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Number 2 | August 2013 | siemens.

com/processnews

process news
The Magazine for the Process Industry

Partners in India
Solutions for growth and innovation

process news 2/2013 | Contents

Focus on India
In the past decades, India has seen rapid change, transitioning from a primarily agrarian economy into a modern society with booming industries. One growth sector is the pharmaceutical industry, which is currently the worlds third largest in terms of volume. The photo shows two researchers in a pharmaceutical laboratory in Mumbai.
Photo: Frederic Soltan/Corbis

Editorial
03 Past meets present

Process Instrumentation
24 Good measures A Sitrans flowmeter helps verify the supplied amount of jet fuel 25 High tech in compact design Sitrans technology in a combined wastewater treatment/biogas facility

Cover
04 Partners in progress Jubilant India benefits from modern process control

Process Control Technology


08 Flexibility in the field Fieldbus integration made simple and cost-effective 10 Going strong together Siemens in India is focused on offering optimum solutions 16 System in a box A complete control system in two containers for Linde India 18 World-class skills and expertise The Siemens Nashik Works supplies cabinets to customers all over the world 20 A safe choice Achieving better safety with less hardware and costs 22 Hands-on security Industrial Security with access protection, guidelines, and instructions

Drive Technology
26 Production sweet spot Spray Engineering Devices Ltd., India, improves energy efficiency in the sugar industry with Siemens drives

Solution Partners
28 Modernization without disruption Process control system migration at a German utility 30 Getting the most out of raw materials Simatic PCS7 supports smooth project implementation at a French sawmill 32 Turn up the gas Aegis Logistics benefits from smooth safety system operations 34 Hot stuff A tailored gas analysis solution helps improve blast furnace operations Folder inside: Competent Partners Individual solutions for the water sector

Pharmaceuticals
12 World-class efficiency Shantha Biotechnics benefits from smooth validation 14 Active and effective Teva API optimizes energy efficiency

Dialogue
35 Compliance, preview

Cover photo: Frederic Soltan/Corbis

Editorial | process news 2/2013

Past meets present

Looking out my ofce window, I can witness just how the society and the economy in India are rapidly evolving. My ofce is located in Thane adjacent to the Mumbai metropolis, which is one of the oldest and greenest cities in India and at the same time a booming suburb with shopping malls, entertainment centers, business parks, and industrial areas. Clearly a country of contrasts, India has made the leap from a predomi nantly agrarian society to a global player in many industries, from food and beverage to pharmaceuticals and chemicals. Companies are no longer just investing in India to benet from low production costs, but draw added benet from a skilled workforce and a growing domestic market. This is complemented by many Indian enterprises making the move onto the world stage, with a focus on their own research and development and state-ofthe-art production standards. Automation technology, in general, and process control technology, in particular, are considered key drivers to improve quality and performance. This is where Siemens, as a supplier for automation and drive systems, stands ready to help companies in India address the challenges of a global market. We can provide the technology and the expertise required to improve operations both locally and globally. Our first multinational project was the construction of the telegraph line from London to Calcutta in 1867 which made us a global player even before there was such a term. Siemens has been a reliable partner to India and its economy and infrastructure for more than 100 years. I consider myself very fortunate to be part of this long and successful partnership, and I hope that with this issue of process news, you will gain some interesting insights into this booming economy. Enjoy the read!

Sascha Mnnl Head of VSS Process Automation South Asia

Siemens AG

process news 2/2013 | Cover

Jubilant Life Sciences Ltd., India

Partners in progress
Siemens becomes a trusted partner to an Indian pharmaceutical and life science company, helping it expand and grow.
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Andres Rodriguez Fotolia

Cover | process news 2/2013

ubilant Life Sciences Ltd., an integrated pharma- to achieve higher productivity with less manual interceutical and life science company, is one of the vention and a faster return on investment. largest custom research and manufacturing services companies in India. The company has earned a The plan for expansion reputation as a high-quality manufacturer, with approval from the US Food and Drug Administration Jubilant is currently developing a sector-specic SEZ (FDA), the Agence franaise de scurit sanitaire des (special economic zone) for chemicals on 265 acres produits de sant (AFSSAPS) in France, and the Phar- of land at Vilayat GIDC Industrial Estate, in Bharuch maceuticals and Medical Devices Agency (PMDA) in district of Gujarat. The facility dedicated to the production of specialty chemicals is located here. Japan. Jubilant has a 300-acre manufacturing facility in ThieBharuch facility consists of multiple processing Gujarat, India, which contains a state-of-the-art plant blocks, along with scrubbers, raw material tank farms, producing specialty chemicals used in the manufac- cooling towers, and the plant utilities. The plants ture of vitamins and intermediates for the pharma- have been successfully commissioned one after the other. ceutical and agricultural industries. To meet the growing demand, Jubilant wanted From the very beginning, Jubilant wanted a distribmore efcient and transparent process control, with uted control system (DCS) for the manufacturing faa high degree of exibility and expandability, in order cility with about 400 I/O devices on Foundation Field-

Complete process instrumentation package: in addition to the process control system, Siemens provided a comprehensive package of process instruments for the referred plant, making the facility one of the largest installations of Sitrans process instruments in India

Simatic PCS7 Seamless Integration

SITRANS LR250
Radar Level Transmitter

SITRANS P DS III
Pressure Transmitter

SIPART PS2-FF
Electropneumatic Positioner

SITRANS F M 6000
Magnetic Flowmeter

SITRANS F C MASS 6000


Mass Flowmeter

Siemens AG

175

155

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process news 2/2013 | Cover

Standards and quality


Shyamsundar Bang coordinates manufacturing, supply chain, and new projects for Jubilant and has been instrumental in upgrading existing technologies, introducing new technologies, and developing and managing projects for Jubilant. In an interview, Bang states that besides a best-in-class manufacturing facility and competitive advantages, it is necessary to comply with all regulatory guidelines and adhere to the highest quality standards. Following best practices for engineering and automation is a must. mentally friendly process we have developed. And what is the role of Siemens in this strategy? Mr. Bang: Siemens enjoys an excellent reputation in India. First known for its power generation systems, Siemens has successfully introduced its automation products and expertise into the Indian market. At Jubilant, we have several plants at our Nanjangud and Bharuch facilities that are equipped with Siemens automation systems, and we are very satised with them. As an international company, we value partners that can offer globally accepted solutions, and Siemens can provide this. Plus, Siemens can support us with knowledgeable teams whose members have both automation and process expertise. All in all, we have had an excellent experience with Siemens as a supplier, and on the operational level the service Siemens provides is always awless, which is very important for the operating team. Consequently, we consider Siemens a preferred supplier.
Siemens India

Shyamsundar Bang, executive director of manufacturing and supply chain operations at Jubilant, has more than 40 years of experience in the chemical industry, including 31 years of experience at Jubilant in various managerial and technical capacities.

Mr. Bang, what strategy does Jubilant pursue on the road to growth? Mr. Bang: Jubilant Life Sciences is an integrated pharma and life science company, and the largest custom research and manufacturing player in India. We are proud to say that we have been growing consistently for many years now, and we intend to maintain annual growth of 20 to 25 percent. A solid manufacturing base is vital in achieving this goal. At present, we operate seven manufacturing locations in the country. New chemical plants will Are there any plans to extend this be built in Bharuch as well as new API collaboration to other elds? (active pharmaceutical ingredient) Mr. Bang: We have a concept called plants in Mysore. Another pillar for partners in progress, where we meet growth is innovation: we are research with preferred vendors and work out a and development driven. The new spe- yearly plan for developing and upgradcialty chemical facility is proof of this, ing their technology and Siemens is as it will operate with a new environ- an important part of this concept.

Cover | process news 2/2013

Jubilant Life Sciences Ltd. pursues drug discovery; functional chemistry; and clinical research, custom research, and manufacturing for advance intermediates, fine chemicals, active pharmaceutical ingredients, and dosage forms

bus technology. The customer saw this as necessary to achieve better plant and system diagnostics, enhanced safety in operations, and consistent nal product quality, along with optimum raw material consumption. Another benet of the DCS was an improvement in plant performance, thanks to a reliable data archive for the process parameters. Cost optimization in manufacturing was another key aspect, especially due to the pressure on prot margins caused by intense competition. In a nutshell, Jubilant was looking for a dependable and consistent partner to supply a turnkey automation solution that included a complete control and instrumentation package with Foundation Fieldbus support.

dance with the internationally recognized regulations of the 21 CFR Part 11 guidelines from the US FDA.

Complete service
In addition to being the main automation vendor for the plant, Siemens was responsible for supplying and commissioning the eld instruments (mass ow, magnetic-inductive ow, radar and differential pressure-type level transmitters), installation commissioning, installation hardware, eld engineering, installation of Siemens and third-party instruments, and site management. The successful commissioning of the plant with such a large Foundation Fieldbus I/O device count conrmed the clients condence in Siemens leadership in the process control systems market.

A valuable addition

Jubilant chose the Simatic PCS7 V8.0 process control system in a redundant conguration for maximum One success leads to another availability. Siemens patented event-based synchronization technology for the Simatic PCS7 system al- The Bharuch project was not the rst successful collows hot standby operation with bumpless switching laboration between Jubilant and Siemens. Impressed within a few milliseconds and without the redundant with the on-time execution and commissioning of systems needing to be near each other. Another key Plants 4 and 5 at Jubilants Nanjangud facility, Jubifactor in favor of PCS7 was the systems ability to lant selected Siemens as the main automation venseamlessly integrate Foundation Fieldbus I/O devices. dor for Plant 6 at the Nanjangud facility as well as the In Bharuch, 400 Foundation Fieldbus I/O devices are Bharuch SEZ facility. Siemens scope of responsibility connected to a single redundant PCS7 CPU, which for the Plant 6 facility includes process automation helps reduce hardware costs. and eld instrumentation on a turnkey basis, along With the help of PCS7, Jubilant Life Sciences is im- with eld engineering, installation and commissionplementing a number of process improvements, ing, validation, and site management. thereby optimizing production costs, quality, and product safety. In addition, continuous recording of all the relevant process data not only enables rapid Info and ContaCt error analysis during servicing, but also allows for siemens.com/pcs7 clear tracking of quality issues and provides higher mahesh.parkhi@siemens.com system availability. The archiving takes place in accor7

Jubilant Life Sciences Ltd.

AFP ImageForum

process news 2/2013 | Process Control Technology

Fieldbus technology

Flexibility in the eld


Fieldbus solutions provide a simple, cost-effective way to combine devices in an automation system. But differing eldbus standards can make integration difcult. With Simatic PCS7, users can integrate HART, Probus, and Foundation Fieldbus, as well as Industrial Ethernet devices, enabling them to choose a eldbus solution that offers maximum return on investment.
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Corbis

Process Control Technology | process news 2/2013

he production and process industries would be unimaginable without eldbus solutions. Fieldbuses simplify the planning, engineering, installation, and operation of plants. Instead of individual wiring, a bus feeds the information from the eld devices via one cable into the central control system. This reduces the required number of cables and saves time in planning and installation. A further important feature is diagnostics, making the plant more transparent so that plant shutdowns can be avoided. Many technologies compete with the eldbus, and the original hope for a single unied communications mechanism has not been realized. However, Simatic PCS7, which can accommodate all the major processing and production technologies (HART, Probus, and Foundation Fieldbus), offers a eldbus compatibility level that is unmatched.

Siemens AG

The Simatic PDM Process Device Manager V8 serves as a central tool for user-friendly parameterization and diagnosis of the process instrumentation

Planning for the long term


Process plants are operated and maintained over Enabling the optimum choice long periods; 15 to 20 years is common. This creates a demand for longevity in the automation systems, The openness and support of different eldbus sysincluding eldbus solutions. A good eldbus choice tems enable planners to select the best eld device must satisfy several requirements: It must be able to for their purposes. Expansions present no problems, use eld devices from different vendors. It should be even during operation. Simatic PCS7 enables easy simple and quick to engineer, commission, maintain, troubleshooting through user-friendly diagnostics to and modify. Installation should be cost-efcient. It support fast commissioning and improve the effecshould provide a high level of reliability and availabil- tiveness of the plant. With Prole 3.02, the Probus ity, and transmit diagnostic information for preven- user organization has created a prole that complies tive maintenance. And it should link the management with NAMUR Recommendation NE107, which will level to the eld level. also simplify the replacement of devices, as it speciThe Simatic PCS7 process control system with HART, es that upgraded eld devices must be capable of Probus, and Foundation Fieldbus communication adapting to a previous version. The device automatcapabilities offers the best combination for meeting ically adjusts itself to the version dened in the deall the requirements of the process industry. All plant vice description used and is transferred during information is collected in one system, evaluated parameterization. centrally, and then used for the open- and closedThe Simatic PCS7 process control system allows all loop control of the plant. eldbuses used in the process industry to be connected in the same manner in the best possible way. A exible and scalable system This integration enables the planner to have a free choice of eldbus system and eld device. The standardization of proxies for Pronet is alTo accommodate the huge variety of different plants and requirements, Siemens provides a exible and ready well advanced and guarantees the future capascalable system for linking the eld level to the man- bility of eldbus solutions not replacing Probus PA agement level. HART devices can be easily integrated and Foundation Fieldbus, but integrating them. This by means of distributed input modules. The integra- means protection of the users investment.  tion has been standardized by the Probus user organization in the prole for HART on Probus. In addiInfo And ContaCt tion, Probus PA eldbus systems and Foundation siemens.com/pcs7 Fieldbus and WirelessHART eld devices can be seamthomasbartsch@siemens.com lessly incorporated via links.
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process news 2/2013 | Process Control Technology

One of Indias industry success stories is the pharmaceutical industry, where Indian companies are evolving from generic drug producers to developing their own drugs for the global market

Siemens in India

Going strong together


Since 1991, the Indian economy has been progressively liberalized and become more deeply integrated into the global economy. The country has seen many successes in the manufacturing and process industry, says Bhaskar Mandal, Sector Cluster Lead, SAS Industry: Today we have a thriving industry that not only produces for domestic consumption but also serves as a manufacturing hub for the whole of Asia, reecting a signicant transformation and development of the industry landscape.

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Frederic Soltan/Corbis

Process Control Technology | process news 2/2013

ne of the major challenges Indian companies face is improving productivity, says Mandal. The automation level in India is approximately 50% lower than the automation level in developed economies and approximately 30 % lower than in China, he explains. Larger, well-known companies in the market are eager to implement automation technologies, but smaller players view it as an expenditure rather than an investment. Our approach has always been to optimize lifecycle costs. For example, from a machine perspective, a company can use an automation system with Pronet that monitors the status of the machine and switches it off in real time when there is no production scheduled. Such measures can enable even smaller manufacturers to benet from increased productivity and reduced costs. Due to the inherent operational and maintenance advantages of a distributed control system (DCS), there is a clear trend toward horizontal and vertical integration, Mandal continues. There is growing awareness that a DCS can provide consistent and reliable quality and that it offers added benets such as increased energy efciency and cost-effectiveness, leading to higher productivity and improved margins, he says. Process automation can also help in detecting and controlling water usage, energy consumption, emission levels, and waste generation in the production process, leading to more sustainable production. However, more than the technology, manufacturers need to choose an automation technology partner whose expertise is completely aligned with their process requirements and that also deliv-

 Our approach has always been to optimize lifecycle costs.


Bhaskar Mandal, Sector Cluster Lead, SAS Industry

Siemens in India
The history of Siemens in India dates back to 1867, when company founder Werner von Siemens took the bold decision to build a telegraph line from London to Calcutta just 20 years after the companys founding in 1847. In 1922, Siemens set up branch ofces in Mumbai and Calcutta. In 1957, Siemens was incorporated as a company in India and started manufacturing switchboards; another factory was set up in 1959 to produce medical equipment. The company went public in 1961. Production of motors commenced in 1966, and another switchboard factory was established in Nashik in 1981. Today, the company has a sales and service network that spans the country, 21 manufacturing plants, 8 competence centers, and 11 research and development centers.

ers a superior return on investment. Because we follow a vertical market approach, we have marketspecic products and solutions for particular industries that are handled by competent sales and execution teams with extensive industry-specic application knowledge. This results in the implementation of optimum products and solutions that enable customers to increase the productivity and sustainability of their operations.

Strength through innovation


A nation like India cannot afford to slow the pace of its industrialization. There are still massive requirements in the infrastructure, healthcare, housing, food, and other sectors sectors that need to keep pace with the rate of population growth and that are critical for the nations development. Siemens will continue to support Indias growth, says Mandal. Our partnership with Indian industry will strengthen thanks to our innovative products, solutions, and services, he concludes. We will also continue to strengthen our portfolio for vertical markets. I foresee our Indian customers riding the globalization wave and Siemens India partnering on more and more offshore developments for our customers from India.
Info And ContaCt
siemens.co.in nair.rajesh@siemens.com

Siemens India

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process news 2/2013 | Pharmaceuticals

Shantha Biotechnics Ltd., India

World-class efciency
By monitoring and managing energy consumption with Simatic B.Data, Shantha Biotechnics is able to track and optimize the energy efciency of the utilities in its production plant and achieve signicant cost savings.

Shantha Biotechnics is the first Indian company to develop a recombinant-DNA human healthcare product in India

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frankoppermann Fotolia

Pharmaceuticals | process news 2/2013

hantha Biotechnics, a wholly owned subsidiary of the global Sano group, is a biotechnology company with state-of-the-art facilities in Hyderabad, India. Shantha Biotechnics was established in 1993 to develop effective, affordable vaccines and therapeutics within the reach of the common man. Shantha Biotechnics is the rst Indian company to develop a recombinant-DNA human healthcare product in India and is prequalied by the World Health Organization (WHO) to sell vaccines to United Nations procurement agencies such as the United Nations Childrens Fund (UNICEF) and the Pan American Health Organization (PAHO). Utilities such as chilled water, hot water, and steam play a major role in vaccine production and represent a large share of production costs. As the company was placing increasing emphasis on energy conservation, the main aim of Shantha Biotechnics was to have a exible utility management solution that could calculate the cost per unit of the utility generated at the block level and generate energy-related reports.

Key points
Shantha Biotechnics prime goal is to provide effective vaccines at an affordable price Controlling energy costs is a key factor in minimizing production costs Simatic B.Data helps Shantha control its energy costs by enabling the company to monitor and understand its energy use

A comprehensive energy management solution


Shantha Biotechnics chose Siemens as the turnkey provider for its utility energy management system. The utilities are now monitored by a Simatic B.Data energy data management system that forms the basis for cost-effective and optimized energy management. B.Data helps Shantha Biotechnics understand the utilities in its plants, which enables the company to plan future utility use and reduce costs. Simatic B.Data readily supports current interface standards such as OPC, ODBC, ASCII, and XML. This enables communication and data exchange between multiple systems, which facilitates functionality such as long-term archiving, energy accounting, and determination of characteristic data (key performance indicators, efciency gures, etc.) with direct reference to production (batches, quantities, etc.). It also enables consumption forecasts based on production- related factors (production planning) and basic load proles. The Simatic B.Data system manages the entire energy management portfolio of the Medchal and Muppireddypalli plants via a virtual private network (VPN), so their top management has remote oversight and control of the companys overall energy consumption. This shows the real exibility Simatic B.Data can provide in an energy and utility management system. The Simatic B.Data system provides a variety of benets such as combined technical and business data processing, balancing of power generation and consumption, and generation of variables for reports to help increase the efciency of systems involving power generation, distribution, and consumption. Other benets include connecting energy costs to the enterprise resource planning system, forecasting

Shantha Biotechnics Ltd.

Established in 1993, Shantha Biotechnics has matured into a successful pharmaceutical venture

production-related loads and consumption in order to increase reliability, and supporting the purchasing department in energy procurement. The Simatic B.Data system also helps companies fulll their legal obligations to monitor and report on greenhouse gas emissions (CO2 emissions).

The complete package


In addition to the utility management system, Siemens project scope also included the supply and commissioning of eld instruments for mass ow and magnetic inductive ow, and radar and differential- pressure level transmitters from the versatile Sitrans portfolio of process instruments. Additionally, Siemens supported Shantha during construction and commissioning, hardware installation, eld engineering, and site management. Shantha Biotechnics was impressed with Siemens innovative products and solutions for the process and manufacturing industry, the companys lifecycle approach to projects, the continuous project reviews and updates by the dedicated local execution team, and the fact that Siemens abides by the principles of ethical, optimized, highly efcient, and sustainable business, just like Shantha Biotechnics.
Info And ContaCt
siemens.com/pharma lalit.bangera@siemens.com

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process news 2/2013 | Pharmaceuticals

Teva API Ltd., India

Active and effective


Teva API, the worlds largest generic drug manufacturer, benets not only from a state-of-the-art Simatic PCS 7 solution in one of its plants for producing active pharmaceutical ingredients, but also from drawing on Siemens expertise to ensure smooth validation of the system.

T
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eva Active Pharmaceutical Ingredients (TAPI) is a stand-alone business unit of Teva Pharmaceutical Industries Ltd., an international pharmaceutical company headquartered in Israel. Teva Pharmaceutical Industries is the largest generic drug manufacturer in the world and one of the 15 largest pharmaceutical companies worldwide. TAPI is the

leading international supplier of active pharmaceutical ingredients (APIs). It specializes in the development, production, and marketing of generic and proprietary-branded pharmaceuticals and APIs in the Americas, the United Kingdom, Europe, Asia, and Africa. TAPI has expertise in a variety of production technologies, including chemical synthesis, semisyn-

Siemens India

Pharmaceuticals | process news 2/2013

thetic fermentation, enzymatic synthesis, high- potency manufacturing, plant extract technology, synthetic peptides, vitamin D derivatives, and prostaglandins.

State-of-the-art automation for a state-of-theart facility


The TAPI manufacturing campus has a state-of-theart multipurpose plant in Malanpur, India, that manufactures a wide range of APIs for use in Teva pharmaceuticals, with a major portion sold to third parties. The plant specializes in producing advanced intermediates for various APIs for the United States and other regulated markets. TAPI needed a trusted and dependable automation vendor for a tank farm system, reactor automation, and solvent transfer system in its MPP-2 and MPP-3 facilities. Automation was desired for the primary processes, since efciency and quality depend on management of those processes. TAPI chose the Simatic PCS 7 process control system for its MPP-2 and MPP-3 plants. The key criteria for choosing Siemens were that the technology was state of the art and also offered a cost-effective solution. The integrated redundant system design and reliable proven components provide high system availability, a key factor in API manufacturing. If a controller or server fails, the redundant component takes over immediately without loss of data, resulting in a bumpless transfer. This substantially reduces downtime and plant and batch losses. The user- friendly Simatic PCS 7 interfaces make the system easy to engineer and maintain. Teva chose Siemens pressure transmitters with the HART protocol for the blind calibration capability, integrated loop-checking functionality, default square root extraction, local re-ranging, calibration

functionality, and many other diagnostic features. Wiring and maintenance were reduced by implementing the Simatic ET 200M distributed I/O system to connect signals in explosion-hazardous areas. Siemens also offered local validation expertise with qualied project teams in India who worked with dedicated engineers to execute and complete the MPP-2 and MPP-3 automation system on schedule. As Dinesh Agarwal, TAPI senior manager of procurement, explains, TAPI beneted greatly from this: We did not have the right in-house capabilities, and hence needed support from outside. It adds to the value of the Siemens solution that they can provide such added value support. During the project, we enjoyed a very good cooperation, and our engineers are comfortable with the services provided by Siemens.

Fully compliant system


Siemens local engineering team congured and validated the entire automation system according to current Good Manufacturing Practice requirements. Simatic PCS 7 offers several features supporting validation in pharmaceutical applications. Together with the engineers expertise, this ensured that the project went perfectly smoothly. Consequently, Agarwal is quite happy with the outcome of the project: We are happy with the services provided by Siemens. And we are looking to expand our existing facilities with Siemens help.

Info and ContaCt


siemens.com/pharma lalit.bangera@siemens.com

Our engineers are comfortable with the services provided by Siemens.


Dinesh Agarwal, Senior Manager of Procurement, Teva API Ltd.
Siemens India

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process news 2/2013 | Rubrik

Linde AG

Linde India Ltd., India

System in a box
In India, Siemens builds a complete cryogenic plant control system inside two shipping containers before sending them to an Indonesian steelworks.

inde India Ltd., formerly BOC India distillation. The rare (or noble) gases 2007 to 2011, Siemens India executed Ltd., a part of the Linde Group are present in the air in only trace several ASU projects for BOC India based headquartered in Germany, is one amounts of parts per million. Therefore, on the Simatic PCS7 process control of the leading companies in India sup- to extract them in viable amounts using system. In October 2011 Linde India seplying industrial gases, both in bulk for the air-separation process, large-scale lected Siemens to supply the control heavy industrial use and as high-purity units with huge air intakes, of the order system for a new 2,000 MTPD ASU to be gases for users such as hospitals and of at least 1,000 metric tons per day installed at a steelworks operated by laboratories. (MTPD) oxygen capacity, are needed. POSCO in Cilegon, Indonesia. The ASU The gases are produced in large The plants operate in a nely balanced was to be installed on a build, own, and air-separation units (ASUs) commonly closed-loop system requiring precisely operate basis. To avoid any additional located within the sites of heavy indus- calibrated analytical instrumentation to building to accommodate the ASU contrial users such as steel plants, glass ensure accurate control and safe trol equipment, a complete preengineered containerized control system manufacturing plants, petrochemical operation. complexes, reneries, and others. ASUs From its Indian manufacturing center was designed. The control cabinets, I/O separate atmospheric air into its pri- at Nashik Works, Siemens supports and marshaling cabinets, PC consoles, mary components, typically nitrogen, Linde India in ASU projects, supplying and other equipment would be comoxygen, and argon, and the rare gases and commissioning distributed control pletely housed, wired, and tested inside neon, krypton, and xenon. The separa- system panels and accessories for instal- two shipping containers at the Siemens tion process uses various technologies, lation inside control rooms, marshaling factory in Nashik prior to transporting the most common of which is cryogenic rooms, and switchgear rooms. From them to Indonesia.
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Rubrik | process news 2/2013

The remote operations center features the latest technology and provides all local HMI functions of the remote process control systems via terminals

System details and architecture


Client server architecture
3 redundant automation systems (AS 417-4H) Simatic PCS7 V7.1 SP3: 2,056 I/Os (ET 200M I/Os) 1 engineering station 2 operator stations, 2 OS servers, 1 OS client with dual monitors, 1 APC 2 ROC servers with 2 clients I/O and system panels: 13 panels (2,200H 1,200W 800D) in container, 8 RIO panels (2,200H 800W 800D) in eld Communication: 30 iMCCs (Simocode), 7 VFDs with H-System on Probus DP Third-party communication over Modbus RS 485

The entire control system was shipped to the customer site as a containerized solution

24/7 uptime with remote operation center


Linde had developed the capability to link its ASU plants to a remote operation center (ROC) from which the plants could be monitored and controlled on a continuous basis. As an extension to its Simatic PCS7 process control system, Siemens developed an ROC solution to meet Lindes requirements, together with a customized block library. This enabled Linde to present a consistent HMI graphics interface in its ROCs throughout the world. Two containers were procured and delivered to Siemens Nashik Works, where all the automation system hardware, software, and accessories were installed. Siemens undertook all the hardware engineering and software

development and assumed overall responsibility for the project management. The ASU installation at Cilegon consisted of two different areas (i.e., core plant and storage area). Two redundant PCS 7 AS controllers were provided in container 1 for core plant, with a third PSC7 AS redundant controller tted in container 2. This unit provided control for the storage area and utilities. ET200M rack systems, both within the containers and mounted remotely, provided I/O connections to the eld. When all the work was complete, the containers were shipped to the POSCO steel site in Cilegon, where nal commissioning was carried out. Classroom training on the Simatic PCS7 was provided to the new operators at Siemens Kalwa Works in India. This groundbreaking project marked the

Linde AG

rst time that Siemens India had manufactured a complete containerized system, and the project required close cooperation between different organizations across three countries.

Info AND ContaCt


siemens.com/chemicals sunil.pai@siemens.com

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The Nashik Works combines high-quality manufacturing and a skilled workforce

Siemens Nashik Works, India

World-class skills and expertise


The Siemens factory in Nashik, India, has been serving customers since 1987. Originally focused on manufacturing electronic products such as programmable logic controllers, uninterruptible power supplies, and AC/DC variable-frequency drives, the Nashik Works has evolved over time and today focuses on manufacturing signaling products for railways and tailor-made engineered cabinets for automation systems and variable-frequency drives.

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Siemens India

Process Control Technology | process news 2/2013

ashik, located approximately 170km from Mumbai, is one of the fastest-growing cities in India. In 1987, Siemens established a manufacturing facility for electronic components at Ambad, one of the industrial areas of Nashik. With its focus on growth, continuous innovation, and high-quality standards, the facility has become an outstanding global manufacturing location. To fuel continuous innovation, the factory has its own research and d evelopment facility and develops many compo nents for products manufactured in the factory as well as adapting global Siemens products for local conditions.

The Nashik Works


Established in 1987 4,900 m2 state-of-the-art electronics manufacturing hall Skilled workforce of 300 Siemens employees ISO 9001 and ISO 14001 certication Ships more than 4,000 engineered cabinets per year

Cabinets for process control


The factory has a broad spectrum of manufacturing capabilities, specializing in systems for railway applications, drives for heavy-duty applications in industries such as mining and cement, and especially the manufacture of engineered cabinets for automation systems (DCS, PLC) and variable frequency drives used for process control applications. The cabinet bodies are sourced from vendors near the factory or from standard local or global cabinet manufacturers. The mounting of components, as well as the wiring and testing, is performed by the factory, adhering to high-quality standards based on detailed engineering performed by various engineering groups within Siemens. Core components for these engineered cabinets, such as controllers and I/O modules, are sourced from various Siemens manufacturing locations around the world, while auxiliary components, such as cables and relays, are sourced from vendors from nearby industrial locations and from across India. The factory also houses high-class testing facilities for the cabinets, including a large dedicated factory acceptance test area for customer acceptance tests.
Core cabinet components such as controllers and I/O modules are sourced from Siemens manufacturing locations around the world

automation cabinets for an air-separation plant in South Korea; and automation, electrical, and variable-frequency drive cabinets for a polyester line in Quality and standards are key Turkey. With its long proven record of successful projQuality has always been the key driver for this facil- ects, the Nashik factory has expertise in project deity and the factory adheres to strong quality manage- sign and execution to back up its stringent standards, ment processes. Every year the factory turns out ensuring the highest quality for every product delivmore than 4,000 engineered cabinets, meeting ered to customers in India and abroad. global standards for various industrial applications within India and across the world such as more than Info and contact 100 automation cabinets for a polypropylene plant in siemens.com/pcs7 Egypt; automation cabinets for a direct reduced iron abhijit.tambat@siemens.com plant in Bahrain via a customer in the United States;
19

SiemensIndia

process news 2/2013 | Process Control Technology

Process safety

A safe choice
Process safety is essential for the protection of people, assets, and the environment. It can also help safeguard plant output and, ultimately, return on investment. With integrated safety systems, users can achieve better safety instrumented system performance with less hardware and lower costs.

ne key factor affecting the cost and performance of a safety instrumented system (SIS) is engineering. The design and programming of safety logic can be quite time-consuming and complex. With the Simatic Safety Matrix tool, this task has been greatly facilitated. This TV-certified causeand-effects tool was specifically created to help users design, engineer, operate, and maintain an SIS through all phases of the safety lifecycle. The tools intuitive interface has helped hundreds of customers comply with the requirements of the ANSI/ISA 84 functional safety standard while reducing their engineering costs by automatically programming the safety logic. Users save time and reduce cost and complexity, as was recently acknowledged by Control Engineering maga-

20

D. Obertreis

Process Control Technology | process news 2/2013

zine in its selection of the Simatic Safety Matrix to receive the 2011 Engineers Choice Award.

S7-400FH controller

Flexible, modular, redundant


The problem with conventional programmable logic controllers (PLCs) is that they need redundancy to achieve safety which comes at a cost in terms of system availability. Traditionally, physically redundant hardware components were thought to be the only means of achieving SIL 3. However, modern safety systems contain special safety-related function blocks with failure control measures that make them independent of hardware redundancy, eliminating the need for extensive redundant logic circuits such as those used in triple modular redundancy or similar approaches. Simatic PCS7F provides the highest level of safety (SIL 3) without the need for redundancy. The exible modular redundancy (FMR) concept supports single, dual, and even triple modular redundancy, helping plant owners achieve their availability targets and providing a cost-effective, scalable solution without compromising safety for any size of safety application. Simatic PCS7 also supports the Safety Integrated concept. While the benets of integrated solutions are widely acknowledged (common engineering, HMI, communications, etc.), this approach provides additional benets by incorporating energy and asset management to help lower plant lifecycle costs. For specic applications in which this tight integration is not required, the PCS7F safety system can operate as a stand-alone SIS and still interface with any third-party system via a variety of communication options.

Probus Triple Simplex Dual 1001 LS

1002 Flow

2003 PT

Simatic PCS7F can provide safety levels of up to SIL 3 without the need for redundancy, providing a cost-effective and scalable solution for optimum safety and availability

technologies, including Prosafe, ASIsafe, and Industrial Ethernet. This eliminates the need for additional networks, complex configuration, or costly gateways to provide safe, secure, and fault- tolerant system communication. Safe signals can be linked via Simatic ET 200ISP, the recipient of Control Engineering s 2012 Engineers Choice Award for failsafe I/O systems. Certified to SIL 3, the systems are replaceable online (under Ex conditions). Simatic ET 200ISP is the perfect I/O solution for remote installations in hazardous areas (up to Ex zone1), extreme temperature ratings (-20 to +70C), and corrosive atmospheres (ISA-71.04 severity levels G1, G2, G3). For better integration and reduced footprints, both safety and standard modules can be installed and congured in the same backplane.

Packaged savings A safer reach into the eld


To easily and safely bring intelligent eld devices directly into the SIS, Simatic PCS7F supports the broadest range of protocols certied for the transmission of safety-critical data over open bus While Simatic PCS7 provides immediate benets during the design and implementation of an SIS, it also helps r educe lifecycle costs, for example, through prolonged testing intervals. In order to claim SIL levels, plant opera-

tors must test their SIS following a r igorously defined schedule. Simatic PCS7F safety performance numbers have been approved for either a 10- or 20-year proof test interval and help reduce SIL verication costs by simplifying calculations while extending test intervals. This feature removes the burden of conducting comprehensive and time-consuming system test procedures and helps reduce annual maintenance budgets, along with enabling simpler SIL verication calculations. Siemens can also use its industry and technology expertise to support customers in designing and building industry- compliant safety systems. Siemens is able to deliver complete systems that are designed and built to meet regulatory codes and safety standards. Prepackaged systems help reduce risk, simplify the scope of projects, and ensure consistent design and better service and support.

INfO aND CONTacT


siemens.com/pcs7 charles.alkowski@siemens.com

21

Siemens AG

process news 2/2013 | Process Control Technology

Industrial Security

Hands-on security
The least predictable element of an IT security strategy is people. And we are not referring to hackers or other people who attempt to penetrate an automation system, but rather to the internal and external systems operators, who require direct access to the system and who prevent intrusions from unauthorized personnel.

he physical components of an automation system should be effectively safeguarded against unauthorized access, and their use should be dened by a clear set of rules. Awareness of security issues should be rmly embedded in the consciousness of those who are in direct contact with the plant. This is precisely the subject of sections 9 and 10 of IEC 62443, Part 2-1, titled Physical Security Measures for Installations, Including Guidelines and Procedures. The chapter highlights ve thematic areas: handling of mass storage media, system servicing either at the plant or by remote access, handling of communication media, how operators are to recognize and properly deal with an attack, and what is to be done about technical malfunctions in order to guarantee the security of automation systems. As in other areas of a defense-indepth security strategy, physical access protection depends upon a bundle of coordinated individual measures that
22

integrate seamlessly and that, in their totality, result in an effective defensive layer that can only be broken through with considerable effort. The three building blocks of this strategy are organizational and personnel procedures, mechanical and physical controls, and electronic surveillance and detection.

Dene and internalize rules


Every information system requires constant support and monitoring. Defective components must be replaced, software must be updated, and the

communications infrastructure must be adapted to changes in operational requirements. These are tasks that must be performed not only by in-house personnel but also by external service partners and suppliers. Both groups need physical access to individual components of the system. Mechanical and electronic protection systems may indeed ensure that this access is only granted to explicitly authorized personnel. However, a responsible approach to these mechanisms also includes personnel procedures. Targeted duties and procedures can be de-

Process Control Technology | process news 2/2013

Defense in Depth The defense of automation systems is based upon a series of obstacles that are activated in succession and that require potential attackers to deploy a variety of offensive strategies. Eight essential security measures are employed in this concept:

Physical access protection Guidelines and instructions Cell protection and perimeter network Firewalls and secured connections (VPN) System hardening User management Patch management Protection from malware (antivirus, intrusion detection)
D. Obertreis

DCS

ned for the companys own employees, can be organized into four security secwhile specic contractual arrangements tors. Sector 0 is considered to be the are an effective approach for managing area outside the property. Sector 1 is external partners. the property line itself. Sector 2 inA sense of responsibility also necessi- cludes all areas within the premises. tates practical knowledge of the signif- And nally, Sector 3 is the direct protecicance of the installed security mea- tion of the automation system itself. sures. This means that the person con- This sector concept can be exibly apcerned must have a clear awareness of plied to almost any architectural envithe far-reaching consequences of ma- ronment. The protection of sectors 0 to nipulating the system an awareness 3 is based on comprehensive surveilthat is best communicated by means of lance alarm management and a precourses and on-site training programs. cisely coordinated system of sensors In addition, the physical security sys- and alarms with different operating tem must be inspected regularly to en- principles. Such a system forms multisure its continued reliability. For this tiered perimeter protection that is process, the day-to-day experience of largely tamper-proof. everyone involved is critical in order to It is supplemented by coordinated acuncover weaknesses and identify op- cess protection, which includes securiportunities for manipulation. ty-critical oors, parts of buildings, and rooms, as well as individual switch cabSecurity begins at the site inets. Siemens relies on an integrated access concept, where interior mechaboundary tronic locking components are comIn spatial terms, a comprehensive pack- bined with online access control sysage of measures for physical security tems in the input area. At the same

time, the use of RFID technology makes it possible to equip all internal and external employees with exactly the access permissions they require for the performance of their duties. But the information system of a company is not only exposed to attacks from cyberspace; it must also be protected against physical attacks in the real world. This is why a physical component is an absolutely mandatory element of a defense-in-depth security concept. The physical component must ensure that authorized persons are able to fulll their tasks unhindered, in order to keep the system running, while at the same time having the capability to block unauthorized entry effectively.

Info and Contact


siemens.com/industrialsecurity stefan.woronka@siemens.com

Note on industrial security: Suitable protective measures (including industrial security, e.g., network segmentation) must be taken to ensure the secure operation of the plant. Further information on industrial security can be found at siemens.com/industrialsecurity

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process news 2/2013 | Process Instrumentation

BKL A/S, Copenhagen, Denmark

Good measures
By installing a Sitrans FUT1010 clamp-on ow metering solution, BKL A/S can now reliably verify the amount of jet fuel supplied from a nearby terminal to the companys tank storage at Copenhagen airport.
The TransLoc mounting system allows for permanent transducer installation outside the sensor

Verifying measurements

A level meter in the tank measures the fuel. BKL noticed discrepancies between the volume of fuel arriving from the supplier and the readings in the tank, so the company wanted to verify the readings with a different meter. Because BKL needed precise, repeatable measurement, the team chose the Sitrans FUT1010 liquid ultrasonic owmeter, which offers several critical f eatures, such as 0.15 % accuracy, Peter Laybourn, General Manager, BKL A/S since even small measurement errors can result in major monetary losses; 0.05%0.1% reading repeatability, since fuel shipments are transferred through the pipeline on a regular basis; and an innovative TransLoc mounting that its meters were correct. This elim- Since the transducers are protected system, which prevents contact with inated the measurement discrepancies. from the medium and the surrounding the fuel and allows ow calibration. environment, the maintenance requireBKL installed a Sitrans FUT1010 on Signicant savings ments are almost nonexistent. These factors add up to signicant cost savthe pipeline into the storage tank, where it could measure the fuel after it Incorporating the Sitrans FUT1010 into ings for our company.  was cleaned but before it entered the our fuel transfer process has proven to tank. Sitrans FUT1010 readings con- be an extremely wise investment, said rmed that BKLs level meter was accu- Peter Laybourn, general manager of Info And ContaCt rate, allowing BKL to conclude that the BKLA/S. The meters accurate and relisiemens.com/ow problem was on the supplier side. BKL able performance allowed us to reconmatt.bird@siemens.com then worked with the supplier to ensure cile our stock with ease and condence.

 I ncorporating the Sitrans FUT1010 into our fuel transfer process has proven to be an extremely wise investment.

24

Siemens AG

ocated at Copenhagen International Airport in Denmark, BKLA/S transports jet fuel from the Prvestenen oil terminal in eastern Copenhagen to a storage tank at the airport, and then to each aircraft stand as needed. Each day, BKL receives about 3million liters of fuel from another supplier and pipes it to a storage tank at the airport. The fuel is ltered before entering the storage tank.

Process Instrumentation | process news 2/2013

Pharmalter, the Netherlands

High tech in compact design


Pharmalter/Siemens AG

Sitrans electromagnetic flowmeters monitor the inflow, outflow, and backwashing filtration cycles

The Dutch company Pharmalter has developed a future-oriented waste management concept for large-scale medical institutions. It combines wastewater treatment and waste disposal with biogas-based power generation in one compact installation. Sitrans measurement technology delivers the precise data to control the process.

he treatment of hospital wastewater is something of a challenge. Community sewage plants are primarily designed for the disposal of biodegradable materials, and not even the most modern of treatment methods can satisfactorily remove high concentrations of drug residue. Distributed wastewater treatment plants built directly on the clinic grounds constitute the most useful approach. But Pharmalters waste disposal concept goes a step further. It follows the principle Recycling instead of reuse and it pays off in a number of ways. It has been tried and tested at the R einier de Graaf Hospital in Delft. There, common reusable hospital articles were replaced by biodegradable, disposable articles made from bioplastic manufactured from renewable raw materials. The used disposables are ground down in special shredders and flushed away to the clinics sewage treatment plant where the water is treated and biogas is produced.

High-precision measurement technology guarantees efciency


The combination of wastewater treatment and biogas production presents a number of challenges, especially for measurement technology. For both processes, a continuous stream of data regarding temperature, flow, level, and pressure is required. In Delft, trust was therefore placed in process instrumentation from Siemens. High-precision Sitrans TH head transmitters operate as temperature measuring devices. Eight Sitrans Probe LU compact transmitters provide continuous level monitoring using ultrasound in the membrane bioreactor (MBR) intake or in the activated carbon lters. Twenty electromagnetic owmeters of the Sitrans FM MAG 5100 type were deployed for the inow, outow, and backwashing ltration cycles. The SitransP DSIII digital pressure transmitter is used for monitoring MBR activity, and the multicomponent Ultramat 23 gas analyzer for the process control of biogas production. Siwarex weighing modules are also in use at this

installation. They are responsible for the exact measurement of the substrate deployed in the fermenter.

A convincing concept all the way down the line


Thanks to the new waste management concept, the amount of waste at the Reinier de Graaf Hospital has been signicantly reduced, and the facilitys wastewater is practically free of contaminants. At the same time, the standard of hygiene has been raised with the use of disposable products. Over and above water purication, the sustainability of this concept is based upon the use of waste material as a source of energy. The efciency and fail-safe performance of the installation is guaranteed by the measurement technology that has been implemented.
Info and Contact
siemens.com/processinstrumentation hans-juergen.huber@siemens.com

25

Spray Engineering Devices Ltd., India

Production sweet spot

With variable-frequency drives from Siemens, Spray Engineering Devices Ltd. found the perfect solution for a new low-temperature evaporator module that helps improve energy efciency in the sugar industry.

stablished in 1992, Spray Engineering Devices Ltd. (SEDL) is a leading provider of energy-efcient and cost-effective integrated technology solutions for the process industry. One of SEDLs areas of expertise is the redesign and engineering of processes and equipment, together with the coordinating process automation systems. With many satised customers in India and abroad, the company has introduced energy-efcient processes in a variety of industries. One industry in which energy efciency has recently gained momentum as a key performance indicator is sugar.

Adoption of better technologies


Owing to a decline in the price of sugar and an increase in sugarcane prices, the sugar industrys focus
26

has recently revolved around cost reduction, quality improvement, and energy conservation. Conserving energy and identifying new or renewable energy sources has emerged as the need of the hour. In sugar production, reducing process steam consumption is a key lever to reduce production costs. Evaporators generally use 2 to 2.5 bar pressure steam in four to ve effects. Using a power and heat cogeneration process, SEDL was able to use the available enthalpy and temperature of vapors for evaporation prior to condensation. Eliminating evaporation processes above 100C increased plant capacity and decreased the cost of evaporation. This low-temperature evaporator module (LTEM), a unique, innovative product from SEDL, can reduce scaling, inversion, color formation, and heat loss. With LTEM, a plant can reduce the process steam ow rate, pressure, and

Unclesam - Fotolia

Drive Technology | process news 2/2013

The production of sugar is a resource- and energy-intensive process, where energy-saving solutions can make a large contribution to overall process efficiency

temperature to a suitable level. LTEM also helps reduce process heat requirements, making power generation more efcient. However, in LTEM, system efciency depends on precise motor control.

Search for a high-quality drive solution


For this project, SEDL was searching for a reliable, energy-efcient, and high-quality drive solution for its evaporator module. After evaluating the available systems, the company opted for technology from Siemens. Vivek Verma, co-founder of SEDL, said: Having experienced Siemens range of high- performance auto mation products, we decided to use Sinamics variable- frequency drives on a Probus network for the evaporators. Not only did the product help achieve commendable control of pressure and all motors, making the LTEM system efcient, but prompt customer service also ensured smooth installation and streamlined internal processes. For ease of use, all field device data gathered by the control system are available on a single screen. Probus communication ensures reliability and better control. Additionally, BICO technology (with binectors for digital signals and connectors for analog signals), along with system conguration and programming that includes a built-in PID (proportional-integral- derivative control loop feedback mechanism), provides ease of use and improves process control.

Excellent performance
In addition to better control and higher efciency, the Siemens drive systems provide energy savings, increased durability, higher efciency, and better monitoring of errors with the Probus network. The cost-effective solution prevents overow by controlling the speed based on the tank level. Thanks to the Profibus network, the solution provides easy plug-and-play performance with minimal maintenance. Better accessibility for remote locations is provided by built-in web servers. Impressed with the on-time execution and success of the project, SEDL has become a loyal Siemens c ustomer and regularly uses Siemens process in struments, Sinamics G130 and G120 drives, and low- voltage motors as well as switchgear. 

 Not only did the product help achieve commendable control of pressure and allmotors, making the LTEMsystem efcient, but promptcustomer servicealso ensured smooth installation and streamlined internal processes.
Vivek Verma, Co-founder, SEDL

Info and ContaCt


siemens.com/drives nair.rajesh@siemens.com

SEDL

27

process news 2/2013 | Solution Partners

Energie- und Medienversorgung Schwarza (EMS) at Rudolstadt in Thuringia, Germany

Energie- und Medienversorgung Schwarza GmbH, Germany

Modernization without disruption


Modernization of process control technology during ongoing operation is an enormous challenge. BN Automation AG, a supplier of automation solutions based in Ilmenau, Germany, used the migration package from Siemens to successfully implement a migration project of this kind at the Energie- und Medienversorgung Schwarza (EMS) utility in Rudolstadt.

MS supplies process and heating were of special signicance. In addition, were entered into the input modules. In steam, electricity, compressed air, existing Siemens controllers could be this way, the team was able to verify and industrial water to several in- integrated without a problem. BN Auto- whether the outputs showed the exdustrial installations locally, as well as mation AG, as a certied PCS7 special- pected switching behavior. Also, the district heating to two neighboring ist, was commissioned to implement operator graphics were completely recommunities. To do so, EMS operates the project, and the original idea of a designed due to the higher resolution. four gas-red steam generators, two 1:1 migration of the engineering from We have matured here as well, said gas turbines, and two steam turbines old to new was quickly rejected. Gunnar Fritsche, who is responsible for for the production of electricity. As cusAs there was no functional descrip- the electrotechnical equipment at EMS. tomer support for the original control tion of the control system, appropriate Subsequently, the new operator termisystem could no longer be guaranteed, specifications had to be created first nals were set out on tables in the conEMS was forced to nd a new solution. using reverse engineering. At the trol room for testing. In this way, the The standard required for the successor Migration Support Center in Cologne, system operator had a chance to try out system was very high, recalled Tino Siemens provided the BN Automation the new user interface. Our employees Danz, manager of the electrical plant. AG project manager with the corre- have really welcomed this measure, After evaluating the various options, sponding information about the exist- said Fritsche. They also had an oppormanagement decided upon the Simatic ing system. With this knowledge, it was tunity to submit their suggestions, and PCS7 process control system. then possible to work out a functional with PCS7, implementing these sugdescription of the automation. Subse- gestions was possible without any Project implementation without quently, implementation of PCS7 was problem. initiated. The new automation solution At the request of EMS, the entire condisruption of supply came into being at BN Automation AGs version was to take place without interFrom EMSs point of view, the openness premises in a matter of weeks. During rupting the steam and electricity genand easy learnability of the system the test run, realistic signal sequences eration. The concept thus made sure
28

Solution Partners | process news 2/2013

 We now have a futureproof control system withwhich the pending easily implemented.
Gunnar Fritsche, Electrotechnical Equipment Manager, EMS
Hubertus Bhm, Siemens AG

only a single processing station. Thanks to intense preparation, this problem was also resolved, and the entire modernization was completed in just four weeks.

Optimized operating procedures


In conjunction with the TIBS plant data collection software, a product from BN Automation AG, the system has grown into a comprehensive multifunctional solution. This has led to significantly o ptimized operating workflows and energy savings at EMS. The functions provided by PCS7 allow TIBS to perform signal connections and calculations, as well as innovative analyses, which are of special interest to management. Now, shift protocols can be created from real-time data and compared with the accounting-relevant data from ow metering. The detailed reports are prepared on the ofce network for users and made available to be called up at any time. Remote maintenance has been set up with the same standard of IT security architecture.

modications can be very


Hubertus Bhm, Siemens AG Hubertus Bhm, Siemens AG

The control room at EMS after the conversion

Professional implementation
EMS is very satised with the progress of the project. We now have a future- proof control system with which the pending modications can be very easily implemented, said Fritsche. The extension of the preparatory phase, in order to guarantee supply to our customers during the conversion, was the right decision and was more than offset by the rapid implementation, emphasized Thomas Fillebck, managing director of EMS. The professionalism shown during the implementation of the installation and commissioning is also reflected in the continuous dialogue that took place throughout the entire project between the project engineers from BN Automation AG and EMS and also Siemens.

www.bn-automation.com
BN Automation AG has developed and implemented solutions for the automation of technical processes since 1990. BN Automation AG employs more than 100 people at its headquarters in Ilmenau. The companys specific focus is on systems for energy generation and distribution, such as combined cycle gas turbine power stations or biogas plants, water processing and wastewater treatment facilities, and technological processes in industry. Specialists in switchboard construction, automation and process control engineering, information technology, service and software development, and manufacturing execution systems work together to form a strong foundation for successful projects worldwide.

that initially only one of the two large steam generators was put out of operation. During this period, the second steam generator guaranteed the supply of steam to customers. This was possible because one of the process stations

in the old system was deployed to ontrol and monitor each of the steam c generators. The auxiliary plant, which served both steam generators, constituted a challenge for technical planning, as its automation was managed using

Info and Contact


www.ems-schwarza.de siemens.com/pcs7 uwe.scheller@siemens.com

29

process news 2/2013 | Solution Partner

Siat Braun, France

Getting the most out of raw materials


Together with optimally organized preliminary planning, the performance and modularity of PCS7 have ensured trouble-free project implementation at a new pellet production plant with an adjacent biomass power station.

he Siat Braun sawmill is one of the This recycled process heat is used to vanced Process Library and dened adlargest of its kind in northeastern dry the sawdust for pellet production dress spaces and naming conventions. France. Recycling and disposing of through a heat exchanger. Thanks to these comprehensive specications, each package unit provider the bark and sawdust produced during could carry out programming and partimber processing used to be time and Multisupplier coordination tial commissioning with a temporary cost intensive. New, modern heating technologies now enable making good Siat Braun chose to use Simatic PCS7, in engineering station independently of use of these materials. Sawdust is its current 8.0 version, very early in the other packages. pressed into pellets without any further planning phase. The challenge lay in additives and is then made available as the drafting of a concept to unify sev- Individual components result in a natural product for the heating of eral technical disciplines (or subsec- amultiproject homes and for further use in industrial tions) and different suppliers so that all plants. The bark produces enough en- areas could be operated by means of a Evias GmbH supported the individual ergy in a boiler to power a steam tur- single system. To help achieve this, suppliers throughout the complete projbine. The electricity produced by a gen- Evias GmbH drafted an engineering ect. In this way, minor problems could erator is fed directly into the public guide a comprehensive document be solved immediately, without affectpower supply. In addition, the steam that species the requirements for the ing the project schedule. Apart from energy remaining after the turbine is project design in a multiproject frame- central coordination, Evias handed over utilized in a condenser to heat water. work: all packages had to use the Ad- the entire electrotechnical design, as-

The nw PCS7 control center: the operators can access all relevant process information via nine screens

SIAT Braun

Solution Partner | process news 2/2013

sembly, and installation of a belt dryer, necessary for the drying of sawdust, tothe Swiss company Swiss Combi W.Kunz dryTec AG. The project was also created as a module of the later PCS7 multiproject. Further subprojects from Evias GmbH include the complete raw material feed system for the boiler, the supply and installation of the Simatic PCS7 network structure (including the complete operating and monitoring system), a control system for the plants central emergency stop circuit, and the control for the energy supply connection.

www.evias.de
The EVIAS GmbH was founded in 2006 in Bad Bergzabern, Germany. Since then, the company has evolved into a product- andsystemindependent engineering rm for automation technology and serves process automation customers at home and abroad. EVIAS can rely on expert staff and a high level of automation expertise to provide tailored solutions to international customers, from process and factory automation solutions to power supply design, custom migrations, and MES, solutions as wellas service, infrastructure, validation, training, and project execution.

Optimal utilization of SimaticPCS7


Many of the functions and options that PCS7 offers were used of throughout the project. Special mention must be made of the seamless integration of erators important fault messages di- which enabled a uniform library and more than 50 Sinamics G120 drives rectly to their cell phones. The operat- uniform operating concept to be used and all the emergency stop technology ing manager and on-call duty person- and inventory management reduced. using Simatic F engineering, which was nel are automatically informed of more We were able to achieve optimal operbuilt into seven S7-400 controllers and major incidents by means of the cell ability around the clock by integrating four additional S7-300 controllers. Al- phone network. all subsections, said Jrme Sittler, most the entire signal exchange beproject and operations manager at tween the subsections was realized Around-the-clock operability Siat Braun. In addition, we have now using a communication bus in a ring to- achieved housed all relevant archive data in one pology, which saved considerable efsystem, with the result that we can, at fort in terms of additional cabling. Op- Under the coordination of Evias it was any time and without any further effort, timal operation of the plant is enabled possible to integrate not only the most produce cross-process analyses and by a redundant WinCC server, which is varied system components but also the reports. connected to four clients. A total of individual subsections of the different nine new monitors have been made suppliers into one great multiproject. available to the operating personnel in The time-consuming preliminary planInfo and Contact the control room. The extensive range ning paid off with the smooth integrasiemens.com/solutionpartner of functions is rounded off with the tion of the subsections. A total of six inthomas.leidner@evias.de Alarm Control Center, which sends op- dividual projects have been integrated,

The SIAT Braun sawmill utilizes waste sawdust as pellets for heating. The pellets are pressed without additived in an eco-friendly process

SIAT Braun

process news 2/2013 | Solution Partners

Aegis Logistics, India

Turn up the gas


The operator of a refrigerated LPG terminal in India chose to work with a Siemens Solution Partner to upgrade its control and safety systems to the state of the art.

/s Aegis Logistics in India moves and distributes petroleum and chemical products from the producers to end users. At Pir Pau the company operates a 20,000 MT refrigerated liquefied petroleum gas (LPG) import terminal. The terminal has advanced safety features such as full- containment LPG storage tanks, a remote control water curtain, gas detectors, automatic shutoff systems, and remote control valves. The terminal is connected to Pir Pau Jetty by 12 low-temperature steel pipelines. The complex consists of three discrete sections: the gas terminal, the liquid terminal, and the Sealord terminal. The processes and parameters in all three terminals are monitored and controlled from a central control room, and, of course, safety is paramount. As part of a plant upgrade, Aegis decided to migrate from the existing S5-155H programmable logic controllers (PLCs) to the latest Simatic PCS7 distributed control system with ber-optic links between the terminals. One key benet for Aegis was the seamless integration of the enterprise resource management system that Simatic PCS7 provides, offering improved order and materials tracking.

Simatic PCS7 advantages


To assist with the upgrade, Aegis hired Control Automation Projects Pvt. Ltd. (CAPPL), a certied Siemens Solution Partner based in India. The project team selected the AS417H CPU, the most powerful in the Simatic PCS7 line, along with four operator stations. The AS417H is a fault-tolerant one-out-of-two redundant system, built for ultrahigh reliability. PCS7 features centralized data monitoring, data reduction, and data analysis, together with access to global information via a web server.

32

Luftbildfotograf Fotolia

Solution Partners | process news 2/2013

 Our condence in the power of Simatic PCS7 grew at every stage of the project. We can see that the OS makes it easy for the operator to manage the processes safely.
Nitin P. Patil, Manager, Instrumentation, Aegis Logistics Ltd.

PCS7 includes an Advanced Process Library (APL) that can be used to provide improved functions and visually attractive graphical user interfaces. These preprogrammed functions were used to great effect during the software engineering phase and were instrumental in minimizing the development time. At Pir Pau the control of rotating machines is implemented via Probus and Simocode Pro intelligent motor control centers (MCCs). The Simocode Pro MCCs enable seamless interconnection between different systems and handle the protection, control, and monitoring of motor drives. The MCCs monitor key operating parameters of the motor drives and are able to perform autonomous actions based on those measurements.

Siemens Solution Partner network


Different industry sectors present their own unique processes and operational challenges. As a result, solution providers often need in-depth industry knowledge and experience to deliver the optimum automation solutions. Siemens Solution Partners are carefully selected systems integrators that are qualied as expert providers in the elds of automation and drive technology. More than 1,200 certied Siemens Solution Partners operate in over 60 countries. In India, Siemens has 85systems integrator partners. The Process Automation PCS7 Solution Partner Program was rolled out in 2008 in India and now includes 10 Solution Partners. The same worldwide standards apply to all partners, with training programs and workshops providing alignment with Siemens Germany. The partners undertake certication testing following training and are subject to requalication every two years. This ensures that Siemens customers receive the same level of specialist technical competence and service wherever they are in the world.

Meeting the challenges


The actual changeover posed another challenge, as the shutdown time allowed was only six hours. To complete the implementation in this short time frame, a new approach of using S5 to S7 adapters was proposed. The adapters enabled the software to be thoroughly tested during the short shutdown period and allowed the option of switching back to the S5 system should any serious problems arise. To prepare for these challenges, CAPPL undertook the basic groundwork off-site. The S5 logic was decoded and converted to PCS7, and the HMI was regenerated in the PCS7 OS. When preparations were complete, a full simulation was carried out on-site prior to the shutdown. On the day of the changeover, the work was nished in just two hours. The Simatic PCS7 system at Pir Pau has gone on to operate problem-free for two years.

Info and ContaCt


siemens.com/pcs7 bipin.pagaria@siemens.com

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process news 2/2013 | Solution Partners

Adage Automation, India

Hot stuff
Indias leading steel producer benets from a tailored gas analysis solution that helps improve blast furnace throughput and quality.
Siemens AG

vital technique for monitoring the performance of a blast furnace is continuous analysis of the gases at the top of the furnace. From these analyses the conditions in the heart of the furnace can be determined and appropriate measures taken to control throughput and quality. The gases analyzed are generally carbon monoxide (CO), carbon dioxide (CO2), oxygen (O2), and hydrogen (H2). The top gas analysis of a blast furnace is one of the most challenging applications that a continuous gas monitoring system can perform. The gas monitors must work in an environment of extremely high moisture, high pressure at the sample takeoff point, and very high dust load. SAIL is a leading steel producer in India, and its largest plant is at Bokaro. The rst blast furnace at Bokaro started production in 1972, and now five 2,000-m3 blast furnaces are at the site. SAIL Bokaro has used various kinds of top gas analysis systems over the years but experienced problems with limited availability and performance compounded by high maintenance requirements. In 2009, Bokaro asked Siemens to develop a better solution.

adage-automation.com
Adage Automation is a Solution Partner Process Analytics and one of the largest exporters of gas analytical systems from India. Based in Mumbai with sevenofces across India, the company has a state-ofthe-art factory with ISO 9001:2000 certication. The facility is one of the largest analyzer system units in India and also includes a modern analyzer repair center and lab.

Designing a robust solution


Siemens Solution Partner Adage Automation designed a robust solution for SAIL based on Siemens gas analyzers. The analyzers used were Ultramat 23 for CO and CO2, Calomat 6 for H2 with cross-interference correction of the IR gases, and Oxymat 61 for measurement of O2. The low drift of Oxymat 61 and the autocal feature of Ultramat 23 with ambient air enable low-cost operation and very stable measurements. The custom design included a specially designed heated sample gas probe and multiple levels of lters at various
34

stages. The graphic touchscreen HMI provided greater ease of operation, and logging of the system components status facilitated preventive maintenance. The rst top gas analysis system was tted to Blast Furnace No. 3 at Bokaro and was immediately successful. With the performance and reliability conrmed, in 2010 SAIL ordered the same solution to replace the top gas analysis system on Blast Furnace No. 2 at Bokaro. SAIL now has a proven reference at Bokaro forming the basis for replacement of earlier systems at other SAIL steel plants with the proven solution from Siemens and Adage Automation.

Info And ContaCt


siemens.com/processanalytics gustavo.bombillar@siemens.com

Dialogue | process news 2/2013

Compliance and Business

Positive experiences

he basic rules for responsible entrepreneurship are integrity and compliance with all applicable laws and regulations. This is also true for sustainable economic activity since it creates new business opportunities that ensure profitable long-term growth. Our Business Conduct Guidelines, containing the basic rules and principles for our actions and our behavior within the company and in relation to external partners and the public, are of great importance in this respect. The consequences of improper and unlawful behavior can be enormous: horrendous penalties, loss of orders, penal consequences, and not least, the resulting damage to the companys reputation. This denitely must be avoided. However, the most important thing to remember is that clear commitment to fair competition results in a consistent focus on product innovation and the customer. In order to continue to do justice to this claim and to strengthen the trust of the customers in the company and its products, Siemens has successfully introduced a comprehensive compliance program. This year the compliance ofce of IIA and IDT once again presented positive experiences with this program to its customers and business partners at Hannover Messe. siemens.com/compliance

We kindly ask all our customers to contact us in the event of any compliance-related problems with relevant business partners (e.g., distributors, sales agents, or business consultants) via the Tell us compliance help desk at siemens.com/ tell-us or our attorney Dr. Andr Groe Vorholt of the law rm Luther Rechts anwaltsgesellschaft mbH at siemens- ombudsmann@t-online.de.

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process news 3/2013

Integrated Engineering

hat will the future of industrial production look like? Many experts predict that production will be increasingly characterized by networked IT systems and software tools. One key aspect of optimizing plant and product lifecycle costs are consistent engineering data. These topics will also be the focus of the next issue of process news that will focus on integrated engineering and the integration of plant design and process control.

In an interview with Siemens executives, process news will illustrate how integrated engineering will benet the total cost of ownership for plants in the process industry and how Siemens systems and solutions can support data consistency over the lifecycle. Other key topics include the new version of the Comos software, process control innovations, new features of the Siemens process instrumentation portfolio, and a thought leadership article on Industry 4.0.

process news July 2013


Publisher: Siemens Aktiengesellschaft, Gleiwitzer Str. 555, 90475 Nuremberg, Germany siemens.com/automation Drive Technologies Division Industry Automation Division Customer Services Division Editorial Responsibility in Accordance with the German Press Law: Ralf Schmitt Responsible for Technical Content: Cornelia Drrfeld Editorial Committee: Lalit Bangera, Thomas Bartsch, Gustavo Bombillar, Charles Fialkowski, Ute Forstner, Petra Geiss, Sourav Ghosh, Punita Kathote, Rajesh Nair, Bipin Pagaria, Doina Pamlie, Mahesh Parkhi, KM. Sundaram, Pai Sunil, Abhijit Tambat, Roland Wieser Publishing House: Publicis Publishing, Postfach 3240, 91050 Erlangen, Germany Tel.: +49 (0) 913191 92-501 magazines-industry@publicis.de Editor in chief: Kerstin Purucker Layout: Reinhard Sorger Copy editor: Susanne Wanke DTP: Mario Willms; Dss Printing: Wnsch, Neumarkt, Germany Circulation: 27,100 Volume 18, process news is published quarterly ISSN 1430-2284 (Print) IWI: TPOG Order No.: E20001-M6213-B100-X-7600 2013 by Siemens Aktiengesellschaft Munich and Berlin. All rights reserved by the publisher. This edition was printed on environmentally friendly chlorine-free paper. Printed in Germany The following products are registered trademarksof Siemens AG: B.Data, ET 200, S7-1200, SENTRON, SIMATIC, SIMATIC Batch, SIMATIC PCS 7, SIPART, SITR ANS, SIMOCODE If trademarks, trade names, technical solutions, or similar are not listed above, this does not imply that they are not registered. The information provided in this magazine contains merely general descriptions or characteristics of performance, which in the case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall exist only if expressly agreed in the terms of contract.

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Visit us at Drinktec! September 16-20, 2013, Munich, Germany Booth107 inHallA4

Smooth processes for higher productivity


A comprehensive approach for beverage plants
siemens.com/drinktec

Design an integrated solution for your production flow, whether you are in the dairy, brewing, or soft drink business. We can provide the beverage production solutions you need with our integrated instrumentation, automation and drives portfolio, and our industry software. As a reliable automation technology partner, we will continue to support you in making things right.

Visit us at Drinktec and learn how to make your production more flexible and cost-effective. We will demonstrate the monitoring of energy flows and thepossibilities to reduce energy costs significantly. Werelooking forward to asuccessful Drinktec see you there!

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