Keep the balance in all aspects of your biogas plantWith modular solutions for automation and energy management

siemens.com/biogas

Answers for industry.

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Content

Modular solutions for maximum productivity

Integrated solutions

Scalable automation systems

Comprehensive instrumentation

Flexible power management

One partner worldwide

Experienced Industry Partner

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Biogas plants are often installed under extreme time and cost pressure.

This can only be achieved with the support of an experienced, globally

coordinated and locally focused partner. Furthermore, a high level of

efficiency must always be maintained during operation of the plant.

In the field of automation and energy management, Siemens offers a

perfectly balanced portfolio.

Modular solutions for maximum productivity

Renewable energy with the greatest potential

Biogas is a flammable gas which is produ-ced by fermenting organic material in bi-ogas plants and is then used to generate renewable energy. This type of energy has a much more favorable environmen-tal impact than many other types of alter-native energy and also offers a high level of fuel output per hectare. Biogas can be used universally – as a rule, it is used as the fuel for combined heat and power plants (CHP) for power and heat genera-tion. However, it can also be processed and transferred to the natural gas grid, making biogas available more widely andenabling more flexible and efficient use, e.g. in gas turbines with combined heat and power. A wide range of natural mater-ials can be used to generate biogas: e.g. liquid manure, corn silage, sewage sludge, organic waste, straw etc.

Increased transparency for economic production

Regardless of the raw material used, the size of the plant or the process used, we can offer products and solutions which cover all aspects of the biogas production process. A certain degree of automation will provide the necessary transparency for repeatable and efficient uses of raw material for conversion to biogas. Based onTotally Integrated Automation (TIA) and Totally Integrated Power (TIP), we offer solutions for the optimum integration be-tween automation and electrical infrastruc-ture which will help simply your operations, avoid unnecessary downtime and make for more efficient maintenance.

One partner for the entire production process

During system installation, which is usu-ally subject to extreme time and cost pres-sure, we can provide support in the form of efficient engineering tools, modular and scalable products. We can also help to mini-mize your business risk during operation of your plant – through the optimization of the processes and the general reduction of operating costs.

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Integrated solutions

With Totally Integrated Automation (TIA), Siemens is the only provider of a compre-

hensive range of products and systems for the automation of biogas plants. Based

on Totally Integrated Power (TIP), Siemens also provides integrated, economic and

safe solutions for energy management.

Totally Integrated Automation (TIA)covers products and solutions – from the field level through the production control level to the company manage-ment level.

Based on Totally Integrated Power (TIP), our power distribution concept ranges from the medium-voltage sup-ply system to the socket. The merging of TIA and TIP and the optimum inter-action of all the components used of-fers technical and economic benefits:

• Central engineering, operation and monitoring of field technology as well as the motor control center and switchgear with one system provides an integrated view of the production and electrical processes

• Increasing plant availability and reducing maintenance requirements through integrated asset management functionalities and revolutionary online diagnostics

• Low installation costs through the use of bus technolo-gy allows you to add devices quickly and easily

• Lower engineering costs due to comprehensive soft-ware tools

• Reduced commissioning time through flexible auto-mation solutions

• Increasing transparency through automatic archiving and reporting of process and plant information

• Reduced total cost of ownership and competitive ad-vantage because of the high reliability to your electri-cal energy utilized in the facility

The benefits of integrated solutions

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Sustainability during the installation and operation of your plant

The high level of integration of TIA and TIP and the optimum interaction of all the components used enable quick com-missioning and the problem-free, profi-table operation of your biogas plant. In automation, our offer ranges from the field level to the management level. For energy management, it is optimally com-plemented by a wide scope of solutions: from transformers, low- and medium-high voltage systems through individual control cabinets, power monitoring to compact container solutions.

Cost-optimized solutions throughout the entire life cycle

Hardware and software from a single source as well as preconfigured and pretested components not only ensure faster commissioning of your plant, they also provide a single resource for global

support and the long-term success and availability of your plant. You will also be-nefit from a reduction in the total cost of ownership (TCO) and can therefore con-siderably improve your return on invest-ment (ROI). The use of state-of-the-art bus technology also reduces installation costs dramatically in this context, for ex-ample. Comprehensive software tools lead to a decrease in engineering effort and associated costs. Our flexible solutions and many years of project management experience minimize the commissioning time for new plants. In existing plants, you can benefit from online monitoring, auto-mated archiving and reporting as well as concepts for preventive maintenance, se-cure remote monitoring and support and thus reduce your operating costs over the entire life cycle of your plant. Consequent-ly, operational analysis and economic via-bility calculations are greatly simplified and make it easier to fulfill the required documentation.

Automation concepts for varying requi-rements

From an automation point of view, biogas plants differ greatly in the way they fur-ther process raw biogas. The process for transforming raw biogas into processed biogas is far more complex in plants which supply the biogas to the natural gas grid than in plants in which the raw biogas is simply cleaned or desulfurized prior to com-bustion in combined heat and power plants. Depending on the process and the required efficiency level, a biogas feed-in plant in-volves far more instrumentation and auto-mation than basic raw biogas production. According to the plant type and require-ments – quantity structure and functiona-lity – we can offer the right products and solutions for your automation concept.

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Scalable automation systems

Customized parameterization

The automation level of a biogas plant must be configured depending on the require-ments and the relevant concept. We offer scalable solutions and different graphical configuration tools – either integrated di-rectly in SIMATIC PCS 7 or using WinCC flex-ible. This enables the efficient parameter-ization of field devices and setup of elec-trical components. Thanks to open state-of-the-art communications standards, all control commands and diagnostic data as well as the necessary operating faceplates and function blocks are available as a func-tion block library. Communication-capable components such as I/O modules and con-trollers use the fast PROFIBUS DP orPROFINET system. This means that remote I/O modules can be distributed to the var-ious areas of the plant, leading to shorter cable paths to the field devices and there-fore reducing installation costs and com-missioning time.

Safety integrated as standard

In biogas plants, reliable explosion protec-tion is a fundamental factor for the safe operation of the plant. For comprehen-sive explosion protection, the distributed SIMATIC ET 200iSP I/O system can be in-stalled via a remote PROFIBUS connection in Class 1 Zone 1 or Division 2 areas. This system is the most cost-effective solution for the hazardous area. The intrinsically safe and modular I/O system is particu-larly flexible and requires little effort in terms of engineering, assembly, space and cabling. For safety-instrumented functions up to level SIL 3, only the

required safety components must be added to the standard components to provide scalable solutions. In addition, the SIMATIC Safety Matrix tool can be used to create a simple and clear cause-and-effect matrix of protection functions. This tool offers considerable benefits during project engineering, operation and maintenance because of its simplied approach. You only need to program your interlocks in the Safety Matrix and your configuration logic, change management, testing, operator environment and system documents are generated automatically.

Savings potential through plant opti-mization

Depending on the plant size and auto-mation solution, there are various op-tions for increasing the productivity of your plant. Special concepts for online and remote monitoring can be used to reduce your TCO considerably. The use of TIA and TIP provides the full range of diagnostic options, because all field de-vices, automation and drive components are monitored. Mechanical components such as motors, pumps, valves, or heat exchangers are also supervised. If you decide in favour of a SIMATIC PCS 7 pro-cess control system, you can benefit from integrated advanced process control func-tions, which can be used to implement effective measurement and control con-cepts, for example to increase output. Further potential can be realized through the use of simulation tools in the control system for engineering change manage-ment and for training plant operators.

Our modular automation solutions are based on hardware and software com-

ponents from our comprehensive SIMATIC product range which are designed,

engineered, sold and supported by our team. At its heart is the SIMATIC PCS 7,

our innovative distributed process control system. The solution can be tailored

to particular requirements. Local control and operation without archiving process data

Local control and operation with automatic archiving

Operator Panel

SIMATIC S7-300 Controller

Gas analyzer

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SIMATIC PCS 7 Box

Gas analyzer

SIMATIC ET 200M with weighing system

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Local control and operation with remote access

Central Control

Central Control

Plant A

Plant A

Plant B

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Central control and monitoring of several biogas plants with web-based local operation

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Gas flare

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SIMATIC PCS 7 BoxOS Single Station

Gas analyzer

SIMATIC ET 200M with weighing system

Gas analyzer

SIMATIC ET 200M with weighing system

OS Single Station

SIMATIC S7-400Controller

DSLIndustrial Ethernet

DSL

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Ex-client

Gas analyzer

SIMATIC ET 200M with weighing system

Gas analyzer

SIMATIC ET 200M with weighing system

Gas flare

CHP

Gas flare

CHP

Web Server

SIMATIC S7-400 Controller

SIMATIC PCS 7 AS RTX ControllerIndustrial Ethernet

Central Archive Server

SIMATIC PCS 7 OS Server

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Comprehensive instrumentation

A large volume of measuring data has to be processed during operation of

a biogas plant. Integrated in the process automation, this forms the basis for

a problem-free production sequence and ongoing optimization of processes.

We support the economic production of biogas and its supply into the natural

gas grid with a wide range of products, both for explosion-proof areas and for

other less safety-critical plant units.

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Weighing technology for every task

The SIWAREX weighing and proportioning system can be used to perform weighing tasks accurately, for example when weigh-ing raw materials and by-products. It also offers calibration and verification capabi-lities.

Precise level meters

The SITRANS L device family provides a se-lection of measuring procedures for con-tinuous level measurement. Especially in the fermenter, the level of liquids and sludge can be measured by radar with the rugged SITRANS LR 200.

Point level switches with comprehen-sive diagnostics

Pointek sensors are used to recognize li-mit levels in order to detect overfilling intanks or foam. They also provide a wide range of diagnostic data, which enables the early detection of encrustation and maintenance requirements.

Intrinsically safe temperature measur-ing instruments

In a biogas plant, temperature monitoring is required at various points, such as in the fermenter or for the quantity of heatproduced after the combined heat and power plant. Siemens offers high-precision, intrinsically safe sensors and transmitters, e.g. SITRANS TH, with all the usual approv-als for combined temperature measure-ment.

Pressure measuring instruments for maximum economic efficiency

Regardless of the point where the pressure has to be measured, be it the gas bubbles in the fermenter or the flow volume of gen-erated gas in the pipeline using a metering orifice, the SITRANS P device family can be used to ensure economic and high-quality operation of the biogas plant.

Flow meters that can be calibrated

The SITRANS F device family can be ap-plied to perform all usual flow measure-ments, e.g. magnetic-inductive measure-ment for precise substrate measurement in pipelines. For heat supply after the CHP,

a heat measuring system with calibration capability is available for custody transfer application.

Positioner with simple operator control

For valve control, the SIPART PS2 intelli-gent positioner is available for linear and part-turn actuators. Its simple operation, numerous diagnostic functions and low air consumption can help insure success-ful and efficient operation of your valves.

Gas analysis for constant quality

Continuous gas analysis with ULTRAMAT 23enables the monitoring and control of the fermentation process and thus con-tributes to the quality of the generated biogas. In order to supply the processed biogas into the natural gas grid in accor-dance with official guidelines, the gas composition and the calorific value and density of the gas must be known. SITRANS CV is the ideal analyzer for de-termining the calorific value.

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Flexible power management

We offer a broad portfolio of medium- and low-voltage components including

power monitoring. Connecting them to the process control system, the world’s

largest installed fieldbus PROFIBUS provides universal integration in the electri-

cal infrastructure and in the communications standard. The selection of drives

for pumps, agitators or heat exchangers ranges from standard motors through

energy-saving motors in accordance with EFF1 up to explosion-protected motors

for Ex zone 1 / Class 1 Division 1.

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Transformers and medium-voltage sys-tems

When it comes to transformers, we offer the choice between commonly used oil distribution transformers up to 2,500 KVA and GEAFOL cast-resin transformers up to 16,000 KVA, which do not require facilities for oil retention. GEAFOL cast-resin trans-formers are largely maintenance-free. You can also choose between air-insulated me-dium-voltage systems (up to 24 KV, type 8BT1) and gas-insulated medium-voltage systems (up to 24 KV, type 8DH/J). The lat-ter are compact, maintenance-free, and can be used in all climates. Communica-tion-capable SIPROTEC overcurrent relays and motor protection can be used to deter-mine the causes of any system incidents quickly and conveniently as they are pro-grammable to protect your equipment and avoid outages.

Low-voltage distribution

SIVACON switchgear comprises the low-voltage distribution and the function of the motor control center (MCC). SIVACON is available in withdrawable, plug-in or fixed-mounted versions. TIASTAR, our low-voltage motor control center for the Americas, offers rugged, safe and effi-cient designs.

For simple switching technology, circuit breakers, overload relays and local switch-es, etc. are available. When controlling and monitoring low-voltage motors with constant speed using SIMOCODE pro, e.g. on pumps, slides or valves, in addition to the motor control all diagnostic data such as switching status, operating hours, phase currents, motor temperature and electrical active power are transmitted to the automation system via PROFIBUS. Our electronic soft starters for AC motors up to 1,200 kW at constant speed ensure soft startup and ramp-down and there-fore reduce the electrical and mechanical load considerably.

Frequency converters for all require-ments

Compact MICROMASTER 440 and SINAMICS G120 frequency converters cover the power spectrum up to 250 kW. They are fully integrated in SIMATIC via PROFIBUS DP and predefined faceplates are ideal for use in agitators, particularly for fermentation. For low power ratings, the converters can be placed directly in the motor control center.

Flexible power management

In larger plants, power management is essential for economic plant operation. Energy-intensive loads can be identified and effective measures implemented for optimized energy consumption. Highly efficient tools are available for plant-wide visualization, dimensioning of the power distribution and for assessing any modifi-cations: e.g. software add-ons such as SIMATIC PCS 7 powerrate and b.data power management, as well as the SENTRON PAC3200 power monitoring device. They use the fully integrated SIMATIC PROFIBUS DP connection and predefined faceplates for easy operation. Modular solutions for rapid commis-sioning

Biogas plants can be constructed and com-missioned more quickly and economically if the components are installed as preconfi-gured, ready-for-use units individually. We offer modular systems, from the compact control cabinet to the complete E-House in a container. Systems are installed accord-ing to functional areas, e.g. biogas genera-tion and gas processing, and with Siemens devices according to customer requirements. The only work required on site is the con-nection of interfaces and field devices.

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One partner worldwide

With branches in 190 countries around the world, we are a genuine global player – with a long ex-

perience in this industry sector. We are, therefore, the perfect partner for planners and operators

of biogas plants. We support our customers on site from the planning phase through installation

and commissioning up to servicing during the operating phase.

For many years, we have been providing optimally coordinated, modular solutions to address automation, instrumentation, drive technology and power distribution for the biogas industry and we can guar-antee the availability of spare parts and professional on-site support over the en-tire life cycle of your plant.

Benefits for plant constructors

Lower installation costs, reduced engi-neering effort, shorter installation times and the lowest possible environmental impact are all major factors in the suc-cessful implementation of projects. With a global network of experts in this sec-

tor, we can concentrate on the specific requirements of our customers and meet the high demands in the market

Benefits for plant operators

We are the leading manufacturer that can offer a complete range of integrated pro-ducts, systems and solutions for the field of automation and energy management. We offer you modular concepts for opera-tional analysis and optimization which youcan use according to your specific require-ments. Together with a worldwide service team we offer the ideal basis for efficiency and profitability of your plant – both now and in the future.

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Thinking globally, acting locally

In the fields of automation and electrical engineering, as in other sectors, interna-tional business requires globally active so-lution partners with excellent knowledge of local conditions. For this reason, a part-ner like Siemens is therefore a great advan-tage – present worldwide and with a net-work for service and support. In addition, Siemens is familiar with national standards, guidelines and regulations and offers an appropriate product portfolio for IEC and NEMA. This helps greatly in the problem-free implementation of global projects and ensures that the system meets all the op-erator‘s expectations from the start.

Solid knowledge of the industry

As a well-known provider of automation and energy management solutions for various industries, we have built up a wealth of ex-pertise over the years. This also greatly ben-efits our customers in the biogas industry. During both planning and commissioning, we synchronize the activities of all partners, be it for a small farm, medium-sized coop-erative or large industrial plant. And at the same time we work very closely together with plant builders and system integrators.

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Experienced Industry Partner

Medium-sized farm-based biogas plant

The privately owned biogas plant in Weyberhöfe produces biogas from liquid manure and renewable raw materials (e.g. corn and grass). To increase the reliability and efficiency of the plant, it was mod-ernized with the compact SIMATIC PCS 7 Box process control system. For the system integrator, Sigma Engineering GmbH, the economic and compact process control system provides exactly the right solution for a medium-sized plant with 500 kW power.

Large agricultural biogas plant

One of the largest biogas plants in Europe has been installed in Jessen by Agratec AG with the system integrator HEROS Anla-genautomatisierung GmbH. Since 2008, silage and grain has been used to gener-ate power and heat as well as organic solid and liquid fertilizer as a by-product. Apart from own consumption, the supply of heat and steam from the plant is used by local companies. Following expansion in a second building phase, 5.3 MW of power and 5.1 MW of heat will then be

We have been providing solutions for the biogas industry for many years. The

reason for our significant role in this sector is the seamless integration of auto-

mation, drive technology and power distribution, which is also demonstrated

in the numerous projects that we have implemented successfully.

generated in four CHP‘s. The plant is equipped with Siemens drive and switch- ing technology and the SIMATIC PCS 7 automation system. Various field devices are connected via PROFIBUS PA and two gas analysis stations are connected via PROFIBUS DP. For servicing, remote diag-nostics and the ACC alarm system for text and voice messages are integrated.

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Waste disposal plant

In the biomechanical waste treatment plant in Lübeck, biogas is generated from organic waste and sewage sludge. The dried digestate is processed into a sub-strate that is suitable for landfill in accord-ance with waste disposal regulations. The gas technology of the plant comprises a gas storage facility, a compressor system and two CHP‘s with 1.9 MW of power and 2.3 MW of heat. Together with our long-term partner Haase Energietechnik AG, we supplied drive and control technology from our product family. Haase also per- forms ongoing diagnostics, maintenance and emergency servicing during operation. To ensure that no time is lost during critical operating states, the fast delivery of infor-mation as text message and remote diag-nostics to remove failure is extremely im-portant.

Industrial biogas plant

The biogas plant in the Höchst industrial park offers disposal options for organic waste. 310,000 m3 of sewage sludge and 190,000 m3 of organic waste are pro-cessed every year and 45,000 m3 of biogas is produced every day. The plant operator, Infraserv GmbH & Co. KG, fed in about 5.1 MW of power and 3.9 MW of heat to the heat and power supply system of the industrial park. In this project, we took on responsibility for the PLS engineering to automate the biogas plant. The plant is controlled using SIMATIC PCS 7, inte-grated field device technology and pump drive systems from Siemens.

Full service provider

Schmack Biogas is a full-service provider for biogas plants and biogas processing. The company relies on Siemens products for the equipment of their vertical market plant systems as well. For the safe plant operation, amongst others, drive technol-ogy with motors and MICROMASTER fre-quency converters, automation components such as SIMATIC S7 or process instruments of the SITRANS family is being used. Continuous recording, monitoring and visualization of all process-relevant pa-rameters are of decisive importance for cost-effective operations. The result: added value that can be noticed.

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siemens.com/biogas

The information provided in this brochure contains merely general descriptions or characteristics of perfor-mance 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 in the terms of contract.

All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.

Subject to change without prior notice 09/12 Order No.: E20001-A80-T111-V1-7600 WS 09120.0 PDF © Siemens AG 2012

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