity with drives

3 days 26-28 Apr (A/C) 02-04 Aug (D/C)

Training for Automation and Industrial Solutions 2010 Training Calendar

S I T R A I N T r a i n i n g f o r A u t o m a t i o n a n d I n d u s t r i a l S o l u t i o n s

infocontact

www.siemens.com.sg/[email protected]+65 6490 6988

Machine communication has never been easier

SIMATIC S7-1200

www.siemens.com/S7-1200

Siemens once again expanded its range by introducing the SIMATIC S7-1200 micro PLC together with the SIMATIC HMI Basic Panels and SIMATIC STEP 7 Basic engineering software for simple-and-speedy programming, networking and commissioning. The micro PLC‘s central processing unit is fully compatible with a range of I/O and communications modules, providing flexible extension options. The system also offers a PROFINET inter-face for easy networking and communication between the engineering system, controllers, and HMI.


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