www.actemium.be

Citrique Belge NV produces citric acid in the Tienen plant in Belgium since 1930.

Citrique Belge is one of the world largest players delivering around 10% of the world citric acid production. Since October 2010 it became part of the German Group ADCURAM. Today Citrique Belge has around 260 employees, mainly skilled laborers working in a 5-shift system.

Citric acid has a wide range of applications. It can be used without risks in the pharmaceutical and food industry. It is used as a flavor enhancer in soft drinks, candy, fruit juices… It functions also as an antioxidant in meat products and canned vegetables/fruits to prohibit taint.

The production process delivers also a number of co-products which are sold separately. An example: the liquid remaining after the fermentation, sold under the brand name Citrocol, is used as binding agent in animal feed.

Lower TCO and hardware costs through virtualization of the WinCC installations at Citrique

Solution Partner

Automation

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Business ChallengeThe existing WinCC V6.0 installations were running on old PC’s causing maintenance problems since finding similar hardware for replacements became impossible. The Total Cost of Ownership (TCO) was too high. Citrique Belge ICT also needed to install new operating systems on the WinCC stations for security and integration reasons. This was only possible by upgra­ding the WinCC installations to V 7.0 SP3.

The requirements to implement the WinCC upgrades to V 7.0 SP3 were:•Fullintegrationintotheexisting

ICT infrastructure•LimitedbudgetfornewPChardware•VirtualizationofallWinCCserversand

clients on standard ICT hardware

Technical ChallengeTogether with the ICT department of Citrque Belge, the general contractor Actemium and subcontractor Axians – both part of the Vinci group – had to pro­pose the hardware specifications for 2 virtualservers,butusingonlyhardwarefrom ICT’s standard supplier Dell.

The2virtualservershadtouseVMWareESXiasHypervisorandhostamongthem23virtualPC’s(4redundantWinCCSer­versrunningonWindows2008R2SP164-bitOS,17WinCCclientsrunningonWindows7SP164-bitOS,1DataMonitorServerwith10clientsand1engineeringstationalsorunningonWindows2008

R2SP164-bitOS).Fullredundancyhadtobe guaranteed in case of failure of one of the2virtualserversincludingimmediateswitch-overoftheWinCCclientswithinasecond.

Inthefield17ThinClientshadtobeusedas stations for the operators to work on, takingoverthedesktopofthe17virtualWinCCclientsthroughRDPprotocol.

The2pairsofredundantserverscontrol4different parts of the citric acid production process : fermentation, „sporen“, fabrica­tionofco-products(FAB)anddownstreamprocessing (DSP). In WinCC V6.0 they

Visibility in production: SIMATIC WinCC SCADA system

With the SCADA system SIMATIC WinCC, Siemens offers an innovative, scalable process-visualization system with nume-rous high-performance functions for monitoring automated processes. Whether in a single-user system or a distributed multi-user system with redundant servers, the system offers complete functionality for all industries and features optimum openness.

wererunningunderWindows2003serverOSandusedSIMATICcommunicationpro­cessorcardsCP1613toincreasecommu­nicationperformancestothe24SIMATICS5and14SIMATICS7plc‘s.TousethevirtualizedenvironmentaftertheWinCCupgrade to V 7.0, the communication processor cards had to be replaced by asoftwaresolution,calledSIMATICNETSOFTNET-IES7,offeringsimilarcommuni­cation performances.

RemoteaccesstotheWinCCdataandscreensinview-onlymodefromtheofficeenvironmenthadtobeimplementedinphase 2 of the project.

SolutionTogetherwithAxians,ActemiumhasimplementedVMWareESXiV4.1asHypervisoron2DellPowerEdgeR720servers.

Server1hosts: •1xWinCCV7.0SP3redundantserver2forthefermentationprocess •1xWinCCV7.0SP3redundantserver2fortheDSPprocess •9xWinCCV7.0SP3clientsabletoviewandcontrolbothprocesses •1xVMWarevCenterServerwithaseparatevSphereClientforcentralmanagement oftheESXiHosts(livebackups)

Server2hosts: •1xWinCCV7.0SP3redundantserver1forthefermentationprocess •1xWinCCV7.0SP3redundantserver1fortheDSPprocess •8xWinCCV7.0SP3clientsabletoviewandcontrolbothprocesses •1xWinCCV7.0SP3DataMonitorServerwith10clients •1xengineeringstationwithStep7andWinCCforonlinemodifications

This was done in 2 phases in order to re­duce the risks in the running production environment.

Phase1ranfor2weeksandkepthalfofthe existing WinCC V 6.0 hardware (2 ser­versand9clients)runningtogetherinparallelwith1virtualservertocheckallclient operations in detail. This was possi­blewithoutanyPLCmodificationsbyusing existing IP addressing in the new virtualenvironment.Redundancywastemporarilydeactivatedduringthisphase1period.Italsoallowedfullytestingandcomparing communication performances with and without the usage of communi­cation processor cards. Value updates of process tags after a screen changes ap­peared almost instantaneously and the operatorshavenotnoticedperformancedifferences between the old and the new system.

In phase 2, the old hardware was comple­telyremovedandthesecondvirtualserverwas put into place, including the WinCC V 7.0 redundancy.

AnewWinCCoption,aDataMonitorserver with10concurrentclients,wasaddedtothesecondvirtualservertoallowremoteaccess to the WinCC data from anywhere in the plant. This increased the user friend­liness of the system for the end customer, since follow­up of KPI data, diagnoses and maintenance was now possible from the officeenvironment,evenfromhome throughVPNconnections.

Finally, the Veeam Backup & Replication software has been implemented for replication and backup of the Virtual machines.

WiththisvirtualizationCitriqueBelgere­duced considerably the pc hardware costs and was able to lower the TCO of the WinCC installations through central ma­nagementandlivebackupsofthevirtualenvironmentbytheICTdepartment.

Actemium Belgium is specialized in Totally Integrated Automation (TIA), containing electrical engineering and software development for the auto mation of production processes and machines. This software is not confined to the work floor but entails the total event of production including the integration of the ERP-system.

Results at a glance

•CostreductionwhenrenewingPChardware

•CentralmanagementofthevirtualserversbyICT

•Optimizationofthevirtualserverresources

•Possibilitytotakealivebackupoftherunningvirtualservers

•EasilyexpandablesystemthroughtemplatesforaddingnewWinCCclients

•Increasedeaseofuseanduser-friendlinessthroughtheDataMonitoroption offering remote access.

•TIAadvantages:1engineeringsystemforScadaandPLC

Information about the Siemens Solution Partner Program

Under the Siemens Solution Partner Automation and Power Distribution Program, we join forces with our Solution Partner. By merging our product and systems expertise with theapplicationandindustryknowledgeofourpartners,wehavecreatedacommonbasis forthefast,smoothandhighlyefficientimplementationofyourrequirement–customizedsolutionsforcompetitiveadvantage.

www.siemens.com/automation/solutionpartner

Actemium

LeonBekaertlaan24BE-9880AalterBelgiumTel:+32(0)93257550Fax:+32(0)93257555

www.actemium.be

Sales Order•Branch:FoodAcidsandadditives•Applicationtypical:CitricAcidproduction•End-Customer:CitriqueBelgeNV•GeneralContractor:ActemiumBelgium•SystemIntegration:ActemiumBelgium

and Axians Belgium•Location:Tienen,Belgium

Project Roll-out•Kick-off:Q3.2012•Engineeringphase:Q4.2012•GoLive:Q1.2013(phase1&2)

1st point of contact •ArletteSente(TechnologyManager)andSvenDebusscher(AccountManager)

•ChristopheSabbe,ActemiumBelgium•MichelBangels,ICTManager, CitriqueBelgeNV

TIA Product Inventory

PLC Controllers•24S5-PLC’s: 2x928BCPUinFermentation 4x948CPUinDSP 8x928ACPUinDSP 4x922CPUinDSP 6x928BCPUinDSP •14S7-PLC’s: 8xS7-416CPUinDSP 1xS7-315CPUinDSP 5xS7-416CPUinFermentation

•IndustrialNetwork:6xScalanceswitches •HMIsoftware: 4xWinCCV7.0RT64Kredundantservers 17xWinCCV7.0clients 1xEngineeringStationRC64K 1xDataMonitorServerwith10clients

•VirtualizationSW: VMWAREESXV4.1