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Your competent partner in automation
Siemens – a name recognized all over the world. A name that stands for innovation, customer orientation and a global competitiveness. Not only for 400,000 employees and millions of customers, but also for hundreds of thousands of suppliers and partners in more than 190 countries. It also stands for a unique range of products, systems and solutions. Siemens also embodies the timeless vision of its founder, Werner von Siemens: “Progress serving mankind”. With more than 50,000 employees in 70 countries, Siemens Automation and Drives (A&D) is one of the largest groups within Siemens AG. As a technology and market leader in automation and drives technology, we are continually making rapid advances in this field – and setting new standards again and again. Siemens A&D offers a unique, complete range of innovative products, systems and solutions. Totally Integrated Automation (TIA) and Totally Integrated Power (TIP) form the backbone of our portfolio – and the basis for customerspecific solutions in the field of automation and energy distribution. Chemicals are part of the fabric of life – from the ingredients in our shower gels and the shoes on our feet, to the colors that surround us and the electronic devices that make life so convenient. Chemicals help to make our world a safer, more comfortable, more pleasant place to live.
Industry Suite Chemicals – the customized solution for you
In the Industry Suite Chemicals, the worlds of automation and power engineering merge into one comprehensive and modular offer for your needs – including the required services across the entire life-cycle of your plant.
Totally Integrated Automation
Optimization of the complete workflow With Totally Integrated Automation, Siemens is the only supplier of an integrated range of products and systems for automation of chemical plants – from the field level and production control level to the enterprise level. Your benefit: considerably lower lifecycle costs for the plant, shorter time-tomarket and consequent improvement of your competitiveness.
Process know-how On the basis of our comprehensive industry know-how, we implement solutions that guarantee optimum fit and maximum process transparency for your plant – while requiring a minimum of manpower. Tailor-made energy concepts With our solutions in the field of energy supply, we make a decisive contribution to the smooth, economical and environmentally friendly operation of your plant. Process optimization by means of MES solutions Our MES solutions are essential to enable you to optimize your processes throughout the plant. They ensure integrated data transfer – vertically from the field to the enterprise level and horizontally from your suppliers to your customers.
With our solutions we cover the entire life-cycle of your plants – from planning and implementation to modernization and maintenance. dynamics. Drive solutions Innovative technology. precisely coordinated components and comprehensive engineering know-how are your guaranty that our drive solutions will meet even your highest requirements – in terms of performance. te Chemicals Totally Integrated Power Power management and distribution from a single source On the basis of Totally Integrated Power (TIP). diagnostics capability and cost effectiveness. System integration In order to guarantee perfect system integration. we implement integrated solutions for power distribution across all chemical production units and industrial buildings. from the medium-voltage supply to the outlet. energy management and building automation – can be seamlessly integrated and comprehensive solutions can be implemented in your plant. Equipped with the same communication standards as Totally Integrated Automation. availability. we cooperate with numerous competent partners – internally with Siemens Industrial Solutions and Services and externally with selected solution partners forming a worldwide network. power distribution.ur industry Basis of the Industry Suite Chemicals: Totally Integrated Automation and Totally Integrated Power – plus our comprehensive know-how in your industry. . Life-cycle services Our comprehensive range of services is an efficient lever ensuring continuous optimum performance of your plants. all resources – for automation. torque.
................................................................... Process Competence ......... 20 Industrial Controls .................................. Industry Suite Chemicals .............................................. 14 Industrial Communication ................................................................................ Totally Integrated Automation .......................................... 22 References . 24 ......................................... 13 Field Devices .... 2 3 4 6 8 Manufacturing Execution System ................ 18 Process Instruments and Analytics ................Content Your Partner in Automation ................................................................... 16 Drive Systems ......... Process Control System..........
Improve your competitiveness in your industry. With Totally Integrated Automation With Totally Integrated Automation (TIA). This not only reduces the cost of interfaces. With a high level of consistency and integration of our products and systems. specialty chemicals to consumer products. On the basis of Totally Integrated Automation. we provide you a high security of investment – avoiding unnecessary interfaces in the system. integrated portfolio of products and systems for the implementation of automation solutions. For all processes in the Chemical Industry from bulk chemicals. ERP Enterprise Resource Planning Ethernet Totally Integrated Automation Control SIMATIC NET Industrial Communication MES Manufacturing Execution Systems Production Order Management Ethernet Material Management SIMATIC IT Framework Production Operations Recording Equipment Management Production Modeler Plant Information Management Detailed Production Scheduling SINAUT Telecontrol System SIMATIC Software Industrial Industrial Ethernet Ethernet SIMATIC Machine Vision SIMATIC Controller/ Automation System SIMATIC PCS 7 Process Control System SENTRON Circuit Breakers Safety Integrated Industrial Wireless Communication/ MOBIC SIMATIC Distributed I / O PROCESS FIELD PROFIBUS PC-based Automation Field Instrumentation / Analytics Sensor Technology IQ-Sense AS-Interface Building Technology GAMMA instabus Micro Automation and Actuator-Sensor Interface Level ECOFAST IP65 Distributed Automation System SIMOCODE pro Motor Management System HART PROFIBUS PA 4 . through the production level to the corporate management level. we implement solutions that are perfectly tailored to your special requirements in the Chemical Industry and which are characterized by their excellent integration. TIA makes an essential contribution to the optimization of your production processes. through the operation to the modernization. Siemens offers a unique. but also ensures maximum transparency across all levels – from field. TIA fulfills your objectives with Siemens technology and products providing an impressive and unique level of integration. It goes without saying that you benefit with TIA throughout the life-cycle of your plant – from the product design phase. In this way.
On the one hand. the consistency in ongoing product innovation offers you maximum security of investment in case of modernization. which let you execute and engineer your customer projects more quickly. flexibility. you must respond to a continuously rising competitive pressure. the highest possible availability. more is being expected of your solutions all the time and the demands that you must meet are becoming increasingly complex. At the same time. ensured quality and prices that are always in line with the market. precisely and economically – from the design to commissioning. On the other hand you require solutions. your plant will benefit in every phase of the life-cycle. Advantages for plant operation The Siemens range of products and solutions is specifically tailored to your requirements. consistent quality – and. What is more. Laboratory Information Management System SINUMERIK Numeric Control SIMOTION Motion Control System SIMATIC HMI Human Machine Interface Totally Integrated Automation is the foundation for: standardized interfaces between E&I engineering packages highest availability of plant equipment lower design and engineering costs faster project execution higher productivity and flexibility SIMODRIVE SINAMICS Drive Systems/ SINAMICS 5 . rising production demands and an ever greater complexity. You know the factors required to achieve higher productivity in chemical plants: a maximum degree of automation. improved quality of engineering shorter and easier engineering and commissioning cost savings in projects Advantages for the EPC As an EPC. These solutions are based on proven industrial standards and are optimized to achieve the highest possible degree of economic efficiency throughout the entire life-cycle of a plant. Top priority is placed on integration and openness – in all key areas from automation to drives right up to process instrumentation. ever shorter product life-cycles. last but not least. safety and resource efficiency are the key to economic success in the production processes of chemical plants. Only companies that can successfully master these challenges can meet the market demands for short delivery times. Totally Integrated Automation is the foundation for: shorter time-to-market from the planning to the delivery higher system availability and flexibility Product Specification Management System Thanks to the system-oriented engineering environment as well as the integrated communication and diagnostics options of TIA. Advantages for system integration Growing pressure on the production side.The answer to growing demands Productivity. the end customer demands for you as a system integrator are immense.
At the same time. highest flexibility. it’s crucial for heat exchangers to quickly and precisely reach the right temperature. together with seamless integration of heat with downstream columns. 6 . Absorption Successful. This is the only way to meet the demands for fast delivery. it’s important to prevent any contamination or unnecessary energy loss.Competence for the processes in the Chemical Industry To ensure economic success in the chemicals business. high and constant quality. for example – whether environmental conditions can be completely controlled. the better the product yield and quality. maximum safety and the efficient use of resources in all your production processes. and – as with heat-sensitive substances. Distillation Two key parameters determine the economic efficiency of the distillation process: how much energy is used for vaporization and condensation. Heat Exchange When process media are being warmed or cooled. key process parameters such as temperature. pressure and flow must be controlled with great precision. efficient absorption of gaseous product mixtures depends on selecting the right absorbing agent and controlling all process parameters. Extraction Using the best possible extraction agents. of course. To ensure the best possible results. and the greater the efficiency and performance of the catalyst. brings long-term cost savings in extraction while maximizing product quality and minimizing environmental impact. you need top productivity. High process and product quality can only be achieved when all factors are optimally combined and coordinated. Typical process units in chemical plants Reaction The reaction process is at the heart of chemicals production. and competitive prices.
8 . PROFIBUS DP and PA is provided Redundant controller and PROFIBUS communication for high-availability processes keep the process running and reduce production downtimes Safety Integrated with the PROFIsafe profile on a single PROFIBUS cable. SIMATIC ET 200M remote I/O modules provide a large variety of digital and analog input and output channels. This saves time and the expense of additional components Standard and fail-safe remote I/O modules on PROFIBUS DP ensure reliable data transmission and diagnostics. At the field bus level. simplify configuration High performance automation systems with SIMATIC S7-400 controller on Ethernet up to 1 Gbps. using one controller and one engineering tool. based on TIA. operation. maintenance and diagnostics Pre-configured function blocks and libraries.Tailored to the demands of the Chemical Industry: Siemens automation solution with SIMATIC PCS 7 SIMATIC® PCS 7 is the Siemens distributed control system (DCS). using standard hardware and software components and can easily be connected to the Manufacturing Execution System level (MES). motors and drives are fully integrated in TIA and PCS 7. adapted to different industry requirements. SIMATIC PCS 7 benefits for the Chemical Industry: One common engineering tool PCS 7-ES for the complete process – saves engineering time One common visualization of all data in all PCS 7 operator stations with a standard alarm visualization – reduces production downtimes Field instrumentation. relative to engineering.
Depending on the plant’s requirements.000 measuring points. redundant archive server Integrate applications connecting SIMATIC PCS 7 to legacy systems and the IT system. 60.000 process objects) 9 .g. such as might be used for a laboratory system or a pilot plant. SIMATIC PCS 7 can be applied effectively in small and large plants. up to a distributed multi-user system with client/server architecture and approx. PID controllers). the operator and the planning engineer can Select from various automation systems with graded performance characteristics Use distributed (remote) or central I/Os step-by-step Layout an optimum architecture for the operator system: from single-user standalone stations up to distributed multi-user system Select the engineering and runtime system software according to the size of the system (scaled by process objects) Configure communication networks and determine network components to support required levels of redundancy and availability Extend the functionality of the operator stations by adding various hardware and software modules.Flexibility and scalability – from a small laboratory system up to distributed client/server architectures As a result of its modular and open architecture that is based on selected hardware and software components from the standard SIMATIC range. It allows easy expansion or system modification (online) to enable customers to meet the changing production requirements of their facility. such as might be used for automation of a very large production plant or for groups of connected facilities. SIMATIC PCS 7 is scalable from a small single system consisting of approx. using SIMATIC BATCH or with a standalone. valves. Stand-alone systems Production facilities Various plants of a production site Scalable from small applications (~160 process objects) … … to the distributed system in client/server (~ 60. 160 measuring points (motors. e.
powerful technologies together with internationally established industrial standards such as IEC. process I/Os and field devices as to operator and engineering systems. SIMATIC PCS 7 consistently applies state-of-the-art. XML. the system offers completely integrated function blocks for motors. industrial communication networks or the SIMATIC IT framework. to mention just a few. TCP/IP. Ethernet. Furthermore. OPC.SIMATIC PCS 7: the distributed control system in Totally Integrated Automation Open DCS for the future SIMATIC PCS 7 is based on modular SIMATIC hardware and software components. guarantee that the typical demands placed on a process control system can be met and exceeded by SIMATIC PCS 7: Simple and safe process control Intuitive operation and visualization Powerful system engineering tools with a common interface simplify the engineering and save money throughout the entire plant life-cycle Online modifications possible throughout the system System openness at all levels makes plant enhancements easy Redundancy at all levels makes high availability scalable to your needs Flexibility and scalability simplifies plant improvements Automation solutions avoid any injury to humans and damage to equipment and provide high process availability at the same time Comprehensive fieldbus integration makes the connection of field devices easy and optimizes the handling Direct interfacing to the IT system opens the DCS. The openness of SIMATIC PCS 7 covers all levels and applies equally to automation systems. together with common data management. communication and configuration. valves and control devices. PROFIBUS. expandable and open for future enhancements through the use of standard interfaces with long-term stability. 10 . flexibility and ease-of-use. High performance. ISA S88 and ISA S95. It is flexible. Common and integrated system SIMATIC PCS 7 can be used on its own or in combination with Motion Control and further SIMATIC components. The innovative process control system is fully harmonized with TIA.
from the field to the production control level. permitting up to 32 OS/SIMATIC BATCH clients to access the data of a single OS/Batch server. any production loss due to shut-down and start-up operations can imply huge economical loss. with overall redundancy through all levels Availability is one of the most important criteria in a chemical production. cards etc. up to 4 monitors per client Batch client/server architecture. Plant shut downs must then be avoided as far as possible – with periods usually reaching from once a year to less than one shut-down every 5 years for example for a steam cracker. To guarantee the highest availability of the automation system. Depending on each of your specific requirements. TIA and SIMATIC PCS 7 can provide you the best adequate redundancy configuration. all system facettes have to be taken into consideration: starting from the controllers up to the operator level and including the whole plant communication networks. On the one hand the capital investment for a chemical plant is extremely high. thus eliminating data gaps. Operator stations (OS) and batch clients Operator station bus level (terminal bus): • Use of standard off-the-shelf components (switches. OS. with automatic and transparent switch-over of the OS client stations. comprehensive concept we can offer up to the highest availability levels.) • Increased availability.and batch servers Redundant OS server. from the sensor/actuator to the control room – while responding to the harshest Chemical Industry environment conditions. seamlessly integrating all plant levels. Based on a flexible. between primary and backup server Redundant batch server Redundant OS clients and SIMATIC BATCH clients OS-LAN (Ethernet) segment 1 OS server OS-LAN (Ethernet) segment 2 BATCH server Double redundant Industrial Ethernet plant bus BATCH server Process data can be archived on each OS server or can be stored on a standalone.Maximum plant availability. and optionally redundant. and on the other hand. plantwide historian Critical OS/SIMATIC BATCH running as a background task on the server are continuously monitored for faults that would result in a client switchover Process data and alarm messaging archives can be automatically synchronized when a partner server is returned to service. S7-400H high-availability automation system optionally with redundant power supply ET 200M Actuator/Sensor ET 200M Redundant PROFIBUS DP ET 200M fail-safe Redundant DP/PA Link PROFIBUS PA Y-Link Connection of non-redundant PROFIBUS DP devices on redundant PROFIBUS DP 11 . environmental and vulnerability aspects of your plant. with single ring architecture or terminal bus split into several LAN segments Multi-monitor operator stations. and consequently the availability of the automation solution itself plays a key role in the economical effectiveness of the plant.
The plant can be equipped with conventional SIMATIC ET 200 distributed I/Os. for even higher level of redundancy. No additional hardware or software tools are required. engineering stations. or with state-of-the-art. Redundancy at the distributed I/O level Multiple PROFIBUS DP segments can either be connected to distributed I/Os via the onboard PROFIBUS DP interfaces. It supports redundancy and failsafe architectures. or using additional PROFIBUS communications processor modules Using the ET 200M distributed I/O system. in addition to online expansions.Automation system and plant bus Dedicated Ethernet LANs for client-server and server-server communication Communication between automation systems. and is based on PROFIBUS technology. using our Y-link. Redundancy of field devices Intelligent field devices on PROFIBUS PA fieldbus segment can be connected via a redundant DP/PA link Non-redundant PROFIBUS DP devices can also be connected to a redundant PROFIBUS DP network segment. at up to 1 Gpbs. The particular highlight here is that the new feature is simply integrated into the SIMATIC PCS 7 process control system. redundancy can be extended down to the I/O module level. connected to plant bus over dedicated Ethernet communications processor (CP) Optionally. both line or ring topology possible Increased availability with redundant ring architecture Redundant. each of the 2 automation station CPUs can be connected via two separated CPs. whereby a single sensor/actuator can be connected to redundant I/O modules Using redundant controllers. Plant operators and maintenance engineers use the same SIMATIC PCS 7 tools and operator interfaces with information that has been filtered and prepared for the relevant application area. operator systems over Industrial Ethernet plant bus. and can be used in standard environments or in hazardous areas. thus each CPU to be connected simultaneously to both networks of redundant plant bus architecture. intelligent field devices. Asset Management for systematic automation and maintenance of plants Siemens offers an efficient solution for plant maintenance: SIMATIC PCS 7 Asset Management. each ET 200M unit is connected to the redundant PROFIBUS DP segments. Complete integration of field devices SIMATIC PCS 7 is optimized for integration of distributed field equipment into the process control systems. 12 . high-availability S7-400H automation systems.
GAMP4. by making it easier to share information with internal as well as external customers. SIMATIC IT Interspec can be implemented separately or as integrated part of SIMATIC IT. The Report Manager meets regulatory requirements for standard and ad hoc reporting (for example.SIMATIC IT: the basis for increased productivity Maintaining a highly flexible and efficient production process allows chemical manufacturers to maintain market position and deal with competition. Statistical Analysis. 21 CFR 11). as well as packaging materials. material management. tracking and tracing and comes with functionality specifically tailored to the needs of the Chemical Industry. SIMATIC IT Interspec is the specification management system that handles product specifications for raw materials. SIMATIC IT Historian is part of SIMATIC IT or can be implemented separately. SIMATIC IT Historian is a collection of software modules to collect. fully integrated and userfriendly reporting functionality. Down Time Management. store and quickly retrieve process and production information for Quality Assurance. ISO 9000:2000. complying ISA-95 standard. These components include MES functionality for order management. Due to its modular. SIMATIC IT offers integrated quality assurance. Certifications. SIMATIC IT Unilab is able to manage all types of analysis in a lot of languages and helps organizations to deal with critical issues in communication between the laboratory and customer service. open and scaleable architecture. GALP. allowing for a clear understanding of the plant’s behavior and visualization of the production. SIMATIC IT Unilab complies with regulatory rules such as FDA (cGMP. personnel management. 13 . SIMATIC IT is the Manufacturing Execution System from Siemens. and ISO17025. Reporting. Overall Equipment Effectiveness (OEE) etc. SIMATIC IT Report Manager is an optional component of SIMATIC IT and offers advanced. SIMATIC IT Production Suite is composed of the SIMATIC IT Framework and SIMATIC IT Components. SIMATIC IT Unilab is the Laboratory Information Management System that models and manages the complete workflow of all quality data in the laboratory and on the production line. GLP. SIMATIC IT Framework provides the graphical environment to model the production process. Performance Monitoring. SIMATIC IT enables customers to standardize repeatable processes at the production level while increasing flexibility at the operational level. retrieval and reporting of laboratory data. optimizing the collection. product specification management. It enables chemical manufacturers to optimize production. SIMATIC IT Historian delivers business information for decisionmaking and plant optimization and complies with the FDA’s 21 CFR 11. semi-finished and finished products. This is possible by bridging the gap between business systems and the control level and by synchronizing operations all along the production and product life-cycle. MES – Manufacturing Execution System SIMATIC IT SIMATIC IT links the plant floor with the business systems and increases plant visibility. This incorporates company-wide specifications as well as individual specifications for a single plant. object oriented. analysis. report management and messaging. supplier or customer. the upcoming REACH and Global Hazard Classification System) and offers valuable operational insights.
EN. humid tropical etc. temperature group T4 (°<135 °C). That is why SIMATIC S7 controllers have the highest global market share. and offers safety and fault-tolerant functionality in one system. SIMATIC S7-400H: high-availability. On the one hand. with the help of highly efficient operation processing. group A. SIMATIC S7-400: powerful. on the other hand. high quantity of I/O framework and an extremely high speed. acc. to IEC 61508. powerful control capabilities. D. Our controllers meet the following standards: DIN. Redundant I/Os and PROFIBUS complete the high availability functionality. UL certification. such as dry tropical. flexible communication extension and reliable. IEC. SIMATIC S7-400FH: safe and fault-tolerant SIMATIC S7-400FH is part of SIMATIC Safety Integrated. noncritical faults keep the high-availability process running. B. All components are SIL3 certified. SIMATIC S7 controllers can be installed and operated in different environmental conditions. low temperature. CSA certification.2. they ensure high tech combined with economical benefits for any automation solution. Class FM1 Sec. hazardous incidents lead to a safe shutdown of the process. C.SIMATIC S7: the comprehensive range of controllers – highly reliable and powerful SIMATIC S7 controllers provide network communication. for system solutions in chemical plants With a large memory. 14 . IT service functionality etc. guaranteeing maximum uptime Controllers that keep your process running with hardware redundancy (hot standby).
15 . The SIMATIC ET 200iSP (iSP stands for intrinsically safe for process industry) from Siemens is a modular. local intelligent and technological modules and safety technology modules. It can be used both in gaseous and dusty atmospheres. This helps to reduce downtime costs by a quick and detailed diagnosis. diagnostics. PROFIBUS has become the standard fieldbus. Increasingly shorter production times and reduced costs are requested in all operational areas. Hot swapping means fast replacement of I/O modules or motor starters during operation in order to keep production downtimes and maintenance work at a minimum. offering three levels of diagnoses for the interface module and bus communication. switches. Advantages Powerful functional modules – internally integrated standard and safety motor starter module.5 kW. SIMATIC ET 200S motor starters: for simple parameterization. and offers many convincing advantages. In order to manage these demands. many users in the process and production industries apply distributed solutions. operating current or overload. pneumatic system modules. also extending into hazardous areas. standard and safety I/O modules. ET 200S for bit granular I/Os and function modules. and monitoring The communication-capable motor starters of the distributed I/O system ET 200S offer integrated safety and diagnostic functions in one device. sensors. valve positioners etc. an electronic overload relay and a contactor or soft starter which switch the motors up to 7. the motor starter reports diagnoses. transducers. to the control system. SIMATIC ET 200 offers a complete product range for any application needs – ET 200M with multi channel design. frequency converter module. which are normally used. ET 200iSP for intrinsically safe applications. resulting in lower service and maintenance costs. The motor-starter is a pre-wired and remote-parameterized unit consisting of a circuit breaker.g. e. are clearly reduced. IS barriers. junction boxes. By means of PROFIBUS. Distribution with SIMATIC ET 200iSP in hazardous areas In most companies. panel lights. with remote I/O devices allowing sensors and actuators to be connected to a bus system in a cost efficient way. This means that faults are immediately detected and can be solved easily. some of them like ET 200S can even be connected to PROFINET. phase asymmetry.SIMATIC ET 200: decentralized field devices for all requirements SIMATIC ET 200 distributed I/O modules can all be connected to PROFIBUS DP. for example short-circuit. They are used to connect various field devices to the industrial control system. time and cost pressures belong to everyday life. pushbuttons. intrinsically safe I/O system with IP30 degree of protection for hazardous areas. Powerful system diagnoses. Cabling costs and the number of standard terminal blocks. ET 200pro for high protection in IP65 and ET 200eco in a cost-effective design with IP65 protection.
and e-mail/web integration Ability to function as web and FTP server and client for communication of production information OPC server included.SIMATIC NET: industrial communication for plantwide automation The business drivers in industrial communication are improved efficiency and safe data transfer in the plant. human machine interfaces etc. weighing & dosing systems. transparent communication and not just on the process level. but also through ERP systems. motor starters. peer-to-peer communication. Siemens communication product range supporting PROFIBUS includes the network interfaces and software you need to implement your network architecture. monitoring. PROFIBUS: the world’s number one fieldbus PROFIBUS network technology provides rich benefits for almost any application in industrial automation. drives. These demands can only be met if the process in your chemical plant works perfectly. identification systems. This can be achieved by using open. Ethernet is number one worldwide in today’s LAN landscape. Devices such as remote I/Os. are connected via a single cable. Connecting controllers to Industrial Ethernet Using Industrial Ethernet for programming. 16 . Industrial Ethernet: today’s leading local area and cell network Across all applications. controllers. SIMATIC NET provides everything you need to create a communication infrastructure designed to share critical production information: Enables production transparency from the field to the management level Leverages the advantages of mobile communication Integrates IT business systems. Ethernet provides important features and performance characteristics which can provide many important benefits for your application: Virtually unlimited communication capabilities and scalable performance Company-wide communication thanks to Wide Area Network (WAN) technologies. PROFIBUS is primarily used at the field level with interfacing capabilities downward to the sensor/actuator level as well as upwards to the production and enterprise levels. SIMATIC NET provides important additions and improvements to traditional Ethernet technology for use in industrial environments: Network components designed for use in rugged industrial environments High availability networks using redundancy even at 1 Gbps Integrated monitoring and diagnostics of network components Fast industrial cable assembly and extension during operation. connection to IT.
indicator lights and other actuators and sensors to the higher-level controller. AS-Interface: communication for sensors and actuators Sensors and actuators play an important role in automated processes. splashproof and dustproof enclosure. securely and cost-effectively. 17 . or Internet/Intranet Operation by means of touch-screen with pen. Whether it concerns the detection of valve states or the correct level in a reactor or tank: sensors are the eyes and ears of process control. MOBIC: industrial mobile internet pad The ultimate device for mobile access: Ideal for operations and maintenance personnel who need to be both mobile and connected to the process Wireless connectivity to your equipment/plant. central control room. finger or additional function keys built into the bezel High-resolution. shock and environment (IP65) with options for redundant power supply. Because the AS-Interface now provides you with a bus system that implements the connection of all automation nodes in the field to the higher-level controller – simply. For a long time the cabling of transmitters and recorders followed the old pattern: each sensor or actuator was connected individually and with parallel wiring to the higherlevel controller. valves. The AS-Interface transmits process-level digital and analog signals and connects proximity switches. and programming Independent communication coprocessor ensures consistent scanning of distributed devices regardless of controller scan Multiple communication processors can be used to segment distributed devices Support for redundant I/O in conjunction with redundant controller OPC server included.Connecting controllers to PROFIBUS Using PROFIBUS for connecting distributed devices. SCALANCE W: industrial wireless communication Install a plant-wide Ethernet network The flexibility of wireless with the reliability of a wired network Deterministic data transmission allows time-critical connections to be realized Security wizard enables Wi-Fi Protected Access (WPA) with encryption for the ultimate in security Designed for industrial applications with enhanced resistance to vibration. peer-to-peer communication. daylight readable TFT display Designed for industrial applications due to its rugged.
MICROMASTER 440 frequency drives: packed with functionality for a wide range of applications Whether it involves mixing drives in conjunction with offset shaft geared motors. soft starting and deceleration in the variable-speed mode goes easy on the entire drive train’s mechanical components. agitators in hazardous areas. and at shorter response times than do mechanical control concepts. pumps and compressors. This permits extremely simple operator control and diagnostics. extruders requiring a high starting torque or. mixers and extruders. Depending on the plant characteristic. filtering. for example. precise and efficient In many applications in the Chemical Industry. In addition. An example are the standard engineering tools – SIZER to engineer drives and STARTER to commission them. parallel transport of gas or solids. metering and mixing. fans. particularly in applications involving quadratic load torque. 18 . This prevents. variable-speed drive tasks in the Chemical Industry are covered by MICROMASTER 440 frequency drives and SINAMICS G150 frequency drives. Savings potential Variable-speed mode also saves a very significant amount of energy. often within only a few months. the use of frequency drives to regulate motor speed makes drive technology more efficient. Because of this. like fans. extruding. the SINAMICS G150 cabinet units and the SINAMICS G130 chassis units are the primary choices for consideration. For the Chemical Industry with its pumps. For the most part. for example. foil processing machines where several drives run in synchronized operation – our MICROMASTER 440 frequency drive is the best selection where maximum functionality and higher dynamic performance is demanded.Drive systems: reliable. SINAMICS: the new drive family All members of the new SINAMICS drive generation profit from the same core technology and have the same ”look & feel“. which are output in plain text via the user-friendly graphic display. pressure waves in pipeline systems. Typical applications: Transportation of fluids or gases and solid substances. energy savings may reach 50%. a frequency drive soon pays for itself. such as cavitation. ultrasonic compression shocks and vibration can be avoided by using a frequency converter. such as the transport and dosing of products. In addition. Variable speed allows much more precise control of processes. all high power cabinet units of SINAMICS are equipped with an AOP 30 operator panel with its selfexplanatory menu prompts. Unfavorable operating conditions. lifting. as compared to fixed-speed motors.
19 . fans and compressors. is also available. For example. Noise levels of only 69 db(A) during full operation. In addition. SINAMICS G150 covers the majority of drive tasks with high power requirements. the modules can be replaced in just a few steps. The clear. With these units. customers take profit from functionalities that they really need. SINAMICS S150 cabinet units and SINAMICS S120 chassis units represent a viable alternative when the energy supplier places particularly high demands on the network quality or in the case of weak networks. the active infeed technology reduces phase effects on the system to a minimum and protects the drive system against power dips. SINAMICS G150 cabinet units have a footprint that is up to 70 percent smaller than the footprint of conventional converters. however. but also constant-torque drives such as extruders. a chassis unit with the same functionality and performance. If required. fans. In order to restrict the steep voltage edges customary for IGBT voltage source converters as well as phase-to-phase voltage on the motor. As alternative to NAMUR terminal blocks.1. Sinusoidal filters are also available for particularly high demands. ”Process Engineering“ mode.Specially for pumps. Preconfigured and thanks to the clear operating concept. An EMC filter for secondary environment category C3 to EN61 800-3 is integrated as standard. the phase-to-phase voltage is also limited in the case of long motor wires. Power ranges are from 75 kW to 1500 kW. even in the case of cabinet units with a power output of several 100 kW. it is possible to use the PROFIBUS Profile PROFIdrive 3. such as pumps. the units are equipped with NAMUR terminal blocks as well as NAMUR functionalities specifically for the Chemical Industry. Simple and user-friendly Above all. SINAMICS G150 cabinet units cover voltage classes from 380 V to 690 V. the units are appealing thanks to their user-friendly operation. Safe electrical isolation according to PELV is also ensured. For drive tasks requiring several megawatts – such as very big mixers or extruders – SINAMICS GM150 medium-voltage frequency drives are the most cost-effective solution. The easy-to-use operator and commissioning functions are shown on the graphic display in plain text. make additional soundproofing measures unnecessary. In case of service. mixers and extruders The units are specially geared toward drive tasks without regenerative feedback in applications with quadratic torque characteristics. Demands of the Chemical Industry are fully satisfied SINAMICS G150s fulfill all demands made by the Chemical Industry. In addition. mixers. compressors. mills and conveyor belts. dV/dt filters are available which limit the voltage gradients. the SINAMICS G130. well-structured design of the SINAMICS G150s makes the units rugged and reliable.
20 . It facilitates the manufacturer-independent operation. All devices fulfill the needed certifications in the Chemical Industry. specialized process instruments (e. Process Instruments Throughout the Chemical Industry. With our SIPART PS2 valve positioner e. the tasks in measuring the flow are versatile. or measuring orifices remain an integral part of our product family SITRANS F.. or programming devices. Pressure Whether relative. Easy and versatile diagnostic functions help to achieve these requirements. weigh feeders and solids flowmeters. high pressures.g. SIL. just as our products are. A created warning message helps the maintenance team to keep the process in optimized run.g. The SITRANS P DS III instrument is ideal where highly aggressive media and harsh ambient conditions require experienced solutions and can be used for safety-related measuring points in accordance with SIL 2. usable for all field devices. and the SIMATIC PCS 7 process control system. or integrated into the SIMATIC PCS 7 automation system. FM. adjustment.Process instruments and analytics: the full range for all measuring tasks Siemens offers a broad product portfolio of process instruments and analytics. it can be applied via PC. temperature measurement applications are not always easy and are often done in harsh ambient conditions. In addition to electronic weighing systems and cells. which is the most frequently used intelligent positioner for linear and rotary actuators. Every substance is different and needs an individual solution. maintenance and diagnostics of intelligent process devices.) Siemens process instruments offer advantages on the automation level as well as for the asset management of your plant. measurement requirements can be extreme. differential or absolute pressure. “Classical” mechanical methods are also available: Rotary piston meters. Regardless of the automation system. variable-area flowmeters. Flow Especially in the Chemical Industry. the SITRANS P pressure transmitters provide precise pressure measurements. or aggressive media. Magnetic-inductive and ultrasonic flowmeters or Coriolis flowmeters are used for this. ultrasonic or capacitive methods. foam and steam – with the product family SITRANS L and POINTEK. To parameterize these functions. Weighing The SIWAREX weighing systems can easily be integrated into the automation structure of the process. Diagnostics Reducing production downtimes is an increasing challenge for a plant operator. pressurized enclosures) are often required for the relevant approvals (ATEX. Temperature Whether high temperatures. leakages at valve drives can be detected immediately. From a storage tank to stirring machines with high pressure. Our SITRANS T transmitters are available in different types. Level Continuous measuring or point level detection is based on radar. you can select from an extensive range of Siemens-Milltronics belt scales. WHG etc. As the measurements are often done in extremely harsh ambient conditions. you can use our Process Device Manager (PDM) software tool. from simple to intrinsically-safe with diagnostics and simulation options. we can fulfill the most common challenges in the level measuring technology.
21 . where competitive analyzers only allow 4% O2. and CALOMAT. Except for the FIDAMAT. Beside this. Because the measuring system has no moving parts and can be ordered in corrosion resistant materials like titanium or tantalum the OXYMAT became the standard oxygen analyzer in chlorine chemistry. all analyzers are available in field housings for operation in hazardous environments. FIDAMAT. while it is crucial to stay below the lower explosion level (LEL). Continuous process analytics The continuous gas analyzer of the Siemens series 6. Due to its outstanding stability. Thus. based on flame ionization detection. The intrinsic design of the analytical part of ULTARMAT and OXYMAT and the materials in contact with the process gas stream are chosen to withstand even highly corrosive gases. the excellent analytical performance of the series 6 analysers make them first choice in critical process applications in terms of sensitivity and stability.Analytics The capabilities of modern process analytics can be the key to a significant increase in efficiency. ULTRAMAT. Optimized production of ethylene oxide The efficiency of the ethylene oxide process increases with the concentration of oxygen. or safety of chemical processes. OXYMAT. the process efficiency is increased by 1%. productivity. only the OXYMAT allows the process to be operated at a set point of 5% O2. were originally designed to fully meet the requirements for process analytics in the Chemical Industry.
SIMOCODE pro meets all requirements for future-proof energy management and offers advantages in all areas: in process management. Innovative software products offer user-friendly parameterization. Using switchgear and switching devices we offer a common integrated communication concept for customized solutions: e. Some extensive features: Multifunctional. SIMOCODE motor management system and SIMATIC. SIMOCODE pro optimizes the connection between control system and motor feeder. Load feeders that have a higher performance and at the same time are extremely compact and able to communicate. a straightforward and efficient service and maintenance as well as a range of graduated functions. This increases the transparency of your process and ensures a significantly greater density of information in the control system – at no extra cost. operations management or in switchboards. It also involves an extremely compact design. diagnostics. commissioning. communication-capable motor starters and circuit-breakers support this trend and make all relevant data available via PROFIBUS. increases the plant availability and achieves considerable savings in the construction. In addition. So SIMOCODE pro is likely to be used in SIVACON lowvoltage Master Control Centers (MCC) and allows load feeders to be configured. service and diagnostics data Open communication via PROFIBUS DP Integration and monitoring of additional process values Detection and monitoring of power-related measurements ATEX-certified (overload protection of explosion-protected motors). Standardized motor function blocks.Industrial controls and power distribution More often the data of the motor feeders are also integrated into the process control system. All of these features provide a seamless integration into the automation environment. 22 . operator control and visualization locally via PROFIBUS DP or Ethernet/Internet.g. with SENTRON circuit-breakers. electronic full motor protection. operation and maintenance of your plant. simplify the integration and the engineering. for example. Intelligent motor management systems. SIVACON systems: for customized communication solutions SIVACON systems are low-voltage communication-capable switchboards and busbar trunking systems with a high degree of flexibility and availability. independent of the automation system Flexible software instead of hardware for the motor control Detailed operating. SIMOCODE pro: the flexible and modular motor management system SIRIUS motor management and control devices (SIMOCODE pro) are the first choice for constant speed motors in the low voltage range. The high degree of modularity allows all communication components to be simply retrofitted.
The products in the SENTRON circuit protection system tie into your automation architecture giving you the power to increase production system availability. reduced operating costs and optimized energy usage for molded-case circuit-breaker 3 VL from 16 A up to 1600 A and for air circuit-breaker 3 WL from 630 A up to 6300 A. a configuration software. configuration and programming is integrated into the automation project SIMARIS manager – Power Management Software to manage energy distribution systems. In addition. you have the possibility of thousands of different combinations for all of your energy distribution applications. SENTRON: power distribution With only a few modular components. Data management. Switch ES Power. operate and monitor SENTRON circuit-breakers. investment and energy supply costs through continuous analysis of energy data. you can further optimize the energy distribution process with a networked power management solution. This modular and integrated power management software is based on SENTRON switching devices and Totally Integrated Automation. alarm.SENTRON: optimized energy solutions SENTRON circuit-breakers address your critical needs for less installation space. operation and monitoring of the SENTRON circuit-breakers can be done via the PROFIBUS DP network. and maintenance of SENTRON circuit protection devices as part of a Totally Integrated Power solution but also optimizes laboratory. The parameterization. Web Server – Breaker Data Adapter (BDA) is the first circuit-breaker communication device with integrated web server to parameterize. This not only facilitates efficient diagnosis. Never before have circuit-breakers been so versatile and so simple. Circuit-breaker data can be accessed from any device supporting an Internet browser with Java Virtual Machine. The BDA Plus incorporates an Ethernet interface for direct connection to Ethernet / Intranet / Internet. SENTRON circuit-breakers are completely integrated into the SIMATIC world and the STEP7 engineering software. 23 . offers complete integration into the automation engineering environment.
000 I/Os. Gladbeck is the largest phenol plant in the world. The legacy systems were changed over “loop by loop“. Germany. and efficient control solution that is based on future oriented standards and Totally Integrated Automation. was the fact that PCS 7 offered a modern. Antwerp. One decisive factor for awarding the contract to Siemens. Customer requirements When INEOS was looking for a partner to modernize the existing process automation system for the entire factory. and Mobile. without interrupting plant operation. Today. INEOS now benefits from increased safety and system availability through redundancy on all levels. The integrated safety technology and the high system availability due to redundant solutions were also decisive. The INEOS order included replacement of all the installed control technology on the entire site.000 tons of phenol and 5. the Gladbeck site has experienced significant development. Customer benefits The conversion from the previous control solution to SIMATIC PCS 7 went smoothly. USA. Siemens solution The new solution is based on a total of eight SIMATIC S7-400FH automation systems. Alabama. was able to establish itself as the winner. though facing strong competition. Germany INEOS Phenol is the world’s largest manufacturer of phenol and acetone. 24 . innovative.000 tons of acetone. the company first performed an extensive comparison of various control system suppliers. with an annual capacity of 630. with production sites in Gladbeck.Best practice example: INEOS Phenol production site in Gladbeck. and the application software of the legacy controllers was also converted. In addition. PCS 7 offered the possibility of replacing installed control technology during ongoing operation – allowing the Gladbeck plant to continue to operate without interruption. The capacity of the plant at the beginning of production in 1954 was a relatively modest 8.000 tons of acetone.000 tons of phenol and 390. with about 8. aside from the previous positive experience INEOS had made with Siemens in low-voltage projects. The entire plant was upgraded with no shutdown of production – a very important aspect in high throughput continuous processes such as phenol synthesis. With SIMATIC PCS 7. One redundant OS Server and ten Clients plus one MultiClient as well as one Engineering System were installed in the new control room that resulted from merging the legacy system. In the course of the company’s history. Belgium. SIMATIC PCS 7. and the merging of two control rooms. and integrated fail-safe technology.
an excellent price/performance ratio of the concept. a subsidiary of China National Petroleum Corporation (CNPC). Production cost. as was local expertise and know-how for project engineering and maintenance. safety. Seamless integration of the safety technology.. The plant consists of two production lines and the capacity of a single line is 300. and a future-oriented solution were central criteria for Jilin Fuel. due to the high stability and reliability of the SIMATIC automation systems and components. Customer benefits The production and process management has been optimized and plant efficiency has been improved. The system also collects and transfers all production and units data. including the corn storage facilities and other utilities. which comprises a total of 9. This project was the first plant dedicated to the production of fuel ethanol from corn in China with a capacity of about 600. have also been reduced. Ltd. high availability. is controlled from two PCS 7 control rooms. Customer requirements This significance and the fact that the application is quite large regarding the extension and the number of I/Os were asking for a state-of-the-art automation solution. 2003. 25 . When choosing the appropriate automation solution. is a joint venture formed by CNPC.Best practice example: Jilin Fuel Ethanol Co. At the bottom line. and last but not least the benefits of the uniform automation solutions based on Totally Integrated Automation tipped the balance in favor of automating the plant using SIMATIC PCS 7. China Jilin Fuel Ethanol Co. using the fiber-optic technology to bridge distances of up to 1100 meters on the plant field.000 tons per year. The data management has become more transparent. Jilin Grains Group (JGG) and China Resources Group. such as materials cost and management cost. with the implementation of Manufacturing Information System (MIS) and the web functionality at the operator-station level. the great openness of the system. the maintenance workload has been reduced. At the same time.000 I/O points. product quality has been improved and now meets one hundred percent of the market requirements.. The first production line was started on September 22. This ethanol fuel pilot plant in China has become a prestige project for the Chinese government. to a real-time production monitoring system. The devices at the process level are connected to the PCS 7 systems via PROFIBUS DP fieldbus. Ltd. 2001 and was launched on August 31. Siemens solution The entire system.000 tons of ethanol per year. Eight safe and fault-tolerant S7-400FH automation systems and two fully redundant optical Industrial Ethernet rings form the reliable backbone of the control system.
Siemens solution SIMATIC PCS 7 and the Bayer toolkit control all processes in the plant. The company-wide specifications were recently implemented with the SIMATIC PCS 7 process control system in the modernization of a small batch line in Thailand. It is characterized by a flowchart that displays the entire production process so that the operating personnel have a complete overview of the current production steps at all times. Customer benefits The automation concept was implemented jointly with local partners and uses standard routines developed by Bayer and Siemens Thailand. The aim was an integrated solution for the automation of the entire production process – a task that was completed through close cooperation between Bayer and Siemens directly on-site in Thailand. After completion of a batch. 26 . training. SIMOCODE and SIMOREG (DC Drives). Siemens is able to optimally support this strategy.or downloaded to the control system in the form of Excel tables. The feeders are also integrated with the control system via a gateway. Customer requirements Bayer operates a polycarbonate production facility in Map Ta Phut in Thailand that supplies base materials for a number of applications. With the company’s unique combination of a local presence and global knowhow. The company wished to equip a small-lot compounding line that produces colored thermoplastics resin with an automation system that was state of the art and also complying with Bayer’s worldwide technology standards.0 of PCS 7. were used as well.Best practice example: Bayer polycarbonate production facility in Map Ta Phut. The compounding line is one of the first in the world to use the latest version 6. The front end is a graphical user interface that is now being used in all Bayer plants throughout the world. Thailand Global companies are increasingly relying on standardized processes and systems – in order to exploit rationalization potential for spare parts. New recipes can be created using a PC in the lab sector and then simply up. The SIMATIC PCS 7 process control system provided the basis. and can also be displayed as an Excel table. and service across all their locations. all the production-related data are returned for documentation. Bayer is no exception. linked to the control system by PROFIBUS. The application is a typical example of a company-wide strategy encountered today in more and more globally active companies: exploiting rationalization potential in production through the standardization of processes and systems.
the plant operational safety was also important. and avoid any wrong production orders.Best practice example: RohMax Additives production facility. the SIMATIC IT MES functions work perfectly with SIMATIC PCS 7 batch flexible at the batch and control levels. batch control. The openness. At the bottom line RohMax can now deliver products with higher and more stable quality. that lead to the highest requirements in the matter of batch planning. Maintenance times could also be reduced thanks to the efficient diagnostic and error identification of the system. processes have been made easier to control and at the same time. It provides the required extensive and flexible production order and material and resource management as well as the necessary archiving and reporting functions in an efficient and user-friendly graphic environment. Customer benefits A higher plant availability was also a decisive factor – with the high standardization level of using TIA components throughout the whole plant. recipe management and route control. With a wide product portfolio of roughly 120 products RohMax belongs to the high-yield companies on the specialty chemicals market. During and after this project. the stock of spare parts was reduced. Siemens solution Heart of the modernized plant are the SIMATIC PCS 7 process control system and the innovative Manufacturing Execution System (MES) based on SIMATIC IT. a Degussa AG´s Company of the Specialty Acrylics Group. improvements could also be reported at several levels of the plant life-cycle. Furthermore. Among several goals of the production improvement. develops and produces innovative and customized additives for lubricants. is seamlessly integrated into the management execution level with SIMATIC IT. The existing ERP-legacy system SAP. Germany RohMax Additives GmbH. 27 . A further optimization potential in this plant has been exploited in creating a direct coupling between the production and business level. Customer requirements The production of additive is a complex multi-phase batchoriented polymerization process – with numerous ingredients. the production has become more flexible. For operators. thus enabling the tightest synchronization between production orders and the plant operation. use of standards and the scalability of this solution are securing ability for quickly and economically adapting the additives production with high flexibility to changing demand. via the Production Planning Module for process industries (PP-PI interface). that have to be selected and batch recipes.
E20001-A310-P200-X-7600 | Dispo 06303 | 41C9051 MK.siemens.YTIA.com/automation .com/totally-integrated-automation All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third party parties for their own purposes could violate the rights of the owners.05 WS 06053.5.siemens. | Printed in Germany | © Siemens AG 2005 www. Siemens AG Automation and Drives www.siemens. The information provided in this brochure contains merely general descriptions or characteristics of performance which in actual case of use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract.LT.com/chemical Subject to change without prior notice 06/05 | Order No.Further information: www.52.GC.
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