process · the control technology in a continuous process ... maxum edition ii for russian...

Systems and Solutions for the Process Industry

processnews

11th edition April 1|2006

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RFID technology in thepharmaceutical industry:

Smart Packs

Siprocess micro process system:

Faster Time to Market

More PerformanceMigrating process control and switchgear systemsin the world’s largest phenol plant at INEOS Phenol

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For INEOS Phenol, Siemens executed severalprojects. Among them was the migration ofthe control technology in a continuous processwith about 8,000 process signals – leading toclear benefits in plant operation

Siemens will be presenting Siprocess atAchema 2006: an open, modular micro-process system with integrated automationthat helps reduce time to market for newand optimized chemical products

RohMax Oil Additives introducedSimatic IT in its production, andhaving filled more than 6,000customer orders, production isnow more flexible and reliable

CONTENT2

process news 1/2006

Cover Picture:INEOS Phenol in Gladbeck,koeppel photoDesign

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3 EDITORIAL

4 NEWSMaxum edition II for Russian steelworks

Sitrans P DS III wins award

Process instrumentation for zinc mine in North Korea

Simatic PCS 7 and Simatic Batch at BASF in Spain

TITLE STORYChemical Industry

6 A Challenging ProjectMigration to Simatic PCS 7 and Simatic IT at INEOSPhenol with no downtime or loss of production

CASE STUDIESAdvanced Process Control

10 Optimal PerformanceAdvanced Process Control solution at INEOS Phenol

Chemical Industry18 Impressive Results

Simatic IT connects Simatic PCS 7 to the ERP environ-ment at RohMax Oil Additives, a division of Degussa

Chemical Industry20 Seamless Changeover

Successful migration to Simatic PCS 7 in minimal time

Pharmaceutical Industry30 Smart Packs

RFID technology for drug packaging in the pharmaceutical industry

Pharmaceutical Industry32 Exact Air Conditions

Clean-room monitoring at Sanofi-Aventis with Simatic PCS 7

Process Instrumentation38 Ensuring Product Quality

A H Marks monitors phenol refining process with Sitrans transmitters

TECHNOLOGIESMigration

12 Migration AheadMigration to Simatic PCS 7 helps plant operators minimize risks and costs

Process Technology14 Faster Time to Market

Siprocess microprocess system: Innovative technology for the chemical and pharmaceutical industry

Renewable Resources16 Green Fuel

Integrated approach helps boost efficiency in ethanol production

Process Safety22 “The Costs are Lower”

Trends in process safety: SIL and Profisafe

Drive Technology23 Comprehensive Product Line

Drive technology for the process industry

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Two major trade fairs are ahead of us this spring: the annualHanover Fair, Germany’s mostimportant industrial trade fair,

and the Achema fair in Frankfurt, which is the mostsignificant trade fair for our customers in the processindustry.

Achema will also be the highlight of our year, as itgives us a golden opportunity to talk to a large numberof visitors and customers about our solutions for theprocess industry, focusing on the chemical andpharmaceutical sectors, and to present our products.At the fair, we will not only focus on innovations in ourprocess technology products and systems – such as theSiprocess microprocess system, which is introduced onpages 14 and 15 of this issue, but we will alsohighlight our broad and integrated range of solutionsand services for all areas of the process industry,including power supply and building servicesengineering.

“Integrated solutions – your key to success” is theslogan for our presentation at Achema. We will presentour integrated solutions for the process industry asthey relate to key customer issues: quality excellence,manufacturing excellence, supply chain excellence,asset valuation, plant safety, plant availability, costreduction, investment protection, and process and plantperformance. Our response to these issues is based onTotally Integrated Automation and Totally IntegratedPower, guaranteeing consistent vertical and horizontalintegration as well as on broad automation andprocess expertise, which we have brought together in our industry-specific Competence Centers.

More performance was one of the main objectivesachieved in a series of projects we undertook inconjunction with INEOS Phenol – particularly themigration of the control engineering and theswitchgear modernization. Our partnership withINEOS is the main subject of this issue of ProcessNews. Moreover, this issue includes plenty ofinformation about interesting technology trends suchas the hot topic of control system migration and apioneering application of RFID in the pharmaceuticalindustry. Consequently, this issue sports more pagesthan usual for Process News. I hope that the following36 pages will stimulate your interest and give yousome exciting ideas.

Enjoy the read!

A pilot project of Limmatdruck/Zeiler andSiemens demonstrates the benefits of RFIDtechnology in pharmaceutical packaging:easy identification of counterfeit drugsand better patient safety

3EDITORIAL

process news 1/2006

Michael BrunsProcess Automation ManagerSiemens Automation and Drives

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Process Control Engineering24 Cutting Costs, Boosting Quality

Simatic PCS 7 equipment modules design guide and engineering templates

Industrial Communication25 Simply Secure

Modular security concept for integrated data networks in the process industry

Water Treatment26 A Vital Resource

Siemens Water Technologies unites water treatment and technology expertise

Manufacturing Execution Systems28 Performance Capabilities

Simatic IT contributes to higher performance and regulatory compliance support in thepharmaceutical industry

Process Analytics34 Process Benefits

Quantra FT-ICR mass spectrometer handleschallenging analytical task in acrylonitrile production

Power Solutions35 Cutting the Energy Bill

Increased reliability, cost-effectiveness, and availability: Totally Integrated Power

Process Instrumentation36 Micro Scale and Mega Precision

New devices supplement process instrumentation line

Process Instrumentation37 Device Selection Made Easy

PIA Selector 3.0 for process instrumentation and analysis

39 DIALOGUE

Dear readers,

process news 1/2006

4 NEWS

S iemens beat off strong competition towin the process analysis contract for two

complete air separation plants that LindeKCA-Dresden is producing for a steelworksin western Russia.

The contract includes several Maxumedition II process gas chromatographs,which will be installed in an analytical shel-ter. Primary sample preparation in the fieldand secondary preparation in the analyticalshelter ensure high-speed transportationof samples. The analysis values are contin-uously transferred to the process controlsystem.

The process analytical equipment moni-tors the individual process stages in theplant – air separation and pure argon gen-eration using low-temperature rectification,cleaning and drying of air as well as com-pression of oxygen and nitrogen. �

Maxum edition II process gas chromatograph for Russian steelworks

Strong Competition

Find out more:www.siemens.com/processanalyticsE-mail: [email protected]: [email protected]

The Sitrans P DS III transmitter securedControl Engineering Polska magazine’s

“Product of the Year 2005” readers’ prize inthe “Transmitter and monitoring instru-ments” category.

At the end of November 2005, the spe-cialist editors of Control Engineering Pol-ska, two engineers from the industryselected in a drawing, and two representa-tives of research institutions came up witha shortlist of products to be nominated forthe award – the three or four best productsin each category. The magazine’s readerswere then asked to complete a survey tochoose their favorites – the products thatbest met the specified criteria: technicalleadership, usability, and market impact.The Sitrans P DS III digital transmitter beatthe other nominees in the transmitter andmonitoring instruments category. �

Sitrans P DS III wins award for transmitter and monitoring instruments

Champion Product

Find out more:www.controlengpolska.comE-mail: [email protected]

Linde KCA-Dresden chose the provenMaxum edition II process gaschromatograph

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Award-winning transmitter: Sitrans P DS III

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5

A fter numerous project discussions and a compre-hensive market survey performed by the customer,

Siemens succeeded in securing the contract to equipthe Komdok zinc mine in North Korea. In association withProtoplan, Siemens convinced the Korean delegation ofthe benefits of Siemens equipment and will now supplya wide range of instruments for various applications,including Sitrans F MAG 3100 and MAG 5000 magnetic-inductive flowmeters, as well as Sipan 34 liquid analyz-ers with sensors for sulfuric acid, sodium hydroxide, andother compounds; Sipos 5 Flash electrical actuators; spe-cial control valves; MSI belt scales with BW 500 for zincconcentrate; and gas analysis cabinets with Ultramat 6analyzers and the appropriate sampling and prepara-tion systems. The contract has a total value of around180,000 euros. �

Process instrumentation for zinc mine in North Korea

Convincing Portfolio

Find out more:www.siemens.com/processinstrumentationE-mail: [email protected]

S iemens has been awarded the contract for migratingthe existing process control and supervision systems

at a part of the dispersions plant for BASF at Tarragona.The plant has been using control, instrumentation andHMI systems from various vendors and wanted to estab-lish an integrated solution in order to increase productionflexibility and to reduce production as well as mainte-nance costs.

The new solution is based on the Simatic PCS7 processcontrol systems with integrated fail-safe technology andSimatic Batch, and uses the standard library that Siemenshas developed for BASF. Siemens was able to win the con-tract for the migration because it offered a technically con-vincing migration concept that met all specifications fromBASF at a competitive price. Moreover, Siemens hadalready been working successfully with BASF on automa-tion projects at Tarragona and was consequently familiarwith the plant and its requirements.

The project is the first step in the migration of the entireplant that is planned for the next years. �

Find out more:www.siemens.com/chemicalsE-mail: [email protected]

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The Komdok mine will beequipped with Siemens

process instrumentation

Tarragona in Spain is an important site of BASF

Simatic PCS7 and Simatic Batch at BASF dispersion plant in Spain

Competitive Edge

BASF

process news 1/2006

The old switchboards that suppliedpower to the distillation section hadbeen in service for a good 50 years

and were no longer state of the art. “In addi-tion, by building new switching stations,we were able to design a redundant energysupply to the drives and combine severalold switching stations for simplified main-tenance,” explains Oliver Sauer, the techni-

cian responsible for electrical planning andthe supervision of the modernization of theswitching stations at INEOS Phenol. Fol-lowing intensive product analysis, INEOSPhenol chose a Sivacon-based switchboardwith a modular switching unit design.“There really are no alternatives that offera better procing for a plant the size of Glad-beck,” says Oliver Sauer.

Detailed analysis of the current status

INEOS Phenol wanted to retain the optionof locally switching the drives because thisswitching is also used in visual inspectionsof the drives. In addition, it had to be pos-sible to switch the drives from the controlstation. This is no problem with the Sivacontechnology.

However, before the power distributionsystem could be converted, a detailed stock-taking was necessary. This was carried outby the Siemens subsidiary FEAG, now a jointventure of the Interschalt company andSiemens, under contract with Siemens. Allexisting consumers and load feeders wereexactly localized with the aid of the docu-mentation tool e-plan 21, mapped, andnamed according to the appropriate stan-dard. With this documentation, all impor-tant information about a drive is containedin one drawing, which is particularly impor-tant for maintaining continuous operationand clearing faults. In addition, the inter-face to the control station was also config-ured to guarantee the smooth integration ofthe low-voltage distribution system with

Migration to Simatic PCS 7 and Simatic IT at INEOSPhenol with no downtime or loss of production

A Challenging ProjectThe partnership between INEOS Phenol in Gladbeck, Germany, and Siemensactually began with an order that had little to do with process automation:modernzing part of the low-voltage power distribution system andconstructing a new central power supply station North at the Gladbeck site.Due to the success of this project, Siemens also won the contract for otherchallenging projects – for example, the modernization of the controltechnology for a continuous process with about 8,000 process signals. Theresult: clear benefits in the operation of the plant.

6 TITLE STORYChemical Industry

INEOS Phenol

INEOS Phenol, one of the membersof the INEOS Group, recentlyacquired Innovene, and is now thethird largest chemical company inthe world.

INEOS Phenol is also one ofthe largest sales contributorswithin INEOS. Currently, about aquarter of the phenols requiredworldwide for products such aspolycarbonates (DVDs, CDs), epoxyresins, and nylons come fromINEOS Phenol production plants.

In addition to the Gladbecksite, which is the largest with anannual production of 650,000 tonsof phenols, the company also hasoperations in Antwerp, Belgium,and Mobile, Alabama. Gladbeck isnot only the largest INEOS Phenolsite, but also the world’s largestphenol plant.

INEOS will continue to investin expanding its production plantsover the next few years. In Wil-helmshaven, Germany, for exam-ple, several major projects areplanned.

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7

the process automation system. The Siva-con system consists of a total of 80 cabinetssupplying 300 motors and drives. Theswitchgear is largely standardized and con-tains undervoltage relays as required,remote on and off functions, and all cir-cuits needed for the local operation of theconsumers.

Thanks to meticulous preparation, it waspossible to upgrade the switchgear with-out interrupting production. The newpower supply station, with a new distribu-

tor and feed, was built first, before some250 kilometers of new cable were laid. Sincecable crossings were to be avoided, thecable routes had to be planned very care-fully – a job greatly simplified through theadvance documentation.

The Gladbeck site is now equipped witha modern, efficient power distribution sys-tem. The entire conversion was achievedwithout any significant faults or produc-tion losses, and INEOS Phenol is completelysatisfied with the result.

Continued cooperation on automation

The excellent results of the power supplyproject were an ideal recommendation forthe next project: the modernization of thedistributed control system. The existingcontrol system from the eighties was out-dated, and problems with obtaining spareparts were already emerging. Within thescope of this modernization, INEOS Phenolwanted to combine the separate controlstations for the two large process areas ofdistillation and oxidation into a single newstation.

In addition to the positive experiencewith Siemens in the switching station pro-

ject, the competitive price of the PCS 7 solu-tion, the thorough documentation in Ger-man, and the impressive technical featuresof the system (such as the tight integrationof the safety technology and the extensivefunctions for effective alarm management),the sophisticated migration strategy fromthe old process control system to SimaticPCS 7 was ultimately a very decisive fac-tor in the company’s decision, says UlrichDallmeier, head of the control and moni-toring technology department at INEOSPhenol. “Before the project even began,Siemens was able to show us a solution thatwould enable us to change over to the newprocess control system without interrup-tions in production.”

Siemens was responsible for all of thesystem engineering. The first project stepinvolved the modernization of the distilla-tion control technology. Six months wereallotted to change over to the new system.Thanks to the excellent planning of theteam and to the information about therequirements and specifications of theGladbeck plants provided by the documen-tation for the power-supply station project,the conversion time was reduced to justfour months – without a single break inproduction.

To minimize the risks associated withthe conversion, the project was divided intothree steps. The plant sections that werenot currently in use were converted first.The planned migration strategy could thusbe tested rigorously without risk. Then, theso-called non-critical plant sections wereconverted, and finally the crucial plant sec-tions were changed over.

“Such a project would have been incon-ceivable without sound, detailed, and logi-cal advance planning,” stresses UlrichDallmeier. “The project team, composed of

“Such a project would havebeen inconceivable withoutsound, detailed, and logicaladvance planning.”

Ulrich Dallmeier, head of EMR at INEOS Phenol Gladbeck

“There really are no less-expensive alternatives for a plant the size of the one in Gladbeck.”

Oliver Sauer, the technician responsible for electrical planning at INEOS Phenol Gladbeckko

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8Chemical Industry

TITLE STORY

staff from Siemens and us, planned theconversion from start to finish and pre-cisely documented all necessary steps.”

“The gradual changeover was also advan-tageous in terms of the training and instruc-tion of the personnel,” says Ulrich Dallmeier.“The personnel was able to be trained slowlyand step by step, making the changeovermuch safer overall.” Thanks to the user-friendly operator faceplates, the employeesquickly accepted the new system.

The new control system consists of atotal of eight PCS 7 switch cabinets with onehighly available AS 400H automation sys-tem each. In addition to the actual processplants, analyzers, a laboratory informationsystem, and a process data archive based onMIS Light are integrated into the PCS 7 sys-tem.

PCS 7 also offered clear advantages interms of the system configuration and con-trol of the processes. For example, thealarm volume was checked and improvedduring the course of the upgrade. “This hasput us in the region of one alarm every 10minutes, as recommended by NAMUR reg-ulation NA 102,” says Ulrich Dallmeier.

Process optimizations and improve-ments are very important in every produc-tion plant. In order to be able to analyzeirregular production conditions profes-sionally with modern, computer-aided sys-tems, INEOS Phenol recently decided toimplement the Simatic IT manufacturingexecution system. This provides the approx-imately 60 users in the chemical factorywith a modern MES platform through theoffice network.

BConversion of the old control system configuration using Access: The migrationtool creates lists that support the changeover procedure and inspection. The toolis continually being improved, and several other migration projects are inprogress at present that can be performed with the aid of the tool

The newswitchingsystem atINEOS Phenolwas the first ofthe Siemensprojects at theGladbeck site

One of thehighlights of

the partnershipbetween

Siemens andINEOS Phenol:the new PCS 7

control stationin Gladbeck

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Spreadsheets generated from the databaseto support commissioning

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expect everything to work perfectly the firsttime in such a large project,” says opera-tions manager Dr. Reinhard Sigg, “but thecritical issue is how a project partner reactswhen there are problems. Siemens wasextremely cooperative and dealt with issuesrapidly and efficiently.” As a result, bothparties are very optimistic about the nextproject step: the transition of the controltechnology in the oxidation unit to thePCS 7 system this year. �

Find out more:www.siemens.com/pcs7www.siemens.com/chemicalsE-mail: [email protected]: [email protected]

“The critical issue is how apartner reacts when thereare problems.”

Dr. Reinhard Sigg, operations manager, INEOS Phenol Gladbeck

With Simatic PCS 7, the operators also have an optimal view of the safety functions– they are highlighted in yellow on the process screens

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Eight barriers for greater safety:

The INEOS Phenol safety concept

With its multistage safety concept, INEOS effectively prevents faults and provides

maximum protection for the plants, the employees, and the public.

B containment of hazardous substances

B operator alarms

B supervisor alarms

B electronic safety devices

B mechanical safety devices

B buffer zones and stationary firefighting equipment

B internal emergency management

B external emergency management

The new PCS 7 system was designed to support maximum process safety at the Glad-

beck facility. Extensive safety functions ensure that personnel can operate the process in

a safe state in the case of an alarm. The safety functions are highlighted on the flow

screens, making the safety equipment easy for the operator to identify.

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Improved performance withoutadditional plants

Additionally, the approximately 30-year-oldcompressors, also integrated into PCS 7,were overhauled and optimized during thecourse of the modernization, allowing thecapacity to be increased by more than fivepercent without the need for another com-pressor.

The process control itself was also opti-mized at the same time. A Siemens teamsupported INEOS Phenol in the develop-ment of an advanced process control solu-tion. The aim was to calculate – with the aidof a multiple-variable controller on anexternal PC – the disturbance variables act-ing on the controlled system, and ideally toeliminate their influence.

An optimistic view of the future

After completion of the first of the twoproject phases, the switching technology

upgrade and the modernization of the con-trol system in the distillation area, INEOSPhenol sees the results of the joint projectwith Siemens very positively. “We do not

The distillation at INEOS Phenol’s Glad-beck facility separates the main prod-ucts of phenol and acetone. Some dis-

tillation columns are interdependent, andtheir heat and material flows are closelylinked. The operation of just a few centralcolumns thus determines the operation ofthe entire unit.

Complex relations

The behavior of these columns is charac-terized by the strong link between the ac-tuating and control variables and by longresponse times. Because of the interde-pendency, some deviations were correctedby manual intervention before the new so-lution was implemented.

Modernization of process control

INEOS wanted to increase the automationof the plant and reduce consumption of en-ergy and materials by implementing im-proved process management on one of thecentral columns.

The decision to optimize the control en-gineering in distillation was made at thesame time that modernization of the con-trol technology was under consideration.Siemens was therefore the ideal partner forthe process optimization project. As a firststep, Siemens was contracted to performPID tuning at several points in the plant,based on the existing control loops.

The Siemens specialists analyzed thecontrol loops in distillation and formulatedoptimized control concepts. Here, Siemensused the RaPID tool from IPCOS, a well-known specialist in the area of Advanced

Process Control (APC). The new control pa-rameters were then implemented in the ex-isting control system. At the same time, acontrol concept based on a multivariablecontroller was developed to optimize theoperation of a column.

While the loop tuning was in progress,INEOS made the decision to migrate thecontrol technology to Simatic PCS 7. Thanksto the open system structure, it was alsopossible to easily transfer the results of thecontroller tuning to PCS7 as new control pa-rameters.

Process optimization usingmultivariable control

The excellent results achieved in the looptuning led INEOS Phenol to put the au-tomation of its control processes for a col-umn in the hands of the Siemens special-ists. They first worked on the old controlsystem to create the models needed forprocess optimization as quickly as possible.Only then was the new control concept in-tegrated into PCS 7, which was then imple-mented.

To control the top stream concentrationand the bottom temperature, Siemens usespredictive multivariable control based onthe INCA software technology from IPCOS.This enables the actuating variables for thereturn quantity, the feed in the column bot-tom, and the adjustable heat exchanger tobe used to control both the concentration inthe column top and the bottom tempera-ture. The controller is capable of identifyingtrends at an early stage and counteractingthem.

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10Advanced Process Control

CASE STUDY

Simple and safe integration intoSimatic PCS 7

After five months (seperated in two projectphases), INEOS Phenol adopted the APC so-lution in January 2006. One very positiveaspect of working with the new control sys-tem is that it is seamlessly integrated intothe Simatic PCS 7 operating environment.With a click of the mouse, the operator cancall up the appropriate screen. Thanks tospecial link modules, the multivariablecontrol system can easily be incorporatedinto PCS 7 without additional program-ming work. The link modules transfer thecontrol valves and parameters and monitorcommunication with the INCA controller.This enables a defined fallback strategy tobe initiated in case of malfunctions, thuspreventing costly errors in the control sys-tem.

This new control solution has enabledINEOS to successfully stabilize the criticaltop concentration. As a result, considerablesavings have been realized in terms of en-ergy requirements and additives. INEOSPhenol is very satisfied with what has beenachieved and praised the excellent collabo-ration with Siemens. �

Advanced Process Control solution at INEOS Phenol

Optimal PerformanceThe old control system at INEOS Phenol was recently replaced by Simatic PCS 7 duringoperation and without interrupting production. Parallel to this major project, the companyalso collaborated successfully with Siemens in another area. Siemens designed an AdvancedProcess Control solution to manage a complex control task in distillation. This has enabledINEOS to optimize the energy requirements for the process step and to achieve a moreconstant level of operation in distillation.

Find out more:www.siemens.com/chemicalswww.siemens.com/spE-mail: [email protected]: [email protected]

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The APC solution can be accessed through the PCS 7 operator station

Individual control variables can be continuously monitored

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Operator screens for multivariable control

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12Migration

TECHNOLOGY

Analysts and experts estimate that worldwide, process control systems with a total installation value of around65 billion Us dollars have reached the end of their service life and will need to be replaced with up-to-datetechnologies in the near future. However, a complete changeover to a new control system involves significantinvestment and considerable risks. With Simatic PCS 7, Siemens offers its customers an alternative to a radicalsystem change with a gradual migration of control technology.

Migration to Simatic PCS 7 helps plant operatorsminimize risks and costs

Migration Ahead

There are many and varied reasons forreplacing an installed control system– for example, to prevent unsched-

uled plant shutdowns or because expan-sion of the business means that a new con-trol system is feasible. However, sometimesthe old system has been cancelled in itsinstalled version or even in general. Replac-ing the control technology is associatedwith high costs and often with productioninterruptions. That is why many companiesprefer to migrate the systems instead ofcompletely replacing the technology – inthis case, only the technology that nolonger meets requirements is replaced, anda detailed migration strategy can reduce

production interruptions or even preventthem entirely.

The existing system represents a majorinvestment in hardware and applicationsoftware, as well as extensive acquiredexpertise. The primary objective of migra-tion is therefore to gradually modernizethe existing system, without plant shut-downs where possible, or with minimalproduction interruptions. At the same time,the investments already made need to besafeguarded for as long as possible to max-imize the return on assets.

It is not always necessary to replace theentire system with a state-of-the-art sys-tem. These days, the service life of the dif-

ferent system components varies from fiveyears for workstations to 15 years for con-trollers to as many as 25 years for field com-ponents and wiring. This means that dif-ferent migration stages are necessary toobtain an optimal solution for the cus-tomer. From this point of view, it makesgood sense to use a modular process con-trol system with standardized interfaces,such as Simatic PCS 7.

Siemens has developed a sophisticatedmigration concept for PCS 7 which enablescontrol systems from almost any manufac-turer to be migrated to PCS 7. This meansthat individual areas of a control systemcan be replaced, or an existing system can

be supplemented with new components,thus reducing the risks and the costs of themigration.

Gradual and function-orientedmigration

The superior integration capability ofSimatic PCS 7 is a key element in imple-menting these migration solutions effec-tively and with added value for the cus-tomer. For example, if only the operatingand monitoring level is technically out-dated, spare parts are too expensive, orfunctional expansions such as IT integra-tion are necessary, the old HMI can bereplaced with the new state-of-the-art oper-ator station from Simatic PCS 7 – protectingthe existing investment in controllers, I/Odevices, and application software.

Gradual modernization may be neces-sary if a plant is to be expanded with addi-tional sections but the existing control sys-tem is to be retained for the time being.Simatic PCS 7 can then be installed parallelto the legacy system during the expansion.This type of modernization can providefunctional expansions such as fieldbustechnology or IT integration, but it also sup-ports combined visualization of both theold and new plant sections, connected ifnecessary by consolidating measuringstations or cross-location operating struc-tures. Comprehensive modernization isnecessary if there are bottlenecks in obtain-ing spare parts for the old system, if thereis a lack of support, or if necessary func-tional expansions put the existing controlsystem at risk. In these cases, the old sys-tem can be replaced with Simatic PCS 7,often while the system is running. Onceagain, the investment in wiring, hardwarecomponents, and valuable application engi-neering is protected.

Making use of experience

Another key element in achieving success-ful and efficient migration is collaborationwith expert partners. When systems fromother manufacturers are to be migrated toSimatic PCS 7, it is important to involve thecustomer’s systems integrators in the pro-ject. They have years of acquired expertiseand precise knowledge of customer andsystem requirements. Efficient collabora-tion between Siemens and the systems inte-grators reassures the plant operators thatthey will be presented with an optimalmigration solution that meets their needs.

Putting theory into practice

The migration solution must consider allaspects of the specific process in order toproduce an optimal, individually tailoredmigration strategy for the relevant appli-cation. When it comes to selecting andimplementing the correct migration solu-tion, Siemens can call upon vast experiencefrom hundreds of Teleperm M, APACS,and PCS systems that have already beenmigrated to Simatic PCS 7, as well as a hostof other control systems from variousmanufacturers. The companies for whichSiemens has already completed migrationprojects include Norsk Hydro (where anmigrated during operation), Air Products,BASF, Degussa, INEOS Phenol, and ZLBBehring, to name just a few.

Alternative to a complete makeover

Migration to PCS 7 means that system oper-ators do not need to start over with a com-pletely new system. The sophisticatedmigration concept makes the transition tothe new system generation fast, reliable,and above all cost-effective. �

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Find out more:www.siemens.com/migrationE-mail: [email protected]

Main factorsnecessitating a migrationu Risk of unscheduled plant shutdowns

(production interruptions)

u Expansion of business not possible

without new system

u No cost-effective support for

installed system

u Old system cancelled in version

or completely

u Existing system no longer meets

current requirements

u Reliability and stability of

system supplier

Experienced partners andsophisticated migration strategieshelp modernize control systemswithout risks and unforeseen errors

Broad range ofmigration solutionsSiemens has migrated various control

systems from different manufacturers to

Simatic PCS 7, including the following:

u TM M

u APACS

u TI505

u Contronic P

u Infi90

u Freelance

u TDC2000/3000

zefa

M icroprocess technology is still anew technology, but it appearsto have considerable potential

in the process industry. At present, it isprimarily used to develop and optimizeprocesses in laboratories, mainly in indi-vidual configurations involving high designand equipment costs. To date, there is notechnical standard that would allow thetechnology to be used widely in laborato-ries and ultimately to be successfully trans-ferred to a production environment. This iswhere Siemens comes in – with an open,modular microprocess system that will bepresented to the public for the first timeat this year’s Achema under the nameSiprocess.

Huge potential for processimprovements

With hazardous process conditions, exother-mic processes generating a great deal ofheat, very short retention times, and com-plex flow arrangements, some chemicalprocesses are extremely difficult and expen-sive to operate safely. The chemical andpharmaceutical industries are looking foralternative technologies, and microprocesstechnology is one of them. It uses micro-structured components at those points inthe manufacturing process where they willbe of most benefit. With these components,it is much easier to discharge resultingheat, mixtures that would be explosive atstandard dimensions can be controlled,

and mixing is more intensive even withshort reaction times, which can signifi-cantly improve product yield.

Although the huge potential of micro-process technology is widely recognized,until now it has primarily been used in lab-oratories. Here, microprocess technology isused to develop new manufacturing pro-cesses or optimize existing processes, gen-erally using individual experimental con-

figurations. The costs of using the micro-structured components remain high: appro-priate, high-quality, and reliable compo-nents are very hard to find and they arepredominantly manufactured by start-upcompanies. In general, the connections anddimensions of the components are notstandardized. Special expertise is requiredfor metering the reactants and maintainingpressure when using them.

process news 1/2006

14Process Technology

TECHNOLOGY

Siprocess microprocess system: Innovative technology for the chemical and pharmaceutical industry

Faster Time to MarketMicroprocess technology – the use of microstructured components formanufacturing in the process industry – delivers particular benefits forchemical synthesis. The small dimensions of the critical components meanthat significant heat generation and flammable reactants and solvents canbe more easily controlled. In addition, a better product yield can beachieved. At Achema 2006, Siemens will be presenting Siprocess, an open,modular microprocess system with integrated automation that makesmicroprocess technology significantly easier to use. The new technologyhelps reduce time to market for new and optimized chemical products.

A microreactor similar to the one con-tained in the Siprocess reaction module

Siprocess is an open, modular microprocess system with integrated automation

sors, actuators, and automation electronicswith preconfigured automation functions.The modules are connected to the SimaticPCS 7 process control system by a bus link.The system has a simple automation con-figuration that can be set up by the opera-tors themselves.

Siprocess supports microtechnology-based reactions of up to three reactants toproduce a product in the liquid phase. Upto several tons of the desired substance canbe manufactured each year. This makesSiprocess ideally suited for initial applica-tions in process-based production.

Trendsetter in the process industry

The Siemens Siprocess team in Frankfurt isresponsible for the microprocess system,which will initially be implemented inEurope in close consultation with users.The aim of this introductory phase is to getadditional operating experience in differ-ent applications in an industrial laboratoryenvironment. This knowledge will theninfluence the subsequent optimization ofthe system, allowing Siemens to work withthe users to define the necessary develop-ment steps to transfer the technology tofull-scale production and prepare it forglobal use in the chemical and pharma-ceutical industries.

As the technology moves from the lab-oratory to production, the benefits of Si-process will come to the fore: faster processand product development in the labora-tory, and the elimination of traditionalscale-up steps and risks, which frequentlynecessitate costly pilot-scale experimentsto ensure functionality. For the chemicaland pharmaceutical industries, this willmean that their own products can bebrought to market faster with Siprocess. �

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15

Open, modular, and with integratedautomation: Siprocess

With its Siprocess microprocess system,Siemens now offers a system that makes itmuch easier to use microtechnology com-ponents in process and product devel-opment. Siprocess is an open, modularmicroprocess system featuring integratedautomation. Its modules address all func-tions required for chemical synthesis:metering, mixing and reacting, sampling,and pressure adjustment and mainte-nance. Each module includes separate sen-

Find out more:www.siemens.com/siprocess E-mail Team Siprocess, Frankfurt:[email protected]

Benefits of Siprocessu Complete system can be set up

and commissioned in one day

u Rapid module exchange

u Space-saving construction

u Open design allows integration of components

u High reproducibility due to low-pulsation pumps

u Excellent reliability due to provenSimatic PCS 7 technology

u Easy handling of automation tasks by the user (no extensive knowledge of Simatic PCS 7 required)

u Easy configuration of automation bythe user (including after exchange ofmodules)

The user-friendlySiprocessautomationsystem

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process news 1/2006

16Renewable Ressources

TECHNOLOGY

With many nations seeking toreduce petroleum imports, boostrural economies, and improve

air quality, world ethanol production roseto nearly 38 billion liters in 2005. Growthin fuel ethanol production is expected toaccelerate as countries seek ways to com-ply with the greenhouse gas emissions lim-its established by the Kyoto Protocol.

Brazil has long required that all gaso-line sold in the country contain approxi-mately 25 percent ethanol. Total US ethanolproduction for 2005 is estimated to be 15billion liters. The biofuel provision in thecurrent energy bill is accepted, US ethanolproduction will reach approximately 30billion liters annually by 2012. AlthoughBrazil and the United States are the lead-ers, Europe and many Asian countriesare ramping up their ethanol productioncapacity as well.

Cost-effective, integrated solutions for the ethanol industry

Siemens offers a broad portfolio of tightlyintegrated products to support the needs ofthe ethanol industry. Totally IntegratedAutomation (TIA) integrates the entire suiteof process control products for data stor-

age, communication, and programming.Moreover, Siemens provides expertise indelivering process control systems, trans-mitters, drives and motors, electrical infra-structure, analyzers, and life-cycle servicesto the ethanol production industry. TIAoffers fuel ethanol producers an entire suiteof process control products to help withevery production phase – including grind-ing corn and other grains, mixing, cooking,drying, fermenting, and storage.

With this integrated set of solutions,ethanol producers can address their busi-ness targets more effectively and increasetheir overall performance by reducing timeto market, lowering the cost of production,improving plant operation efficiencies, andincreasing bottom-line profits.

Another challenge facing ethanol pro-ducers today is the burden of reducinginstallation cost. By leveraging a standard-ized process solution, including standardsoftware packages, and hardware compo-nents that are optimally matched to the fieldof application, Siemens offers cost-effectiveautomation solutions that can improve pro-cess efficiency during the entire life cycleof a plant. During production, the processautomation solutions help manage a facil-

ity in such a way that overall maintenancecosts are reduced, operational reliability isassured, and a fast return on investmentsis achieved.

Easy-to-use automation systems lever-age state-of-the-art technology and prac-tices that can help improve day-to-day oper-ations, and standard out-of-the-box systemand communication interfaces provide ahigh degree of integration, from the con-troller to the operator interface of the pro-cess control system. The combination ofstandard operator interfaces and easy-to-read diagnostics enables operators toquickly identify and resolve process issueson the fly.

A wide range of expertise

Siemens has years of experience in help-ing customers in the ethanol industrymanufacture products in a timely fashion.Over 65 percent of all ethanol facilitiesbuilt since 2000 in the United States useSiemens systems. In 2005 and early 2006,Siemens has provided process automationservices and products to more than 30plants. Combined, these new plants areproducing more than 5 billion liters ofethanol annually.

In Brazil, Siemens works together with Dedini, the main process provider forbio ethanol in the Latin American region.Siemens and Dedini have developedpatented process solutions for bio ethanolproduction. In Asia, Siemens provided theprocess automation for the world’s largestbio ethanol plant (750 million liters), inJiling, China.

Siemens closely cooperates with differ-ent construction companies and processproviders to make this expertise availablein other regions. �

Integrated approach helps boost efficiency in ethanol production

Green FuelThe development of alternative, renewable sources of fuel hasrecently gained momentum. Emission guidelines issued under theKyoto Protocol, along with rising oil prices, have made ethanol anattractive and increasingly competitive player in the fuel market inmany countries. Offering an integrated set of systems and solutionsfor ethanol production plants, Siemens has successfully equippedethanol facilities in the United States, Brazil, and Asia.


process news 1/2006

17

Starche.g. Wheat, Corn

Enzymes

Starche.g. Cassava

ThinStillage

Fuel Ethanol

Pretreatment

Mashing

Milling

Liquefaction,Saccharification

Fermentation

Dehydration

Distillation

Denaturizing

DGS: Distillers Grains with Solubles

Decantation

CO2

DGS

Gasoline Drying

DDGS

Water

DDGS: Distillers Dried Grains with Solubles

Evaporation

Syrup

Green fuel from starch: the ethanol process• Milling: After the corn (or other grain or biomass) is cleaned it is ground in hammer mills.• Liquefaction: The ground grain is then mixed with water and enzymes and passed through

cookers where the starch is liquefied. At an elevated temperature, the bacteria level in the mashis reduced.

• Saccharification: The mash from the cookers is cooled and the enzyme glucoamylase is addedto convert starch molecules to fermentable sugars (dextrose).

• Fermentation: Yeast is added to the mash to convert the sugars to ethanol and carbon dioxideeither in continuous or batch processes.

• Distillation: The fermented mash containing approximately 10 to 16 percent ethanol is thenpumped to the continuous flow multicolumn distillation plant. The ethanol leaves the top of thefinal column at about 96 percent strength, near to the azeotrop composition.

• Dehydration: The alcohol then passes through a dehydration system, where the remainingwater is removed. Molecular sieve adsorption is the most frequently used technology for this,other technologies include membrane filtration.

• Denaturing: Fuel ethanol is then denatured with a small amount (2–5 percent) of gasoline tomake it unfit for human consumption.

• Decanting and Drying: The distilled residue is decanted in centrifuges (DGS) and afterwardsdried to yield the DDGS cattle food.

process news 1/2006

18Chemical Industry

CASE STUDY

Knowing just how much, what, andwhen to add to a batch is a funda-mental component of the production

process at RohMax. Some of the informa-tion required for this is stored in the ERPsystem in the form of complex rules thatdescribe how a recipe (known as a produc-tion card) is put together, based on theinformation from SAP R/3.

In the past, the rules were coded as man-ufacturing instructions in the SAP PP-PI(Production Planning-Process Industry)module. The manufacturing instructionsgenerated by SAP were passed on to thecontrol room as a printout (productioncard), where they were used for controllingand monitoring the process using theSimatic PCS 7 process control system andthe Simatic Batch batch control solution.There was no online exchange of informa-tion between the ERP and control systems;the data from the production cards wasentered into the process control systemmanually. Production feedback also had tobe entered manually in SAP R/3.

Flexible MES with Simatic IT

To ensure a higher and more consistentproduct quality and enable more rapid and

effective implementation of process inno-vations and process improvements, RohMaxneeded to manage these rules graphicallyand in a configurable format at the MESlevel. After a thorough evaluation of thesolutions available on the market, and duein no small measure to positive experiencewith Siemens as a technology and projectpartner in previous projects, the manage-ment opted to implement a solution basedon Simatic IT.

At RohMax, Simatic IT manages the elec-tronic exchange of information betweenSAP R/3 and the production system. SimaticIT now maps the entire process, from ordermanagement through to actual productionexecution. The orders planned in SAP areautomatically transferred to the MES levelas control formulas. A Simatic IT standardmodule for SAP integration ensures tightintegration with the ERP system. The Batchintegration module provides the connec-tion to the formula control system.

Object-oriented business process modeling

At the heart of the MES is the ProductionModeler module, which enables object-ori-ented modeling and graphical representa-

tion of business and production processes.The rules for the creation and executionof production cards are entered and rep-resented as graphic models (equipmentstructure and process flow). These rulesalso contain dialogs that assist the equip-ment operator during processing. Onemajor advantage of graphical modeling isthat it can be adapted easily and flexibly toprocess changes resulting from innova-tions or equipment upgrades.

The close link between the MES and theautomation system, using standard inter-faces, makes it possible to create and exe-cute production cards and equipment for-mulas for batches in the formula controlsystem, gather feedback from these batches,and transfer it to the ERP level. The MES andSAP R/3 are linked by a certified standardinterface which enables a close, stable, andcost-effective connection.

The tight link between Simatic IT andthe ERP system allows all relevant data

Simatic IT connects Simatic PCS 7 to the ERP environment at RohMax Oil Additives, a division of Degussa

Impressive ResultsThe production of oil additives is a complex process thatinvolves numerous stages. More stringent quality standardsand the need for greater flexibility place significant demandson process planning and control. For this reason, RohMax OilAdditives in Weiterstadt, Germany, introduced a manufacturingexecution system (MES) based on Simatic IT and linked it to the enterprise resource planning (ERP) system and the SimaticPCS 7 process control system. Having successfully filled morethan 6,000 customer orders, production is now more flexibleand reliable than ever.

Piping at Degussa’s Weiterstadt site

process news 1/2006

19

needed for production (such as materialinventories, material master data, andbatch-specific quality data) to be adjusted,the printing of sampling instructions to betriggered, and test results to be down-loaded from SAP to the MES. The MES alsorecords various production data which canthen be used to calculate key performanceindicators (KPIs), or to create production-related messages.

Significant gains in production flexibility

The electronic production cards automat-ically derived from the control formulascan be modified by the scheduler ifrequired – for example, by adding newsteps or changing parameter values. Thebatches are then created in the formulacontrol system and the production cardsare transferred to the control room asbatch orders. The operator in the controlroom executes production card. The MES

gathers and posts feedback during the pro-cessing of the batch and reports the resultsback to SAP. The use of Simatic IT meansthat both the production scheduler and theoperator have an overview of the produc-tion status at all times.

In addition to mapping the core process,the MES also provides supporting infor-mation. This includes production and qual-ity assessments, master data management,and master data comparisons with SAP.This makes production more efficient and,above all, more flexible, and means that anup-to-date representation of the produc-tion process is always available. Onlineintegration between SAP R/3 and PCS 7reduces the incidence of errors in runningthe equipment and in the data fed back toSAP. At the same time, it minimizes theneed for manual activities in the controlroom and allows the equipment operator toconcentrate on his or her core task – man-aging and monitoring the process.

More efficient and more reliable

The MES solution has enabled RohMax toachieve important goals. Production is nowmore flexible and more reliable. Automaticdata exchanges ensure maximum data con-sistency, prevent data losses and errors,and facilitate plausibility checks. The con-sistent and comprehensive integration ofthe ERP system and the automation sys-tem, based on Simatic IT, has significantlyimproved the efficiency of the processchain. Finally, the solution was imple-mented by the specified deadline and withinthe budget requirements – with absolutelyno loss of production. �

Find out more:www.siemens.com/chemicalsE-mail: [email protected]: [email protected]

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Processes at the logistics level, such as palletization, are also integrated into Simatic IT and PCS 7

Integration of the process control and MES levels makes production more reliableand efficient

process news 1/2006

20Chemical Industry

CASE STUDY

Located in Weil am Rhein in southwest-ern Germany, near the borders toFrance and Switzerland, Lofo High

Tech Film GmbH, part of the Lonza Group,produces innovative high-tech films. Thespecialty films are manufactured for a widerange of applications using a solvent-castprocess. Series products include polarizerprotection films for LCDs, specialty filmsfor microphones and speakers in cell phones,films for the graphics industry, and prod-ucts for the pharmaceutical industry and

for the manufacture of circuit boards. Thedemand for these specialty films is con-stantly increasing, particularly since theintroduction of LCD displays for PC moni-tors, notebooks, and TVs. Lofo films arealso used in fuel cells and optical storagemedia, and as high-temperature films inengineering.

Specialist in demanding processes

The complex production method and thehigh environmental protection require-

ments mean that solvent-cast technology isused by only a handful of manufacturersworldwide. To maintain optimal control ofthe complex procedure, Lofo was lookingfor a new control system for its castingplant, as the existing technology was nolonger state of the art. After extensive com-parisons of the available options, the com-pany decided to migrate its existing sys-tems to the Simatic PCS 7 process controlsystem.

The system’s open architecture, which isbased on established industry standards,played a critical role in the decision. Lofowanted the modernization to provide a sys-tem that would protect the value of theinvestment and be able to handle futureexpansion or production changes. In addi-tion, the company wanted to implementa standardized method of operation forall production areas in the casting plant.With its sophisticated migration strategy,Siemens was also able to guarantee a seam-less changeover without any major impair-ment of production capacity. Finally, thestrong local Siemens presence in nearbyFreiburg and the excellent support from

Successful migration to Simatic PCS 7 in minimal time

Seamless ChangeoverSiemens migrated the control system in the Lofo High Tech Film moldingplant to Simatic PCS 7 with practically no production stoppages. Thanks toexcellent preparatory work and a proven migration strategy, the entireproject was completed in just six months. The majority of the existingsystems were retained – yet Lofo still derives maximum benefit from theopenness and integration that the new PCS 7 solution provides.

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the option not only of expanding and mod-ifying its Simatic PCS 7 system, but also ofextending the vertical integration of itsprocesses at a later date with the Simatic ITmanufacturing execution system. Thiswould provide further improvements inproduction efficiency. �

The conversion of the plant was trouble-free and, thanks to the proven migrationstrategy and the excellent performance ofthe project team, the critical commission-ing date was met and the project completedwithin the planned cost framework. Oper-ation start-up of the new PCS 7 system tookplace in May 2004 without problems, andLonza is extremely satisfied with the newsolution. The standardized and integratedoperating and monitoring level makes iteasier to control and monitor the processesin the casting plant.

Thanks to the open and flexible TotallyIntegrated Automation concept, Lofo has

process news 1/2006

21

the Siemens team were further pointsweighing in favor of the PCS 7 solution.

Changeover with practically noproduction downtimes

The control system of the casting plant isdivided into three areas. As part of the mod-ernization project, the control technologyfor the first casting line was replaced bothon the operating and monitoring level andon the control side. In areas 2 and 3, theexisting controllers from different manu-facturers were integrated into the newoperating and monitoring system.

Siemens managed the project and wasresponsible for the specifications, hard-ware and software engineering, controlcabinet construction, management infor-mation system, project planning, factoryacceptance test, and commissioning. Onlysix months were available to the projectteam for the entire implementation of thenew solution. Continuous operation of theplant had to be maintained, with the excep-tion of a three-day shutdown.

New client/server-based solution

The new Simatic PCS 7 process control sys-tem has a client/server structure. The cast-ing operation components are controlledby three PCS 7 automation systems, whichcommunicate with the redundant PCS 7server pair and the PCS 7 engineering sta-tion via Industrial Ethernet.

The control functions for the complexmolding process that had been imple-mented in the old Contronic P system weretested and streamlined. The functions thatwere also to be available in PCS 7 were thenadded to a conversion list and ported toPCS 7. At this stage, the Siemens projectteam worked closely with Lofo to ensurethat all necessary functions were trans-ferred as efficiently and smoothly as possi-ble. The conversion list was also used as abasis for the factory acceptance test andcommissioning.

Securing the investment

The migration to PCS 7 enabled Lofo to con-tinue using some of the functioning controlengineering, as well as the I/Os in the plant.This meant that the total investment in themodernization of the control system wassignificantly lower than total replacementcost would have been. It also allowed keep-ing downtime in the plant to an absoluteminimum.

Find out more:www.siemens.com/pcs7E-mail: [email protected]

The solvent-castprocess is used by only a fewmanufacturersworldwide

The standardized and

integrated interfaces

make it easier to

control and monitor

the processes

22Process Safety

TECHNOLOGY

Mr. Kumpfmüller, safety loopscurrently account for aroundten percent of all processinstrumentation. Will theintroduction of SIL certificationcause this figure to risesignificantly?

Hans-Georg Kumpfmüller: Idon’t think so. After all, SIL cer-tification does not change thenumber of fail-safe measuringpoints. Having said that, SIL 1and 2 do appear to have becomethe standards, also in non-safety-critical applications. Con-sequently in the future, somedevices such as pressure trans-mitters will be available onlywith an SIL 2 certificate.

Does this mean that the SIL certificatewill someday replace the “proven-in-use”certificate?

Hans-Georg Kumpfmüller: Certainly not.In terms of Namur requirements, an SIL 2certificate does not even come close to re-placing proven-in-use certification for abrand new device. However, other users arealready requesting an SIL certificate with adevice. We expect that the two concepts willultimately exist side by side – proven-in-use and SIL certificates.

In this context, howimportant is fail-safecommunication?

Hans-Georg Kumpfmüller:With digital fieldbuses, thecommunication itself can bea source of faults or errors. Itis therefore extremely im-portant to use a fail-safe pro-tocol such as Profisafe, whichuses special detection mech-anisms to counter possiblecommunication failures. Fail-safe measuring points mustalso be accurately definedduring engineering. How-ever, in the real world, it oftendoes not become clear untillater exactly where these

measuring points are required. Profibusnetworking, in conjunction with Profisafecommunication, allows fail-safe devices tobe easily added at any time.

So standardized communication usingProfibus DP and PA with Profisafe leadsto savings in engineering?

Hans-Georg Kumpfmüller:Exactly. Fewer IOs are re-quired, and engineering fora fail-safe solution isessentially no differ-

ent from that for a standard Profibus solu-tion. The costs are lower because fewercomponents are required.

Compared to 4–20 mA technology, thepercentage of installations that useProfibus PA is still very low. Does it makesense economically to develop a customsoftware stack for Profisafe for PAdevices?

Hans-Georg Kumpfmüller: A problem isthat the standard communication stackcannot simply be replaced by the Profisafestack. It is essential to demonstrate thatthere are no undesirable interactions be-tween the communication stack and the de-vice software. This is sometimes extremelyexpensive.

When is upgrading to Profisafeparticularly advantageous?

Hans-Georg Kumpfmüller: Whenever anexisting Profibus system has to be expandedto include fail-safe measuring points.Profisafe then enables an existing measur-ing point to be converted into a fail-safemeasuring point simply by replacing thetransducer.

Thank you for speaking with us.

Trends in process safety: SIL and Profisafe

“The Costs are Lower”When it comes to fail-safe measuring points, everyone is talking about SIL (Safety Integrity Level) certification.However, Hans-Georg Kumpfmüller, manager of the Process Instrumentation and Analytics division at Siemens,is convinced that certificates asserting the proven-in-use status will remain an important indicator of theoperational safety of process instruments.


Hans-GeorgKumpfmüller:

“The twoconcepts will

ultimatelyexist side by

side – proven-in-use and SILcertificates.”

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Drive technology for the process industry

ComprehensiveProduct LineWith its complete range of drive systems, Siemens addresses all applicationsin the process industry. The individual components and the system as awhole are ideally equipped to meet the specific requirements of the industry,including the ability to operate in corrosive and explosion-hazardousenvironments as well as in conditions requiring stringent safety standards.

process news 1/2006

TECHNOLOGY

mentation, including ATEX certificates forthe chemical and petrochemical industries.The Dynavert T converters have all the nec-essary industry-specific features and areperfect for customer-specific plant solu-tions that call for a high level of industryexpertise and, above all, flexibility. As a spe-cialist in explosion-proof drives, Loher alsoprovides motors and converters in ATEX-certified combinations for EExn and EExdtypes of protection.

Completed with geared motors

On the mechanical side, gears from Flendercomplete the drive system. Flender gearshave been used for various tasks in thechemical industry for more than 30 years.They are low-noise gears and feature excel-lent efficiency, reinforced bearings, andabsolute impermeability to oil. Combinedwith ARPEX and N-EUPEX clutches withtheir proven capability in the supply andpumping of aggressive and hot media, theyprovide an environmentally friendly andtechnically sophisticated solution for theprocess industry.

Compatible systems increaseproductivity and return on investment

The electrical and mechanical componentsare perfectly coordinated and tailored tomeet the specific requirements of the pro-cess industry. As a result, they ensure maxi-mum productivity and reliability whileminimizing operating costs. �

Drive Technology


The robust, explosion-proof gray cast-iron motors from Siemens are devel-oped, manufactured, and certified in

line with EU directive 94/9/EC and ATEX100a. They are available for all requiredtypes of protection – from increased safety(EEx e II) to flameproof enclosure (EEx de IIC), to “nonsparking” (EEx n A II), and dustexplosion protection.

Improved energy efficiency

In the process industry, it is useful to oper-ate motors at variable speeds. Frequencyconverters ensure accurate delivery anddosing processes, protect the mechanicaland pipe systems, and save up to 50 percenton energy, especially for pumps, ventila-tors, and compressors. Siemens’ range ofconverters covers all standard voltageclasses in the process industry and meetsall industry-specific requirements, includ-ing NAMUR terminal strips and NAMURfunctionality; Profibus Profidrive 4.0 pro-file, process technology mode; safe electri-cal isolation; and PELV and dU/dt filters tolimit voltage spikes and gradients. Thisapplies to the Sinamics and Micromasterequipment series and to converters fromLoher GmbH.

Specialty products supplement portfolio

The Siemens line of motors and convertershas been extended with products fromthe specialist supplier Loher GmbH, fromRuhstorf near Passau, Germany. The LoherChemstar motors are available in specialdesigns with all explosion-proof types ofprotection and come with complete docu- Si

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The Siemensdrive line:

variable-speeddrives, motors for

explosion-proofapplications, and

gear solutions


process news 1/2006

24Process Control Engineering

TECHNOLOGY

The PCS 7 industry library containspreconfigured software templatesand comprehensive documentation

on various issues, and brings togetherengineering experience from past PCS 7projects. For about a year now, the PCS 7libraries have been supplemented by adesign guide and templates for buildingequipment modules. These enable easy,reliable, and more efficient software cre-ation for process automation in the chem-ical industry. The equipment modulesdesign guide saves system integrators andsolution providers time in the specificationphase and helps them quickly create an

appropriate software solution for the rele-vant task. The guide and associated tem-plates also noticeably simplify the softwareengineering.

Models for batch processes

The design guide is based on the equip-ment modules that are defined in variousstandards for the automation of batch pro-cesses, such as NAMUR NE33 and the ISAS88.01 guidelines. The S88 model distin-guishes between process cells such as fer-mentation or oxidation, process units suchas fermenters or reactors, equipment mod-ules such as dosing pumps or mixers, and

control modules such as individual valves.The equipment modules correspond to the“Technische Einrichtungen” category in theGerman NAMUR guidelines. Within anequipment module are various tasks thatare typically performed and can be resolvedby standardized routines – for example,in a heating system, a function for regulat-ing the heating elements must always becreated.

Guide and templates increaseefficiency

Siemens has published the equipmentmodule design guide which describes theessential strategies and concepts to ensureefficient engineering of the equipmentmodules in PCS 7. Thus, it is no longer nec-essary to start from scratch in every pro-ject. As a supplement to the design guide,Siemens also offers various templates thatsystems integrators and solution providerscan obtain from the Siemens sales team.These templates are best practice examplesthat present typical solutions for tasks in abatch process. �

Simatic PCS 7 equipment modules design guide and engineering templates

Cutting Costs, Boosting QualityWith the new equipment module design guide and a selection ofengineering templates, Siemens enables systems integrators and solutionproviders to benefit from past experience in successful projects, andsimplifies the software engineering for the automation of batch processes.

Process cells

Equipmentmodules (EM)

Controlmodules (CM)

Process units

The ISA S88.01 guidelines define process cells, process units, equipment modules,and control modules for the automation of batch processes

Equipment moduleengineering templatesfor batch processesTo date, Siemens has developed a totalof eight templates covering the mostfrequently required tasks in batchprocesses:B Dosing with control valveB Dosing with open/close valveB StirringB Temperature regulationB DrainingB Pressure regulationB Manual dosingB Analysis

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process news 1/2006

25TECHNOLOGYIndustrial Communication


A few years ago, the different areas ofcompany operations were still sep-arated by system boundaries. In an

attempt to increase the productivity ofentire processes, these islands are increas-ingly being networked with each other.However, this horizontal and vertical inte-gration also means that industrial commu-nication is becoming more and more partof the conventional IT world and is thusexposed to the same risks – for example, toattacks by viruses or Trojan horses.

Modular security concept

It is absolutely essential that networks beprotected by appropriate security meas-ures. However, it is important to ensurethat the use of office security functionalityin automation technology is strictly regu-lated, as the security software can severelyrestrict the performance of the modulesand can prevent access to actuators inemergencies. Siemens has therefore devel-oped a security concept that reliably pro-tects industrial communication while at thesame time taking into account the specialrequirements of automation technology.

As a first step, Siemens has upgradedits Simatic PCS7 process control system toincorporate security software from theMicrosoft Office world. From version 6.1or higher, all security patches released byMicrosoft can be integrated. In addition,the virus scanners from Symantec andTrend Micro have been approved for oper-ation with Simatic PCS7 from version 6.1on, for both online and offline components.This means that all computers can be kept

Modular security concept for integrated data networks in the process industry

Simply SecureIn addition to opening up new opportunities, the increasingintegration of process automation and the office world increasesthe risk of virtual attacks from inside and outside the company. As a response to this threat, Siemens has developed specialsecurity packages for the process industry, combining integratedcommunication with a maximum level of network security.

up to date in terms of their security withoutaffecting the production process itself.Simatic PCS 7 also supports protection ofthe automation network through the rec-ommendations and guidelines in the PCS7security manual.

The new security concept also takes intoaccount an issue that is frequently over-looked: hazards that arise within the net-work such as the bugging of communica-tion. Setting up a virtual private network(VPN) tunnel provides an extremely securemethod of preventing such attacks. Thistask is performed by the Scalance S mod-ules from Siemens. Their protection func-tion is essentially based on secure VPNcommunication combined with an inte-grated firewall. The modules, which can beintegrated into existing networks with no

adverse effects on addressing, can easilyprovide the requisite level of security for alldevices at the process level.

Security for integrated systems

These strategies are capable of flexiblymeeting specific network security require-ments in different areas based on the prob-ability of attacks on the network. Together,they provide a comprehensive security solu-tion for the process sector, enabling usersto fully realize the benefits of integrationwhile minimizing the associated risks. �

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Horizontal and vertical integration means that industrial communication is part of the conventional IT world and is exposed to the same risks

water with active carbon powder to wet airoxidation, from chlorine dioxide disinfec-tion to membrane filtration, and from con-tinuous electrode ionization to sterilizationwith ultraviolet light. It is a broad areathat will make a crucial contribution toensuring water supplies for the foreseeablefuture.

Synergies to benefit customers

Siemens has all of the expertise required todeliver complete systems, including instru-mentation, automation, and process man-agement. Synergies between the various

established Siemens Water Technologiesdivision. Siemens Water Technologies,which acquired the North American USFil-ter Corporation in the summer of 2004,provides a wide range of products, systems,and automation solutions for public, indus-trial, and commercial customers, includ-ing conventional treatment lines, state-of-the-art membrane filter treatment systems,instrumentation and automation systems,process management systems, sludge treat-ment, and odor control. Siemens WaterTechnologies can handle every step of thewater treatment process – from treating

process news 1/2006

26Water Treatment

TECHNOLOGY

Siemens Water Technologies brings togetherwater treatment and technology expertise

A Vital ResourceClean water is a resource that is vital for life and is increasingly indemand. Estimates suggest that water consumption will increase byaround 40 percent in the next 20 years. To help ensure that water is

available in sufficient quantity and quality wherever it is needed,Siemens has concentrated its water-related expertise in the

newly established Water Technologies division.

Water can be polluted in differentways and is also used in differentways: it is needed, for example,

for drinking, irrigation, washing and clean-ing, cooling steel, treating oil sand, and –with a high level of purity – for producingcosmetics and medicines. In short, the righttype of water in the right quantity and qual-ity needs to be available at the right place.

Transporting water economically, pro-viding it in sufficient quantities, and treat-ing it so that it meets all necessary legal,medical, and technical criteria – these arethe major fields of activity of the newly

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Siemens divisions are consistently exploited,and the former core competence of waterand wastewater treatment is now combinedwith physical treatment methods, electricalengineering expertise, water transporta-tion, and infrastructure services. Combin-ing modular, standardized products withtried and tested solutions not only enablesprojects to be completed more quickly andefficientl. It also guarantees an exceptionaldegree of reliability and flexibility.

Investment security and cost-effective-ness are critical. Local authorities and com-panies need to constantly invest in newwater and wastewater technologies, andthey expect to be able to flexibly expandand modernize their systems. By usingsolutions based on the Simatic S7 con-troller family, the Simatic PCS 7 control sys-tem, the industry-specific Siwa Plan mod-

service business and placing a greaterfocus on the industrial sector. Siemens hasa clear advantage over the competition inthis area. It can supply the manufacturingand process industries with equipmentand systems from the process level to theautomation and control system level rightthrough to the management level, thusenabling integrated automation and pro-cess optimization. Water treatment canthereby be optimized – regardless of whetherthe process is in a refinery, in a steelworks,a paper factory, or on a production line. �

ules, and supplementary product linesfrom Envirex, Memcor, Wallace & Tiernan,Zimpro, and RJ Environmental, Siemenscan offer a wide range of technologies andservices that meet the most diverse require-ments from country to country and fromcompany to company.

Experience on demand

Success is based not only on innovativeproducts. Process expertise is an importantingredient for optimal water treatment.The division now known as Siemens WaterTechnologies has many decades of experi-ence in the treatment and distribution ofwater, with more than 200,000 installationsmeeting strict industrial standards andstringent government regulations.

In the future, Siemens Water Technolo-gies aims to concentrate on expanding its

Find out more:www.siemens.com/waterE-mail: [email protected]

IntegrationIncreases CapacityThe R.L. Sutton sewage plant in Cobb

County, Georgia was completely modern-

ized between 2001 and 2004. Every day

the plant cleans more than 227,000 cubic

meters, or 227 million liters, of wastewater.

The modernization program enabled the

plant’s capacity to be increased by 50

percent. As in all four plants in Cobb

County, products from various suppliers

were replaced by standard solutions from

Siemens. This reduced spare parts inven-

tories and improved plant availability.

Solutions such as the Simatic S7-400,

S7-400H, S7-300, ET 200M, OSM TP 62,

and TP 270 from the Siemens portfolio

were implemented. The low- and medium-

voltage drives were supplied by Robicon,

which was acquired by Siemens in 2005.

The preliminary and secondary treatment

plants, the analysis equipment, and the

odor control and ventilation systems all

came from USFilter, a company that has

been part of Siemens Water Technologies

since 2004.

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process news 1/2006

28Manufacturing Execution Systems

TECHNOLOGY

Simatic IT contributes to higher performance and regulatorycompliance support in the pharmaceutical industry

Performance CapabilitiesGrowing market pressures and a changing regulatory landscape that encouragesprocess innovation and optimization are forcing pharmaceutical manufacturers tomodify their manufacturing infrastructures. The Simatic IT manufacturing executionsystem (MES) can help pharmaceutical companies link process demands and marketrequirements with business targets.

N ew product development is crucialfor the success of any pharmaceuti-cal company, which means that the

entire research and development processmust be streamlined and the final productinformation seamlessly transferred to theappropriate manufacturing facilities. Equallycritical is the ability to manage a large quan-tity of product and packaging specifications,especially in formulation and packagingareas. Simatic IT can, thanks to its Simatic ITInterspec, Simatic IT Unilab, and Simatic ITProduction Suite components, play a signif-icant role in aligning research and develop-ment and manufacturing environments

through integration with both the enterpriseresource planning (ERP) and MES layers.

Simatic IT Interspec is a product specifi-cation management system that can beimplemented separately or as an integratedpart of Simatic IT. It helps manage the largenumber of product specifications by serv-ing as the repository for all product-relateddata. Maintaining all product-related datain Simatic IT Interspec ensures consistentcontrol and management of product andresearch and development data, thanks tofunctionality such as configurable work-flows, life-cycle control, access rights, andaudit trails.

Built-in qualityDriven by regulatory initiatives such as theUS Food and Drug Administration’s (FDA’s)process analytical technology (PAT) initia-tive, pharmaceutical companies are focus-ing on integrating quality into the processand on in-line quality control to improveprocess understanding. With an integratedMES system that can maintain productspecifications and quality parameters andserve as single point of reference for qual-ity, data relating to product, process, andquality can be transformed into businessand product value. However, the laboratorywill continue to play an important role, aswill laboratory information managementsystems (LIMS) such as Simatic IT Unilab.The laboratory will remain a point of refer-ence for the quality parameters of the prod-ucts and will manage and maintain thisinformation as well as the workflows in thelab. By linking the quality parameters fromthe LIMS and the process parameters acces-sible through Simatic IT Historian, qualityis integrated into the process at a secondlevel. These data can then be fed back to thecontrol systems, completing the loop andensuring real-time measurements of param-eters that are critical to quality.

Improving performance

Simatic IT Historian handles plant per-formance analysis and key performanceindicator (KPI) management. Simatic ITHistorian also holds OEE (overall equip-ment efficiency) and DTM (downtimemanagement) data, which allows man-agers to monitor equipment efficiencyand make informed decisions based onperformance indicators. Through thesededicated functions, underperforming pro-

ERP

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Simatic IT Production Modeler

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Simatic ITUnilab

Simatic ITInterspec

Simatic IT utilizes a component-based approach to help pharmaceutical companieslink process demands and market requirements with business targets

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duction areas can be quickly identified andplant performance continuously improved.Integration with the entire Simatic IT envi-ronment allows corrective actions to betaken in reaction to decreases in efficiency,thus dramatically improving economicreturn on assets.

Higher productivity

Due primarily to regulatory issues, thepharmaceutical industry until recentlycould not fully exploit the benefits of newproduction and productivity strategies andmethods. In its new guidelines, the FDAstates that processes must be reliable andrepeatable in order to guarantee quality andsafety. Inherent in the FDA’s risk-based reg-ulatory approach is a clear preference forstandard products and solutions based oninternational standards, as these facilitatetechnology transfer.

Simatic IT Production Suite not only man-ages production but also has extensive andunique modeling capabilities that enablerepeatable processes. Simatic IT providesthe necessary coordination between the con-trol and the business level, enforces stan-dard operating procedures and workflows,and coordinates all activities. As Simatic ITcan be directly linked to corporate ERP sys-tems, order transactions are automaticallymanaged in the Production Order Manager(POM), thanks to Simatic IT DIS (Data Inte-

gration Services). From the Simatic IT POM,orders can, for example, be dispatched, can-celed, or split, all with a complete audit trailof all actions performed. Simatic IT Produc-tion Suite also supports full and unambigu-ous traceability and tracking of transactions.This can be used to create forward and back-ward genealogy displays.

Reaping the benefits of technology

Regulatory bodies worldwide have launchedcomprehensive new initiatives relating torisk management, data integrity, and inte-grated quality, as well as adopting morestringent product liability regulations. Con-taining manufacturing costs and increasingproductivity with reliable processes are nowmore important than ever. These require-ments, combined with the need to strengthenmarket positions and increase the ability toinnovate, are driving pharmaceutical man-ufacturers to adopt new strategies for sus-tainable success. Simatic IT, a component-based manufacturing execution system withmodeling capabilities, allows pharmaceu-tical manufacturers to reconcile regula-tory, business, and production con-straints. This enables vastly improvedmarket responsiveness, reduction ofwaste, shorter cycle times, betterasset utilization, increased pro-duction efficiency, and regu-latory compliance. �

Find out more:www.siemens.com/simatic-itE-mail: [email protected]

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process news 1/2006

30Pharmaceutical Industry

CASE STUDY

Pressure on the pharmaceuticalindustry is growing: billions are beinglost each year due to counterfeitdrugs, and the US Food and DrugAdministration (FDA) is demandinggreater safety for pharmaceuticalproducts as of 2007. Radio frequencyidentification (RFID) technology, with transponders placed on thepackaging, is one possible solution. A pilot project by Limmatdruck/Zeilerand Siemens demonstrates what thefuture of pharmaceutical packagingcould look like.

L immatdruck/Zeiler is a leading pack-aging supplier renowned for its inno-vative solutions. With Siemens as a

technology partner, the Swiss companypresented the first RFID technology forpharmaceutical products at the Interpack2005 international packaging industry fair.“Many visitors were amazed that we werealready able to present a close-to-seriessolution with an integrated RFID reader,”recalls Stephan Ruske, project manager atLimmatdruck/Zeiler.

“In the pharmaceutical industry, RFIDtechnology is generally seen as a very promis-ing solution for safeguarding drugs againstcounterfeiting,” says Ruske. However, thereis still a great deal of hesitation concerningapplying this brandnew technology. Nev-ertheless, it is clear that the pharmaceuti-cal industry must take action to protect notonly its revenues but also patients. TheWorld Health Organization (WHO) esti-mates that around seven percent of alldrugs marketed worldwide are now coun-terfeit. This is the equivalent of around 30billion US dollars in lost revenue. However,an even greater concern is the potential haz-ard that these cheap counterfeit productspose for patients. This is the reason why,despite all reservations, Limmatdruck/Zei-ler is already collaborating with customerson two projects.

To date, the FDA has merely recom-mended that drugs be made safer. How-ever, more stringent legislation is expectedto go into effect by the end of 2007 at the lat-est. Then, inadequate safety precautionscould result in severe penalties, at leastin the United States. “A class-action lawsuitcan force even a large pharmaceutical com-

RFID technology for drug packaging in the pharmaceutical industry

Smart Packs

RFID technology can make a significant contribution to the safeguardingof drugs against counterfeiting

process news 1/2006

31

The packaging machine allows fully automatic folding,bonding, and filling of the packaging

The boxes are checked by an RFID read/write unit that isintegrated into the machine controller

pany to its knees,” says Ruske. Some com-panies are now responding and taking con-crete action. Pfizer, for example, wants tostart tagging all Viagra bottles, starting inthe United States, with RFID transpondersas early as 2006.

Integration into existing technologies

To develop its RFID solution, Limmatdruck/Zeiler is using expertise from the SiemensRFID Solution Center in Switzerland. Theprototype packaging machine with RFIDtechnology presented by Limmatdruck/Zeiler is quite similar to a conventionalmachine for packing tablet blister packsin cardboard boxes. The crucial differenceis that every box is labeled with an RFIDtransponder in the process. Once themechanical packing process is complete,an electronic product code (EPC) is writ-ten on the chip, giving each individualpack a unique ID.

The packaging machine can be inte-grated into any existing production infra-structure. The built-in transmitter fromSiemens operates at a frequency of 13.56megahertz, a widely used standard that ischaracterized by low sensitivity to interfer-ence caused by metals and liquids. A PCcontrols the machine. The RFID transmitter

is connected to the clock of the PC to allowclear monitoring of every batch. Throughan additional interface, the machine can beintegrated into a master control system oran ERP system such as SAP.

Limmatdruck/Zeiler and Siemens havedeveloped a close partnership to create apackaging solution that is specially tailoredto the requirements of the pharmaceuticalindustry, including research on possibleinteractions between the radio tags and thedrugs themselves and the production envi-ronment. Siemens expertise and technicalresources were critical in this area. The ulti-mate aim was to ensure that neither metal-lic blisters nor liquid drugs and storage andtransport systems would interfere with thepackaging process.

Much more than track and trace

It is certainly true that drug safety could beincreased using conventional methodssuch as bar codes or holograms. But onlyRFID technology allows genuine interactionbetween the manufacturer and the patient,making it the ideal solution for the future.In the future, for example, patients couldinquire about the authenticity of the drugsvia a PDA and contact the manufacturerdirectly to obtain additional information or

to find out about similar products. Particu-larly for nonprescription drugs, this opensup a wide variety of possibilities relatingto safety, information, and marketing. Theadditional benefits go far beyond productsafety. “It is incredible what using RFID canoffer in terms of new options,” says Ruske.

Although it is still a relatively new tech-nology, RFID has already reached a remark-able level of maturity. Siemens alone hasdelivered more than 300,000 read/writeunits to date. There is no doubt that thepackaging industry will be one of the primemovers as RFID becomes increasingly wide-spread. This will have numerous clear ben-efits, and not only for the pharmaceuticalindustry: increased customer protectionagainst counterfeiting, easier recall actions,clear detection of breaks in the coolingchain, prompt detection of use-by dates,and, in general, easier and more cost-effec-tive logistics processes. �

Find out more:www.siemens.com/rfidwww.siemens.com/pharmaE-mail: [email protected]

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32Pharmaceutical Industry

CASE STUDY

Clean-room monitoring at Sanofi-Aventis with Simatic PCS7

Exact Air ConditionsWhen active pharmaceutical ingredients or drugs are produced in clean-room environments,all ambient conditions must be monitored reliably and comprehensively. Sanofi-AventisDeutschland GmbH, located at the Höchst Industrial Park in Frankfurt, Germany, now usesthe Simatic PCS7 process control system for this task and has recently upgraded its entiremonitoring system to version 6.

process news 1/2006

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W ith annual sales of around 25 bil-lion euros, Sanofi-Aventis is Eu-rope’s largest pharmaceutical

company. At the Höchst Industrial Park,where sterile drugs are manufactured un-der clean-room conditions, Sanofi-Aventishas been operating a clean-room monitor-ing system since 1999 to monitor particles,humidity, room temperature, and pressuredifferences.

Significantly stricter requirements

International standards for drug manufac-turing have become increasingly stricter inrecent years and now call for sophisticatedambient-conditions control technologyto guarantee that the ambient air meetsclearly defined clean-room standards. Inaddition, comprehensive documentationof all production parameters is obligatory,which requires constant monitoring of theair quality.

To meet these stricter requirements,Sanofi-Aventis decided to modernize itsexisting Simatic PCS7 V4.2 process controlsystem by upgrading to version 6. Thelatest version of Simatic PCS7 meets all FDAand GAMP regulations, making it the idealsolution for the pharmaceutical industry.The system’s simplified engineering en-ables the upgrade to be performed without

interrupting operations. New measuringpoints can be added without stopping dataacquisition, thus ensuring that compre-hensive data acquisition is maintained at alltimes. Simatic PCS 7 version 6 is signifi-cantly more user-friendly, and thus con-tributes to making clean-room monitoringeven more efficient and reliable.

Implementation on schedule

After the required qualification documen-tation was compiled and finalized, the new

system was installed and commissioned onsite between Christmas and New Year’s Eve.All clean rooms were back on line as sched-uled on December 31 with absolutely no in-terruptions in production. �

Find out more:www.siemens.com/pharmaE-mail: [email protected]

Upgrade with clear benefitsFor Sanofi-Aventis, the crucial benefits of upgrading to version 6 of Simatic PCS7were the following:

B Online upgrades: Measuring points can be added or changed withoutinterrupting continuous data acquisition

B Simplified engineering: When creating a new measuring point in theautomation system, the required visualization is automatically created in theoperating and monitoring system

B Optimized data transfer: If the connection between the process control systemand the operating data information system fails, the data is buffered andforwarded automatically when communication is restored

B Updated systems: New server and terminal computers use Windows 2000instead of Windows NT

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process news 1/2006

34Process Analytics

TECHNOLOGY

The Sohio process was patented in 1947and first commercialized in 1960.Thereby, propylene, ammonia, and

air are fed into the reactor in near stoichio-metric ratios. A slight excess of ammoniaforces the reaction closer to completion,while a slight excess of air continually re-

generates the catalystused in the reaction. Bymeasuring the crudeproduct, the process canbe optimized to achieveoptimum yield.

Multiple benefitsthrough improvedanalytics

Process optimization inacrylonitrile produc-tion serves three mainobjectives. First, depen-ding on market de-mands, various ratios ofacrylonitrile vs. cyanicacid, which is a by-prod-

uct of the main reaction, are desirable. Sec-ond, it is important to minimize excess am-monia, because excess ammonia reacts toammonium sulfate containing heavy metalcatalyst residues in the quench reaction.This is a hazardous waste and must be dis-posed of. Finally, delay times can be reducedthrough on-line monitoring, which can leadto a significant increase in overall yield.

Multiple challenges to conventionaltechnology

However, the acrylonitrile reactor effluentposes a difficult analytical problem. The

sample is hard to transport via a heatedline because it contains high amounts ofwater and heavy components that areprone to polymerization as well as particlesof the fluidized bed reactor. Moreover, thehigh water and ammonia contents makethis an analytical task that is hard to solvewith process chromatography, and somecomponents of the sample stream such asnitrogen, carbon monoxide or ammoniaare not resolvable with low-resolution massspectrometers. Additionally, some compo-nents are invisible or difficult to detect inthe infrared range.

In-process mass spectrometer solution

With the Quantra FT-ICR mass spectrome-ter and sampling system, it is now possibleto effectively master this challenging task.Quantra can handle high water contentsand complex sample mixtures, and analyzecomponents previously not seen by gaschromatographs. Moreover, Quantra is ableto cope with mass interferences much bet-ter than any quadrupole instrument, andhas a shorter cycle than any gas chromatog-raphy system. The system also enables sub-ambient sampling and has lower mainte-nance requirements. Considering the var-ious benefits enabled by using Quantra, itis not surprising that a leading acryloni-trile company has recently placed severalorders for the Quantra system. �

Quantra FT-ICR mass spectrometer handles challenginganalytical task in acrylonitrile production

Process BenefitsAcrylonitrile is produced domestically through a single process: the Sohioprocess of propylene ammoxidation. By monitoring the crude product streamdirectly after the reactor, it is possible to optimize the reaction. Until now, themonitoring task has been difficult to solve with the help of chromatographic orinfrared systems. The Quantra mass spectrometer, however, offers an excellentsolution for handling this task.

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The Quantra mass spectrometeroffers various benefits that can beexploited in acrylonitrile analysis

Find out more:www.siemens.com/processanalyticsE-mail: [email protected]

Acrylonitrile is the monomer ofpolyacrylics that is used in manysynthetic fibers

process news 1/2006

35TECHNOLOGYPower Solutions

R eliable power is an indispensablerequirement for the continuousoperation of industrial processes.

Siemens has developed TIP to provide areliable and cost-effective power supply inbuildings.

With this new concept, Siemens offers anintegrated, comprehensive portfolio of prod-ucts, systems, and tools for power distri-bution. TIP covers the entire life cycle of apower-distribution system, from designand engineering to development and con-struction to cost-effective operation. Per-fectly compatible products and systemswith optimized interfaces guarantee reli-able operation. Standardized interfacesprovide trouble-free links to process con-trol technology and building automationsolutions. Maintenance-free power distri-bution equipment, such as gas-insulated

medium-voltage switching stations, alsohelps cut life-cycle costs.

Integrated engineering improves safety

During the design phase of an electricalpower-distribution system, the dimension-ing software Simaris design from Siemensassists the operator in selecting tailoredand compatible products to achieve anuninterrupted power supply. It providesevidence of selectivity for all power-distri-bution and backup power-supply systems.

This proven dimensioning and calcula-tion program for electrical power distribu-tion enables electrical planners to selec-tively configure the entire electrical infra-structure of a building. This ensures that inthe event of a short circuit in the powersupply, disturbances and system downtimeare kept to a minimum.

Find out more:www.siemens.com/tipE-mail: [email protected]

Increasing power availability

A key function of a power distribution sys-tem is ensuring a reliable supply. To achievethis, the operating personnel require a highlydetailed overview of the condition of thepower-supply equipment. Computer-basedinformation management is used to or-ganize and optimize the use of the variousdata available in the switching station. Thisis done using the Sicam PCC power au-tomation system. �

Increased reliability, cost-effectiveness, and availability: Totally Integrated Power

Cutting the Energy BillIntense global competition requires companies to take an integrated view of all cost factors over the entireservice life of their equipment. Electrical power accounts for a significant proportion of operating costs andshould therefore be a focus of attention when planning equipment installations. With Totally Integrated Power(TIP), Siemens has developed a concept that helps cut energy costs right from the start.

process news 1/2006

atures and is available in ETFE (ethylenetetrafluoroethylene) and PVDF (polyvinyli-dene fluoride). The Sitrans Probe LU is con-figured using a manual programming unitor Simatic PDM software.

Industry-specific pressure transmitter

The new Sitrans P300 pressure transmitterwas specially developed to meet the require-ments of the food and beverage industryand the pharmaceutical industry. This trans-mitter with stainless steel housing andmeasuring cell flush with the front panel iseasy to clean and sterilize. The transmitteris suitable for process temperatures ofup to 200 degrees Celsius, and is availablewith the full range of hygiene connections.Sitrans P300 provides exact and stablemeasurements over a long period. Forexample, the deviation in measured valueis less than 0.075 percent with a long-termdrift of only 0.25 percent in five years.

Sitrans P300 is operated locally usingthree keys and a display. Comprehensivediagnostics and simulation functions per-mit easy start-up of measuring circuits andprevent plant downtime. The pressure trans-mitter parameters are set using SimaticPDM software and the integral HART orProfibus PA interface. �

New devices supplement process instrumentation portfolio

Micro Scale and Mega PrecisionGeneralists and specialists have been added to the Siemens processinstrumentation product portfolio, offering new technical details and newapplication options. Compact devices concentrate added functionalitiesinto smaller dimensions, communication devices can be integrated intohigher-level control system structures, and special designs have beendeveloped for industry-specific requirements.

observation, as well as with several sampleapplications and a preconfigured S7-200control program.

Communication capability with high precision

The Sitrans Probe LU ultrasound trans-ducer supplements the line of Profibus-compatible transmitters, and now commu-nicates via Profibus PA (profile 3, class B)as well as via the HART protocol.

The patented Sonic Intelligence echo-processing software enables an unprece-dented measuring accuracy of 0.15 percentto be achieved. The sensor is resistant tochanging chemical influences and temper-

The compact new Siwarex MS (Micro-Scale) weighing module combinesweighing and control technology.

The Siwarex MS can be easily integratedinto the Simatic S7-200 automation systemas an expansion module. The controllerprogram can use the Simatic CPU to accessthe current data for measured weight andforce directly, without the need for an addi-tional interface. The combined weighingand control package is ideal for freely pro-grammable modular weighing systems fea-turing one or more scales.

The Siwarex MS is also available as amicro automation set with an additionalTP177micro touchpanel for operation and

TECHNOLOGYProcess Instrumentation

36


process news 1/2006

37

Find out more:www.siemens.com/piaselectorE-mail: [email protected]: [email protected]

mouse. The download options allow thedata found to be processed in customertools, and because the product search isfollowed by error-free configuration withthe relevant order information, there is noneed for additional queries. Making fewererrors during device configuration ulti-mately means that the entire procurementprocess becomes quicker and leaner.

A tool with great potential

At Achema 2006, Siemens will be present-ing a basic version of PIA Selector 3.0,focusing functionality on offering variousselection functions and covering the mostimportant product groups. The tool’s func-tionality will then be expanded graduallybased on intensive customer dialogue, inorder to provide the customer with optimalsupport at all times when searching for theright measurement or analysis device. As aportal to the world of process instrumen-tation at Siemens, the PIA Selector alsoincorporates innovations and new trends inprocess instrumentation, thus ensuringthat the user receives the perfect informa-tion at all times. �

PIA Selector 3.0 for process instrumentation and analysis

Device Selection Made EasyEfficient engineering and electronic procurement demand tools thatfacilitate technical product selection and error-free configuration. ThePIA Selector enables users of process instruments to quickly and easilyfind and configure the right product from the Siemens processinstruments and analytical portfolio.

ensures that the user has the correct ordernumber. What is more, the PIA Selectorsupplies information about spare parts andaccessories and includes comprehensivefunctions for ordering and processing prod-uct data in various formats.

Fast and easy

The PIA Selector does more than justgreatly simplify the search for the correctdevice. The tool is also a source of back-ground information on all aspects of pro-cess instrumentation and analysis. Allinformation is made available via a portal,allowing the user to retrieve any informa-tion at any time with just a few clicks of the

The PIA Selector is a Web-based tool.Its latest release, version 3.0, sup-ports a variety of different selection

methods and entry options that allow theuser to quickly find the right product. Italso provides a range of additional func-tions relating to a broad spectrum of pro-cess instrumentation and analysis issues.Whether selection is based on the require-ments of the measuring point, a specificmeasuring principle, a special industryspecification, or product and model num-bers, the PIA Selector can find the rightproduct in no time. The tool also providesa configurator which guarantees error-freeconfiguration of equipment, and which

TECHNOLOGYProcess Instrumentation

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38 CASE STUDY

AH Marks produces chemicals in largebatches up to thousands of ton,involving one to three-stage synthe-

ses. Products include styrenic and non-stryenic inhibitors, biocides, chlorophe-nols, and various intermediates. Key aspectsof the refining process are acidification andwashing to purify the phenols. In the pro-cess tanks, agitators mix the material withthe acid or water before allowing the mix-ture to settle. In the settling process, thephenolic material and the waste (acid,water, and other impurities) split into twovery separate layers due to their differentspecific gravity. At this point, the phenolicproduct is allowed to drain from the reac-tor. Monitoring the draw-off of phenolsused to be done manually by observingthrough a sight glass. The company wantedto automate this process to enhance accu-racy and free operators from this time-con-suming task.

Sitrans solution

Acids and water are highly conductivematerials, while the phenols are non-con-ductive. This difference is a good way todetect the end product from the wastematerial. In the settling tanks, the companyinstalled a Sitrans LC 500 capacitance trans-mitter to measure the interface of wasteand end product. Another LC 500 trans-mitter is mounted directly in the steam-jacketed line to monitor the draw-off pro-cess. Unlike conventional capacitancedevices that measure voltage drop or cur-rent flow, LC 500 employs a unique fre-quency-based technology that consistentlyoutperforms other devices. Even small levelchanges create large changes in frequency,resulting in better resolution and accuracy,along with repeatable level detection. TheLC 500 is designed for extreme and criticalprocess conditions. For this application, the

probe is coated with enamel to handle thehot process and corrosive materials.

Monitoring benefits

“The Sitrans LC 500 provides a continuous4–20 mA signal to our central DCS,” saidSteve Hodges, control and instrumentationengineer with A H Marks. “It gives us con-stant, reliable monitoring of this harsh pro-cess with consistent results. We have nowmade this instrument the standard for thisapplication.” A H Marks can now detect andcontrol the product-to-effluent interfacewithout human intervention. Accurate, reli-able measurement helps ensure product qual-ity and enhance plant safety. It frees a tech-nician from the sight-monitoring task, rep-resenting a saving in staff time as well. �

A H Marks monitors phenol refining process with Sitrans transmitters

Ensuring Product QualityA H Marks and Company Limited, located at Wyke in West Yorkshire, is the UK’s largest privately-owned, independent chemical manufacturing company. It produces a wide range of specialty chemicals for customers in the agricultural, petrochemical, and personal care markets. With Sitrans capacitance transmitters, the company has found a reliable and cost-effective solution for monitoring phenol draw-off.


Process Instrumentation

User Seminar on EDDLAt this year’s Hanover and Achema trade fairs, the Electronic DriveDescription Language (EDDL) Cooperation Team will be organizinga user seminar entitled “EDDL – The key to interoperability,” whichwill report on the status of the harmonization and enhancementsachieved to date and on the future development road map for ED-DL. EDDL is the world’s leading integration method for incorporat-ing field devices into automation technology.

The heads of four organizations – the OPC Foundation, theFieldbus Foundation, the HART Communication Foundation, andthe Profibus User Organization (PNO) – will be highlighting thebenefits of EDDL technology from their point of view. Live demon-strations will illustrate how EDDL is used in different host systems.The four experts will then be available for individual discussions.

Hanover Trade Fair / Interkama 2006, April 26, 200610:00 – 12:00 in German14:00 – 16:00 in EnglishRoom: Hall 2, Prague Room gallery

Achema 2006, May 16, 200610:00 – 12:00 in German or EnglishRoom: Hall 10.2, Inspiration Room 2 – 3

Attendance is free of charge.

infosinfosDo you want to know more about the systems and solutions forthe process industry from Siemens Automation and Drives?Simply visit our information portal on the Internet:

www.siemens.com/processautomation

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39DIALOGUE

process news 1-06PublisherSiemens Aktiengesellschaft,Bereich Automation and Drives (A&D), Gleiwitzer Str. 555, 90475 NurembergGermany

www.siemens.de/automation

Group Executive Management Helmut Gierse, Hannes Apitzsch, Dr. Peter Drexel, Anton S. Huber

Responsible for ContentPeter Miodek

Responsible for Technical ContentCornelia Dürrfeld

ConceptChristian Leifels

EditorCornelia Dürrfeld, Siemens AG, A&D CC P MCSiemensallee 84, 76187 Karlsruhe, GermanyTel.: +49 (0) 7 21/5 95-25 91Fax: +49 (0) 7 21/5 95-63 [email protected]

Editorial CommitteeAlexandre Bouriant, Sigrun Ebert-Heffels, Michael Gilluck, Birgit Gottsauner, Walter Huber,Keiren Lake, Bernd Langhans, Bernd Lehmann,Silvana Rau, Rüdiger Selig, Roland Wieser, Wolfgang Wilcke

Publishing HousePublicis KommunikationsAgentur GmbH, GWACorporate Publishing ZeitschriftenP.O. Box 3240, 91050 Erlangen, GermanyTel.: +49 (0) 91 31/91 92-5 01Fax: +49 (0) 91 31/91 92-5 9

[email protected]

Editor in chief: Kerstin Purucker

Layout: Jürgen Streitenberger

Copy editing:Irmgard Wagner

DTP: Doess, Nuremberg, Germany

Printed by: Stürtz GmbH, Würzburg

process news is published quarterly

Circulation: 31.500

Jobnummer: 002100 RPE61

© 2006 by Siemens Aktiengesellschaft Munich and Berlin, Germany

All rights reserved by the publisher.

This edition was printed on environ-mentally-friendly chlorine-free paper.

ISSN 1430-2292 (Print)

The following products are registered trademarks of Siemens AG:ET 200, MAXUM, MICROMASTER, S7-400,SCALANCE, SICAM, SIMARIS, SIMATIC, SIMATIC IT, SINAMICS, SIPAN, SIPOS,SIPROCESS, SITRANS, SIVACON, SIWAREX, STEP 7, TELEPERM, TOTALLY INTEGRATEDAUTOMATION, TOTALLY INTEGRATED POWER,TP170, TP270, ULTRAMAT, WinCC

If trademarks, trade names, technicalsolutions or similar are not listed above,this does not imply that they are notregistered.

The information provided in this magazinecontains merely general descriptions or characteristics of performance whichin case of actual use do not always applyas described or which may change as a result of further development of theproducts. An obligation to provide therespective characteristics shall only existif expressly agreed in the terms of contract.

Order No.: E20001-M6106-B100-X-7600

Printed in Germany

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