Experience. Technology. Community. - · PDF filePage 12 2011-08-08 Industrial Automation Systems. ... Page 16 2011-08-08 Industrial Automation Systems. Simatic PCS 7 DCS Centralized

© Siemens AG 2011. All Rights Reserved.

Siemens Process Automation

End-user Summit 2011 Experience. Technology. Community.

Food & Beverage

© Siemens AG 2011. All Rights Reserved.Industrial Automation SystemsPage 2 2011-08-08

Development TOP Accounts

Development Sub-Industries

Development Countries

Food & Beverage Strategy

(Technology)Automation

Portfolio

SugarEdible OilTobacco

Bakery & CBrewery

Dairy & Juice

Sust

aina

bilit

y, S

afet

y, S

tand

ardi

zatio

n

CountriesSub-segments

Accounts

& Projects

Systematic Business Development

Globalization, Time-to-M

arket


Food & Beverage Top Accounts

with Corporate Account Managers

Robert Belleil

Olaf Plante

Rainer-Markus

Schmitz

Jean-Claude

Ecarla George Mazzoli

David Lee

Tim Shafer

Karen BeanUlrich Brynjulfsson James Gavin

Thomas Kroll

Anders Thulin

Henrik Lund

Chris

McCombScott Hudson

Brett Renken

Detlef

Prinz Alexander Maier

Customers with more than 6,500 plants worldwide.


End users

Consulting for

planning and upgrading

Joint development of

selected strategic projects

One concept for end users, OEMs and System Integrators

Joint strategy for important customers and markets

We work as partners with OEMs and System Integrators

to promote products, systems & solutions with the end user in mind

Key Factor to Success:

The „Balanced Triangle“

Approach

OEMs and SI

Cooperation in

preparing quotes and

handling projects

Joint development of

solution concepts

Work together to coordinate logistics, service and

spare parts delivery


Food & Beverage

Supported Sub-Segments

6 Sub-Segments with Individual Industry Solutions

Bakery & Confectionary Dairy & Juice Edible oils

Sugar Breweries Tobacco

... plus continuous scanning of the market for other attractive sub-segments.


F&B Sub-Sector Dairy

Portfolio

Dairy Functional Tool Set (DFT)

DFT is a proven and comprehensive solutions for

all aspects of the industrial production of dairy products

for green field projects, expansions and modernizations

DFT covers key functionality

material, tank and transfer management

archiving and reporting

flexible cleaning in place (CIP)

process and product safety

DFT offers significant benefits

in engineering efficiency, integration, migration, commissioning speed, asset management and diagnostics, as well as functional advantages over traditional PLC+SCADA solutions.

DFT makes use of “Advanced Process Functions”

(APF)

Engineering Tools for PCS 7 that offers a standardized material and order management in an non-Batch PCS 7 environment


Advanced Process Functions (APF)

Dose, Mix and Transport Materials beyond F&B

Material lotmanagement

Storagemanagement

Parametermanagement

Jobmanagement

Storagemanagement

Material lotmanagement

Arc

hivi

ng

Material managementPo

wde

r A

Pow

der B

Pow

der C

Liqu

id A

Liqu

id B

Liqu

id C

ScaleMixer

Reactor

Liqu

id D

Liqu

id D

R(R

ewor

k)

Mixer

Separator

Dryer

Prod

uct A

Prod

uct B

Prod

uct C

Prod

uct D

Prod

uct E

Filter


Standardized Solutions

for Food & Beverage Processes

Planning Engineering Start-up Production

Planning Engineering

Optimization by

pre-definedToolset

Conventionally designed application

Siemens as a Partner

Optimization through “Engineering Toolset”

usage

Start-up Production

Optimization By

IndustryToolset

Optimizationby

Pre-testedsolutions

Optimization by

Uniformity,Flexibility

Costs : 5 –

10%Time : 15 –

20%

Reduction

OEM / SI End Customer


PCS7 for Edible Oils

Complete Solution from seed storage to special fat

Toolbox for fast and simple Engineering

For the complete supply chain from oil seed to special fat

Investment protection: A globally supported solution

Consulting and Engineering support by Support Center for Edible Oils

Predictive Maintenance and Energy Monitoring functionalities



Energy Monitoring -

PowerRate

An untypical power consumption value of a press is a hint for

Wear

Wrong conditioning of seeds



Energy Management –

B.Data

Allocation of consumption and costs to cost centers and batches

Export of consumption data to Excel

Processing in configurable reports (table, graphics, duration curve)

Automatic and time-controlled generation

of Excel export and reports


Preventive Maintenance:

Centrifugal Pump Monitor

Pump monitoring

function

Shows the health of the pump

Recognizes capacity losses

Displays the safety clearance to the pump’s cavitation

limit

Current operating point

Performance curve new pump

Performance curvePump in operation

Safety Clearance

Cavitation

limit

Current operating point


Preventive Maintenance:

Vibration Analysis

Health of the complete drive at a glance

Maintenance during planned shut downs

Replaces vibration measurements of external provider

Continuous monitoring

is better than annual check

Temperature/

damage

Field fault

Alignment fault

Part resonance

Heavy spotGear box damages


Steam

Meal mixed with 25% Hexane from Extractor

Exhaust vapor with Hexane > 65°C

Meal with 300 ppm

Hexane

TC

Model-based Predictive Controller (MPC)

Lower steam consumption in Desolvenizer/Toaster

MPC controller


65°C

73°CPID controller

100% Steam 69°C

65°C

69°CMPC controller95% Steam 67°C

65°C

85°C

Manual control130% Steam 75°C

MPC Controller for lower steam consumption: Typical temperatures of exhaust vapor


Simatic PCS 7 DCS

Centralized Structured Engineering Approach

The controller programming based on objects (motors, valves),

assignment of memory and management of function and data blocks

is handled by the system and not by the programmer.Typical DCS Characteristics are:

-

Integrated Centralized Engineering Platform for HMI/Batch/PLC/etc.

-

Object Oriented Engineering

-

Top Down Engineering: Plant Tree / Plant Explorer

-

Functional Libraries (incl. Faceplates)

-

Technological Libraries

-

Embedded Configuration Software

-

Redundancy options at all levelsDCS advantages include: Higher quality in engineering, less mistakes, higher transparency,

less individual footprint of different programmers,

no "black box programming",

clearly structured projects, easier extension,

better portability of SW, better readability of SW.


Sugar, Starch & Biofuels Portfolio & Value Added

Deep technological expertise in

sugar applications gained from

more than 50 years of experience.

NAHMAT PCS7, NAHMAT Pan Control,

NAHMAT Drives and NAHMAT MIS

Technological solutions developed and enhanced in close collaboration

with our top-customers.

Modular solution packages for the key sugar production areas enable new customers to come onboard and/or

form the basis for partnerships with EPCs

Approach:

Pre-tested process optimization solutions

(energy consumption, sugar quality, …)

Risk minimization through standardization

Integration of Technological Functions

Reporting

Diagnostics

Operation

Data Interfaces

Communication

System Layout

Automation Software

Hardware

Standardization


Standard Solutions for

Industrial Sugar Production


NAHMAT Pan Control Solution

For perfect Crystallization

Draw in /

ChargeConcentrate Graining

/ Mixing2nd Boil

/

TighteningDisch.Steam Empty

DensityLevelStirrer -

current Vacuum pressureVapour pressure

Prepare

Seed

Setpoint

Level ControlGraining time

(Slurry)

Seedpoint

max. Density

f. strike

hold

Density

Strike

end

Time to

strike

end

Strike end

by stirrer-

currentTk

1st Boiling

TdMixing time-

when

boiling

with

Footing

Actual

Startvalues

for

1 st. Boil


What means solutions business in reality?

Scope of Supply and Services

From Beet / Cane -

Yard To Silo & Dispatching

From Electrical Infrastructure / Drives / Field Devices

To IT-Solutions

Totally Integrated Automation

(TIA)

Totally Integrated Power (TIP)


Cost-effective Integrated Solutions

for the Sugar Industry

Power Generation & Distribution and Drives

Project Support

Electrical infrastructure, motors and drives, instrumentation and valves,

process control systems in combination with process know-how,

engineering experience and professional highly skilled project management.

one partner, one responsibilityuniform handlingtime and cost savingsless expenses on logistics and traininghigh quality standards

Instrumentation & Valves

DCS-System

http://www3.ad.siemens.de/bilddb/picdetails.asp?objID=23425&aktprim=0&lang=de&nodeid=10013883


BRAUMAT

The right decision

More than 30 years of experience in brewing automation

Globally available standardized automation platform

Covering the complete range

from „Micro“

to „Mega“

Breweries

including malthouses

for simple to sophisticated market requirements

Covering the whole range of recipe control

from simple parameter recipe

to recipe based implementation of complex brewing technology

Technology and life cycle is based on

SIMATIC S7-400 –

the „Heart of brewing automation“

High level of standardization, high flexibility in commissioning, low operational cost

Global network of service, support and engineering from Siemens as well as partners

References all around the world


Standard process control system with brewery-specific technology

Universal platform matched to the special requirements of the brewery industryAdded value by integration with COMOS, SIMATIC IT, asset management etc.DCS standard product for medium-sized, large and "unlimited" breweries

SIMATICPCS 7BRAUMAT

BRAUMAT CLASSIC

Based on S7Technology

BRAUMATCOMPACT

Based on PCS 7Technology

Brewery process control system for defined applications

Industrial control system that meets the needs of

small, medium-sized and large breweriesGreenfield with defined requirements profileMigration projects and brownfield

projects with heterogenic automation

Compact package, stand-alone solution for small breweries

Small breweries and partial installationsPre-defined standards for engineering and operation breweries

SIEMENS Brewery automation

BRAUMAT Portfolio


Brewery Automation

Totally Integrated Automation with Siemens

COMOSIntegrated plant design

& engineering

PCS 7 BRAUMAT

top market segment

BRAUMAT Classic cost driven markets

BRAUMAT compactstandardized package


International F&B Technical Competence

to support business development and projects

SC BreweryWuerzburgGermany

SC B & CErlangenGermany

SC F&BMannheimGermany

SC BrewerySt. Louis (MO)USA CoC F&B Nafta

AtlantaUSA

HQ F&BNurembergGermany

SC F&BLinzAustria, CEE

SC DairyMumbaiIndia

SC SugarErlangenGermany

SC Edible OilsKarlsruheGermany

SC TobaccoErlangenGermany

Technology Competence for a worldwide approach

SIASShanghaiChina


Food & Beverage Regional Focus

F&B Dedicated Sales SetupF&B HQ F&B Set-up with Project Engineering Services


Hans J. RoeslerBusiness Development Food & BeverageI IA AS S BI F&B

NurembergGermany

Phone: +49 (911) 895-6601Cellular: +49 (173) 3565743

E-Mail: [email protected]

Thank you for your attention!


Siemens Process Automation

End-user Summit 2011 Experience. Technology. Community.

Food & Beverage

References


Large Scale Dairy

Milch-Union Hocheifel

Milch-Union Hocheifel is one of the most

modern plants of the European dairy industry.

It processes over 3 million liters of milk daily.

MUH is one of the larges UHT-milk producers

with more than 700 employees in Pronsfeld.

MUH plans to double capacity in five years.


FrieslandCampina

Dairy Plant Modernization Cologne

Solution implemented in Cologne:PCS 7 for Dairy, Flexible CIP,

2 x PCS 7 Server, 3 x OS Client,

2x AS S7-400,

optical redundant Industrial Ethernet, Profibus, ET 200.

Customer Information:

FrieslandCampina is the 4th

largest

dairy company globally

1,4 Mill tons of raw milk are processed into high quality milk products.

Project Description:

Campina Cologne plant migration

of existing control systems

to Simatic PCS7

for basic dairy (milk reception, raw milk storage, service room) and CIP.

Equipment Manufacturer:

VA-Food Processing System Integrator:

KS-Systemtechnik

Initial situation:

Various automation systems within the plant

No real structured data handling within the plants and the company

Project goal:

Migration of existing control systems to Simatic PCS7

Make PCS 7 as Standard in Campina (2nd Project Gütersloh)

Value to customer:

Automatic operation of orders and material transfers

Plant status and plausibility check, safe production.

Full flexibility in creating individual CIP programs for each object. Optimal cleaning results, saving acid and time

Automated data processing replaces manual input

Electronic data archives for better analysis

Improved quality & standardized solution library: PCS 7 for Dairy


Alpenmilch

Continuous Plant Expansion and Upgrade Salzburg, Austria

Solutions implemented:

PCS 7 double redundant server,

3 x SIMATIC S7-400, Profibus-DP, ET 200S remote I/O

Hardware and software engineering,

MCC’s,iInitial

operation,

after sales support, operator and maintenance training

Customer Information:

Dairy for fresh products:

milk, yoghurt and whey,

cheese, bio (organic) products

1st Project: Renewal of pasteurization, special milk and UHT

Processing amount:: 158 Mio. liters

Continuous involvement since 2002 Project goal:

Continuous migration of Alpenmilch

Salzburg Dairy

Ongoing

cooperation

from 2002 up to now

Value to customer:

Expansion of the plant’s product range, rebuilding and

new installation of two pasteurizer lines incl. tank farms and centrifuges while the plant was running.

Hardware, software, project planning, installation, initial operation and training from one source.

Continuous addition of standardized process automation based on Simatic PCS 7 enabled product tracking and resulted in transparency and reproducibility of the production.

Increased flexibility and security by dairy compatible user interfaces. Increase of productivity through integration


Tetra Pak Processing Systems

PCS 7 as standard solution for system integration

Solutions implemented:

“PCS7 has become a very efficient, stable and attractive

Automation platform for the Food and Beverage Industry.

Tetra Pak Processing System has decided to adopt

the PCS7 system

as one of its standard platforms.

Libraries developed for Tetra PlantMaster

will now be transferred and further developed

for the PCS7 system.

The good corporation with Siemens Sweden and Siemens HQ

is also one of the good reasons. “

Value to customer: Fewer Suppliers Less complexity Better machine performance/availability

Project goal:

A more integrated system with less complexity. Same supplier for

DCS and other automation systems (PLC, HMI etc.)

Initial situation:

One supplier for DCS and another supplier (Siemens) for the rest

of the automation. Not a “Totally Integrated Automation”

system.

Customer Information: Tetra Pak is market leading global

manufacturer of Food Processing and Filling machines for the dairy and soft drink industry. Tetra Pak also produces the

Packaging Material

that is used in the filling machines


References

PCS7 in Edible Oil Industry

Customer: IOI / Loders

CroklaanLocation: Netherlands, Rotterdam

Year of start up: 2005

Project Description: Complete automation system and energy distribution in largest European palm oil refinery using Simatic PCS7 and Simatic IT

Customer: ADMLocation: Hamburg, Germany

Year of start up: Continous

cooperation since 2000Project Description: Migration to PCS7 in various steps since 2000

Customer: International Edible Oil Plant OperatorLocation: Various Plants in China

Year of start up: Since 2000 10++ plants

Project Description: Complete crushing plant and refinery automation

Customer: Dutch Crushing PlantLocation: Botlek, NetherlandsYear of start up: 2005

Project Description: Refinery and special fats plant modernization using Simatic PCS7

and Simatic IT


Customer Brazilian Edible Oil Plant

Location: Brazil

Year of start up: 2005

Project Description: Complete automation system using PCS7 and low voltage infrastructure for soy crushing plant

Customer Saipol

Location: Various locations in France

Year of start up: Since 2000 six projects

Project Description: Complete Automation Systems using PCS7 for crushing plants and other edible oil plants

References

PCS7 in Edible Oil Industry


SIMATIC PCS 7 Reference

Konya Seker

Fabrikasi

A.S. Turkey

Largest private sugar producer in Turkey

Green Field Plant in Cumra

(Anatolia)

12,000 t sugar beets per day

(corresponding ~1,700 t of sugar)

Decision for Siemens:

Siemens’

long-standing & comprehensive

know-how of plants for sugar production

Providing good local support

All products & services from single source

-

Power technology

-

Automation technology

Simatic PCS 7 one DCS system

plant-wide for all process sections

PCS 7 –

Quantities:

7 Controller (417) with ~8,000 I/O

(>90% Profibus

PA)

2 redundant OS-Server

10 Standard-Clients

Project characteristics:

Comprehensive scope of supply

-

Power Generation

(2 x

8-megawatt steam turbo-sets)

-

HV-

/ MV-

/ LV-Distribution

-

complete Field Instrumentation

-

Drives and Drive Controls

Links to different package units

(with separate Siemens PLC’s) e.g.

-

Filter Presses

-

Lime Furnace


Lousiana

Sugar Refinery, Gramercy USA

1st

new Sugar Refinery in the US after 50 years

Project Highlights Project

Decision for Siemens

Cargill Refinery project in Syria (2007/08) as successful reference for Siemens project business

was the key success factor

Technological know how is key for Cargill to execute successful project

International project execution and support driven from HQ in Erlangen, and

strong local project management & execution capability was additional deciding factor.

Siemens also supported international machine OEMs during project

execution and commissioning

Cargill wants to establish a standard for sugar project execution with Siemens as global partner.

5-6 Mio.€

Order

incl. machine supply

Technological support and

engineering package from Siemens AG HQ

Project mgmt and

execution by Siemens

Industry Inc., USA

New Sugar Refinery

PCS7 based concept

as door opener for complete

automation and drives scope

Complete drive packages

for 10 centrifuges

Complete MV and LV package


Dakahlia

Sugar Company, Egypt

This is what success looks like:


Grupo

Modelo

Piedras

Negras, Mexico Reference BRAUMAT

The brewery

:

Planned cast out of wort: 30 mill. hl

Three identical blocks of 10 mill. hl each

First block commisioned

in spring 2011

Engineering partner: Ziemann

Customer benefits:

High Production Flexibility

High-performance Operation

Keeps capital equipment/plant assets working at peak performance

Transparent information flow and scalability

http://www.logotypes101.com/files/388/0D41C62AC745811A6EBCEFF21782B0E2/lrg_grupomodelo.gif


Grupo

Modelo

Zacatecas, Mexico Reference BRAUMAT

The brewery

:

Annual production 22 mill. hl

More than 100 fermentation / maturation tanks

About 70 malt silos

OEM partner: Ziemann

Customer benefits:

High production flexibility

High-performance operation

Long-time investment protection

Local support from global player

http://www.logotypes101.com/files/388/0D41C62AC745811A6EBCEFF21782B0E2/lrg_grupomodelo.gif


Customer benefits:

Efficient engineering through long-time partner of brewery

Simple integration of existing automation of utilities

Increased flexibility due to online changeability

of the recipes by the brew master

Continuous batch reporting through central data archiving

Weldebraeu

Plankstadt, Germany Reference BRAUMAT Compact

The brewery :

Capacity 100.000 hl

8 different sorts of beer

Engineering partner: Local System Integrator

http://csd-konstanz.de/alt/img/links/welde.jpg

http://de.wikipedia.org/w/index.php?title=Datei:Plankstadt-Welde.jpg&filetimestamp=20080722103327


Hans J. RoeslerBusiness Development Food & BeverageI IA AS S BI F&B

NurembergGermany

Phone: +49 (911) 895-6601Cellular: +49 (173) 3565743

E-Mail: [email protected]

Thank you for your attention!

Documents

Experience. Technology. Community. - · PDF filePage 12 2011-08-08 Industrial Automation Systems. ... Page 16 2011-08-08 Industrial Automation Systems. Simatic PCS 7 DCS Centralized