II World Wide Pasta Congress Venezuela October 2000 PAGE 1 Totally Integrated Automation SIEMENS in the Pasta Plants Competence in Pasta Plant Automation

II World Wide Pasta Congress Venezuela October 2000

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Totally Integrated Automation SIEMENSSIEMENS

in the Pasta Plants

Competence in Pasta Plant Automation

the partner for theFlour Mill and Pasta Plants

SIEMENSSIEMENS


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PRESENTATION PROGRAM

►Introduction►Concept►Requirements►Solution►Communications►Information management►Advantages►Conclusions


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INTRODUCTION (1)

The automation of pasta plants had in these last years an important evolution.

The programmable controllers are able to integrate all the process control functions into a PLC and now into PC integrating through Profibus, peripherals as inputs/outputs, drives, intelligent devices and operator panels

The actual scenario is characterized by a Totally Integrated Automation Concept using a common hardware/software platform standard networking to satisfy the customers demand.


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INTRODUCTION (2)

The Totally Integrated Automation Concept consists in integrating under a single automation system, three important areas which till now were automated separately as:

Semolina silos (upstream) Pasta production (mainstream)

Packaging and warehousing (downstream)

Totally Integrated Automation (T.I.A.) is performing process control, recipes handling, lots scheduling, products tracing, traceability, warehousing and web connectivity.


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Raw Material

Wheat Receiving

Raw Material

Wheat Receiving

Milling

Semolina Silos

Mixing Silos

Milling

Semolina Silos

Mixing Silos

Press

Extrusion

Press

Extrusion

Drying

Cooling

Drying

Cooling

Packaging

Palletizing

Warehousing

Packaging

Palletizing

WarehousingUtilitiesUtilities

Ups

trea

mU

pstr

eam

Dow

nstreamD

ownstream

MainstreamMainstream

PLANT FLOW SCHEMATIC DIAGRAM


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Wheat ReceivingWheat ReceivingMilling

Semolina

Silos

Milling

Semolina

SilosPress Extrus.Press Extrus. Drying Cool.Drying Cool. Packaging

Palletizing

Packaging

PalletizingUtilitiesUtilities

PLANTWIDE ISSUES

Distributed I/ODistributed I/O

ControllerController

HMIHMI

Drives / Field devicesDrives / Field devices

Co

mm

un

icatio

nC

om

mu

nica

tion

Co

nfig

urin

g/P

rog

ram

min

gC

on

figu

ring

/Pro

gra

mm

ing

PCSPCS

Data

ma

na

gem

ent

Data

ma

na

gem

ent


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Handling,Packaging

Palletizing,Warehousing

Field Automation

Process Control System

Manufacturing Execution System

Enterprise Resource Planing

Semolina Silos

Extrusion,Drying,Cooling,Utilities

ARCHITECTURE STRUCTURE


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► THE CONCEPT

T.I.A. means design the plant automation introducing a new concept that has to consider the factory in its entirety.

Production flexibility, costs control and total quality approach are successful key points for small and large companies.

The target is to change a production process from a critical factor to a qualifying factor.

To perform a complete control of all the different production phases starting from raw materials receiving and forwarding to the finished products.

TIA is given an important contribution in terms of costs reduction, for revamping and new pasta plants


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PASTA PLANT WIDE ARCHITECTURE

Ethernet TCP/IP, 100 MBit

Engineeringstations

Short pasta line

ERP

Industial Ethernet TCP/IP, 100 MBit

Water treatment

Waste watertreatment

Compessedair

Cooling

Silos floor

Fieldbus system

PROFIBUSAS-Interface

MES

Boiler

Ground floor

Press Bridge

Press Foot

Cutter

Pre dryer

Dryer

Cooling/Storage

Grinding

Last floor silos

Press bridge

Flour silos

Long pasta line

Press Bridge

Press Foot

Spreader

Pre dryer

Dryer

Cooling

Storage

Packaging Palletizing

WinccClient

Grain Receiving

Milling

Sieving

WheighingSistem

Flour silos

Flour Silos

WinccServer

Milling Plant

WinccClient

WinccClient

WinccClient

Packaging

Handling Palletizing

Warehousing

WinccServer

WinccServer

WinccServer


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► PLANT REQUIREMENTS

Real time monitoring of process variables through supervisory system, and relevant corrective actions in order to guarantee high quality.

Client/server technology to address information of concurrent process to Control Room and plant Information Room in order to maximize the sinergy.

Communication and interoperability of production areas (orizontal way) and other plant departments (vertical way)

Production data provided simply and clearly to the decision level


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► AUTOMATION SOLUTION

SIMATIC S7 controllers with distributed ET200M, drives technology and field instruments linked through Profibus.

SIMATIC OP panel for distributed visualization and monitoring

Drives Technology

WINCC supervisory system based on client/server architecture with Industrial Ethernet networking

SIMATIC Industrial Software integrated through all Project Phases


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SIMATIC Controllers

More than just PLC's

• S7 300 , S7 400 , S7 400H•I/O ET200M , ET200S•Operator Panels OP27 , OP37•Profibus and Ethernet Cards


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DRIVES TECHNOLOGY


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The Multi Client server architecture

A Multi Client provides a common view ofthe process data of distributed servers in one pictureall the measured value archives, e.g. in one curve windowall the message archivesthe pictures/picture windows of different servers

WINCC SUPERVISORY SYSTEM


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WinCC Goes Web

Operation and monitoring of the plant via the Worldwide Web

WinCC WEB TECHNOLOGY

VENEZUELA H.Q.

USA Plant

INTERNET

MEXICO Plant


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ENGINEERING STARTS WITH TOP-DOWN DESIGN OF YOUR SYSTEM

Plant / SystemPlant / System

Unit OperationUnit Operation

Equipment GroupEquipment Group

Device / LoopDevice / Loop

- Overall plant architectural structure - Control strategy- Operator visualization- Local operator panels- Peer communication- Field devices, including transmitter parameteriz.- 3rd Party PROFIBUS devices

THE SIMATIC MANAGER IS THE SINGLE TOOL

TO COORDINATE THE COMPLETE TIA SYSTEM CONFIGURATION


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S7 400

AUTOMATION SYSTEM TOPOLOGY FOR LONG PASTA LINE

WIN CCINDUSTRIAL ETHERNET

PRESS DRYER/PREDRYER COOLING/STORAGE SPREADER

DOSING SYSTEM

MIXER

EXTRUSION SCREWUP TO 4

PRESS BRIDGE PRESS FOOT

REMOTE I/0ET200

REMOTE I/0ET200

REMOTE I/0ET200

PROFIBUS-DP

REMOTE I/0ET200

FAN

CHAINE MOTOR

REMOTE I/0ET200

OP OP


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Distributed I/O systems save up to 20% of the wiring costs:

A family of distributed I/O systems provides the right I/O for the right application and reduces wiring costs

distributed motor starters and drives used in the pasta lines allow distributed wiring of the power bus

Savings in wiring costs

20%

Co

st f

or

wir

ing

REDUCED INVESTMENTS IN THE PASTA PLANT

DISTRIBUTED I/O SAVE WIRING COSTS


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Each supervisory station can handle supervision functions of the entire plant in addition to graphic pages, recipes handling, data archiving real time/historical trending, alarming.

Comunication and interoperability are key factors for data flow from orizontal way to vertical way.

To achieve production flexibility , for successful growth, of small, medium and large companies

►COMMUNICATIONS (1)


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With T.I.A. concept and relevant networking /communications we can assure data flow from process level to supervisory and management level, from incoming raw materials to the finished products.

It means :

- Right info

- To right people

- At right time

- At right place

In any kind of pasta plants

►COMMUNICATIONS (2)


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TYPICAL SYSTEM TOPOLOGY FOR PASTA PLANT

WINCC

Multi Client

ETHERNET

WINCC SERVER

WINCC SERVER

PROFIBUS DP PROFIBUS DP PROFIBUS DP PROFIBUS DP

SHORT PASTA LINE

IND.ETHERNET

SHORT PASTA LINE LONG PASTA LINE LONG PASTA LINE


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VERTICAL INTEGRATION– TCP/IP, @aGlance, ODBC, SQL, OPC,

Net DDE...– Web Browsers, intra / internet...– Gensym bridge...– SAP R/3 PP-PI…

HORIZONTAL INTEGRATION– Ethernet, PROFIBUS,, ASi-Bus

DATA MANAGEMENT STANDARD INTERFACING APPROACH


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► INFORMATION MANAGEMENT

MES and ERP Connectivity in order to have plant information and management decision support

Process optimization and data analysis

Web connectivity for remote information and production control

Certified module for linking to SAP


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MAIN FEATURES:

- process data acquisition

- data analysis

- process optimization

- certified module for linking to SAP

MAIN BENEFITS:

- improved production quality

- improved process diagnostic

OperationOperationManagementManagement

DraftDraft

Model

Intelligent Production Systems

Profound Process Knowledge

Integrated Software and Services

Platform Independence

PCS

Process Control Systems

Field Instrumentation & Operating Control

ERPCross-Company

Resource PlanningSupply Chain

Management & Business Systems

COMPLETE INFORMATION MANAGEMENT WITH INFOPLUS.21


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► THE ADVANTAGES

It is able to satisfy adequately the requirements to operate and manage integrally the plant.

It trasforms the process control into plant production control with a single system solution.

It is garanted quality and HACCP certifications

It can begin from a minimum architecture of one to several lines, of a small to a large plant.

It reduces costs and spreads the investments according to plant growing, with an interesting pay back.


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INCREASING EFFICIENCY IN THE PASTA PLANT

E.U. ADVANTAGES:

Central control room to control upstream, mainstream and downstream areas data production

Repetitive quality and relevant improvement

Fast trouble shouting (more lines availability)

Less Spare parts (maintenance costs reduction)

Energy saving

The Totally Integrated Automation advantages are the followings:


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COSTS REDUCTION IN THE PASTA PLANT

ENERGY SAVING

OUTPUT QUALITY

LESS HUMAN RESOURCES

Due to optimization of motors control according to production needs (less power consumption using drives technology)

Repetitive quality and relevant improvment ,due to integrated process control and less reject during shape change

Fast trouble shouting ,less spare parts,resources optimization due to T.I.A. concept,central control room, diagnostic systems, intelligent allarms


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► CONCLUSIONS

T.I.A. concept will give an important contribution in terms of costs control and cost reduction.

T.I.A. concept will increase the possibility to build up new plants in new geographical areas where there are new markets with less specific experience

The experience tipically of the Mediterranean countries is now available using T.I.A. concept in the ROW.

By using T.I.A. both the pasta lines manufacturer and pasta producer can achieve important market advantages.


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SIEMENSSIEMENS Thank for your attentionThank for your attention

Contact A&D Competence Center Food & Beverage - Mill &PastaAntonio Rossetti :phone +39 02 66762933

Massimiliano Andreoli :phone +39 02 66762889 fax +39 02 66762916E-mail to [email protected] [email protected]

Documents

II World Wide Pasta Congress Venezuela October 2000 PAGE 1 Totally Integrated Automation SIEMENS in the Pasta Plants Competence in Pasta Plant Automation