The world’s largest plant for themanufacture of formaldehydebegan operation at BASF AG’ssite in Ludwigshafen in Decem-ber 2000. With an annual capaci-ty of 180,000 tons, the new plant,established to meet the growingdemand for formaldehyde, is set-ting new standards. Its size, tech-nology and economy make it no. 1 in the world. Its automationtechnology also had to be capa-ble of meeting these high de-mands. That is why BASF decidedto use the future-oriented Simat-ic PCS 7 process control systemfrom Siemens.

Formaldehyde, one of the mostimportant key chemicals in thechemical industry, is one of the

initial ingredients in many end prod-ucts. It is a very versatile component,from which many different productssuch as solvents, resins and plasticscan be manufactured. BASF is Eu-rope’s market leader in the manufac-ture of formaldehyde, producingover 400,000 tons of it at its existingplant in Ludwigshafen in 1999.

existing plant sections was modern-ized at the same time and integrated,along with the new plant, into thecompany-wide flow of information.

Excellent price/performanceratio

The selection of the automationsuppliers for this project was a verycareful process. After very detailedcomparisons of all the tenders, BASFdecided on the Simatic PCS 7 processcontrol system from Siemens.“PCS 7 did not only meet all thetechnical requirements, but it alsohad the best price/performance ratioof all the bids,” explains Georg Deck,

BASF maintenance and service man-ager for the formaldehyde plant inthe field of process control technol-ogy. For Dr. Klaus Pandl, Opera-tions Manager of the formaldehydeplant, the numerous references, evenon an international level, were thedeciding factor and the proof thatSiemens had the necessary expertisefor this project.

A demanding project

Even at the beginning of the plan-ning phase, BASF formulated thehigh requirements which would beplaced on the new process controlsystem. Both the existing production

Due to the growing demand forformaldehyde, BASF decided to in-crease its production capacity and tomodernize existing facilities. Thenew plant complex for formalde-hyde at Ludwigshafen comprisesfour production lines and a tankfarm. Two production lines whichexisted prior to the modernizationand the tank farm were equippedwith the latest technology, anotherline was built completely fromscratch. To expand formaldehydeproduction in Ludwigshafen, theBASF project team decided to inte-grate a new plant into the existingproduction. The automation of the

lines which were equipped with verydifferent instrumentation and thenew plant would need to beequipped with state-of-the-art tech-nology and the existing measuringtechnology was, as far as possible, tobe reused. The different levels of theinstalled technologies required acarefully thought out concept. “Thegoal was to come up with a future-oriented solution having maximumfunctionality, flexibility and cost-ef-fectiveness.” says Arno Keller, the re-sponsible sales engineer at Siemens,

Process News8th Edition February 1 2001

I N F O S , N E W S A N D T R E N D S F R O M T H E W O R L D O F P R O C E S S A U T O M A T I O N

CCononttenentsts

Dear readersThis past year was an eventful one. The faceof Siemens process automation has changed.Through the numerous acquisitions we wereable to considerably expand our range ofproducts, systems and solutions and increaseour expertise. The integration of the newSiemens companies is as good as completedand our range of products and services isavailable to you wherever you are in theworld. This magazine reports in detail on ournew strengths. In particular, we consider theexpansion of our process technologyexpertise as a result of the acquisition ofAxiva a decisive advantage for our customersin the process industry. Our business in theUSA is doing well. Numerous references provethat our Simatic PCS 7 process control systemis also making a name for itself there. Ouractivities in the US are supported by SiemensMoore, which is already well known for itsAPACS+ control system. The New Force is ourmotto for process devices. Everything thatcan happen in a year, we are showing you in anew special insert to this magazine called‘Take a good look at us now’.

The editorial team

Applications

B 2 Degussa-Hüls:Perfect process management

B 3 Axiva intensifies Siemens skills

B 4/5 USA business:– APACS+, new in Siemens

process control

– RONA: safe explosivesproduction with Simatic PCS 7

– Novartis: Simatic PCS 7 in a new pilot plant in EastHanover

– Genentech: APACS+manufacture ofbiopharmaceuticals

B 7 Carlam: integrated field busapplication in Belgium steelindustry

Maxum: process gaschromatographs used in Canadian College

Products

B 6 Simatic ET 200iS: DistributedI/O device for the Ex area

Simatic Controller S7-400F/FH:standard and safety technology

Product selector: service offer on the Internet

From around the world

B 8 Success stories, Stop press, Trade fair calendar, Net News

Superlative productionWorld’s largest formaldehyde plant, owned by BASF, uses process control system Simatic PCS 7

from Siemens

(Continued on page 2)

with SPECIA

L ENCLOSURE

“The New Force“

Field In

strum

entatio

n for

Process A

utom

ation

Profibus and the Simatic PCS 7process control system facilitateefficient process managementand the smooth running of a newDegussa-Hüls plant inRheinfelden.

M ore than 50 years ago, De-gussa-Hüls filed a patentapplication for a high-

temperature process for the manu-facture of extremely fine oxide.Since the 1950s, the product, knownas AEROSIL, has also been manu-factured commercially and is usedin products such as paints, printinginks and plastics.

Globally, Degussa-Hüls producesAEROSIL at five sites. As demandhas increased dramatically in recentyears, Degussa-Hüls has decided toincrease its production capacity atRheinfelden.

Expert partner

As part of the new build project,Degussa-Hüls sought an expertpartner for the development andimplementation of an innovativecontrol system architecture. Criti-cal criteria included openness andcontinuity as well as simple engi-neering. After detailed compar-isons, Degussa-Hüls decided to au-tomate the new plant using SimaticPCS 7 and Profibus-PA.

The pivotal and central points ofthe automation are two AS 417-4automation stations. Two redun-dantly configured process operat-ing stations communicate with the

automation stations via a fiber op-tic industrial Ethernet network.The central engineering station isalso connected via the Ethernetnetwork.

The field level is connected to thecontrol level via a redundant fiberoptic Profibus-DP ring. The systemuses several Simatic ET 200M de-vices to collect the digital signals,Simocode DP for the integration ofthe drive in the Profibus-DP net-work and the Profibus-PA field bussystem for the connection of thefield devices in explosion hazardousand non-hazardous areas.

Smooth integration

Degussa-Hüls and Siemens em-ployees worked closely togetherthroughout the project. The contin-ual and uniform Profibus conceptenabled both the planning and com-missioning times to be significantlyshortened. The Degussa-Hüls em-ployees were particularly impressedby the Simatic PDM software toolfor parameterization and operationof the process devices. The tool,which is wholly integrated in theSimatic PCS 7 control system, makesit possible to parameterize and main-tain all intelligent field devices with

Profibus-DP/PA capability from acentral point.

Because, in addition to cyclical da-ta such as measuring values and de-vice status, diagnostic data can also betransferred via Profibus. Service per-sonnel can call up all the relevant da-ta on any individual field device atany time. This assures that a higheravailability of the plant is achieved.

Further projects planned

The new production plant was com-missioned in March 2000 and hasoperated smoothly since then. Thesmooth (efficient and problem free)flow of the entire planning and com-missioning phase and the overallpositive experience which Degussa-Hüls gained have already bornefruit. For example, the new plant’scontinuous smooth operation. Hence,Siemens and Degussa-Hüls are nowplanning to work on further projectsusing Profibus-PA and SimaticPCS 7. C

Jürgen Giegerich, Siemens Frankfurt

describing the challenge. As a resultof the close and mutually fruitful co-operation in the planning phase, itwas decided to use a remote I/O sys-tem to connect the field level in thenew plant.

The 25 remote I/O systems werejointly designed by BASF andSiemens and adapted to the needs ofthe formaldehyde plant. The signifi-cant focus was placed on uniform

structure and sufficientreserves for future ex-pansion. The require-ments of an outdoorplant and the regula-

tions for the installa-tion of the remote I/Osystems directly in explo-

sion hazardous areas (Zones 1 and 2)had to be considered.

The straightforward integrationof the distributed peripherals in theSimatic PCS 7 process control sys-tem was essential in this plant. Thedistributed Simatic ET 200Mrecords the electrical signals of theexisting plant sections, already part-ly available in the switchroom. Themodular system is ideal for distrib-uted installation and can be used onsite either in switchgear cabinets orin an open configuration, e.g. direct-ly behind the terminal blocks. This iswhy the ET 200M system is the idealsolution for cramped spaces. In theother plant sections and in the newplant, the Stahl I.S.1 remote I/O sys-

tem was used in the explosion haz-ardous zones 1 and 2. For both theET 200M and I.S.1, communicationwith the automation system isachieved via the powerful Profibus-DP field bus. The fact that the pro-ject engineering of these differentI/O systems takes place in uniformgraphic form in the engineering sys-tem, and that no additional engi-neering bus is required for commis-sioning, demonstrates the strengthsof the Simatic PCS 7 process controlsystem.

Some field devices were also in-cluded in the Siemens delivery. Inaddition to the Sipart PS positioners,the Sitrans P pressure and differen-tial pressure transmitters as well asthe Sitrans F ultrasonic flowmeterswere also installed in the formalde-hyde plant.

Modification in several stages

The actual modification of the exist-ing plant and construction of thenew plant were carried out in sever-al stages. First, the central plant sec-tions such as the tank farm weremodernized. Then the new plant wasconstructed, followed by the step-by-step commissioning of the au-tomation systems relating to theplant sections, along with the dis-tributed I/O peripherals. Thanks tothe modularity of Simatic PCS 7,every production line could be con-figured with its own automation sys-tem. Communication of the individ-ual systems with each other via In-

dustrial Ethernet, or Profibus-DPwith the distributed peripherals, re-duced expenditure on cabling dur-ing installation and commissioningand also contributed to the rapidrenovation phase. Thanks to theopenness of PCS 7, the existingstructures could be easily integrated.The last checks were carried out atthe end of 2000, before the entireformaldehyde plant went online.

The decision to award the entireproject, from the detailed engineer-ing to assembly and commissioningto one supplier, was with hindsight,the right one for Dr. Klaus Pandl andGeorg Deck.

The result of the completion ofthe modernization and expansionof the formaldehyde production at BASF is a state-of-the-art plant,which is also best equipped for fu-ture projects thanks to the use ofstandardized components and themodular and scalable Simatic PCS 7process control system. “It is easierand more cost effective to controlseveral production lines and plantsections via just one control system.It enables us to increase productionvolumes without additional workfor our staff,” explains Dr. KlausPandl.

Through the unifying of the op-erating and maintenance conceptacross the entire formaldehyde pro-duction, the handling of the planthas been made considerably easier.Even before the plant was com-missioned, Siemens held trainingcourses for the operators to famil-iarize them with the new system. Allthis led to a lively exchange of ideasand numerous suggestions from theoperators were considered in theconcept.

The next project

Upon completion, all participantsdeclared the project a success. Thesuccessful partnership between BASF

2 Process News 1/2001

A fine thingSimatic PCS 7 and Profibus PA at Degussa-Hüls

and Siemens will be continued as thenext expansion of formaldehydeproduction is already planned. C

Arno Keller, Siemens Mannheim

Cornelia Dürrfeld, Editor

Successfulcompound

conceptComplex compound structuresand a market-oriented productrange are the basis for the suc-cess of the BASF Group which isrepresented on all continentswith more than 100,000 em-ployees.

• The latest productionmethods and their own rawmaterials guarantee highquality and deliveryreliability of the production

• The networking of energyand material flow allowsefficient utilization of theimplemented raw materials

• This reduces plant waste to aminimum

• This saves transport costsand time.

Example Ludwigshafen

With almost 8 square kilome-ters, the Ludwigshafen site is thelargest single chemical site in theworld. Here, BASF manufac-tures 8000 retail products with atotal quantity of about 8 milliontons. Two thousand kilometersof overground pipelines distrib-ute heating gas, steam, raw ma-terials and by-products to theindividual production plants.

(Continued from page 1)

Superlativeproduction

With the major takeover of the process and engineeringtechnology supplier, Axiva,Siemens has once again proventhat it is continuing to pursueits aim of being a leadingsupplier to the process industry.The first step came with theacquisition of AppliedAutomation, Moore andMilltronics – a clearstrengthening of its range ofproducts and market presence,but these changes are only onestage. Working in closecollaboration with the processindustry, changes experiencedby customers must be takeninto consideration andsolutions to them sought.

G lobal competition, produc-tivity, increased cost pres-sure – these are the chal-

lenges which companies must faceon a daily basis. They are forced toanalyze their own process flows andto continually improve them. Cur-

rent regulations and working meth-ods are questioned and adapted tochanging conditions and require-ments. This is the same for all com-panies.

For Siemens, as an importantsupplier to the process industry, thisapplies in two respects. It influencesthe formation of its products, but al-so dramatically changes the cooper-ation between supplier and cus-tomer.

The repercussions of thesechanges are new technology, newfunctionalities and in particular,new interfaces to superior systems.The basic requirement for the devel-opment of new automation technol-ogy products and concepts in a com-pany is, in addition to the automa-tion technology and the system inte-gration, a deep knowledge of theprocess technology.

New partnerships

It is also worthwhile being a partnerwith the customer in all optimiza-tion processes, whether it involves

the development and the construc-tion of new plants or the optimiza-tion of individual processes or exist-ing plants. In order to create the nec-essary freedom to concentrate on itscore business, Siemens must intensi-fy and expand its process technolo-gy skills in addition to its well knownautomation skills. Individual sec-tions and phases in the constructionof a plant are no longer clearly sepa-rated. It is now more common forinterdisciplinary teams to work onall phases of a project. Such a work-ing method opens up potential formore efficient project managementand makes new solutions possible,yet places greater requirements onall participants. This means, for ex-ample, that automation engineersmust have a detailed knowledge ofprocess technology. For Siemens, itmeans that it needs to strengthen itsown skills in this area in particular.

With the acquisition of Axiva,Siemens now has access to processtechnology expertise as well as au-tomation skills and is therefore in a

SiemensAxiva

With around 570 employeesand an annual turnover of ap-prox. EUR 77 million (1999),Siemens Axiva GmbH & Co.KG, Frankfurt/Main, is a lead-ing supplier of process andengineering services for theprocess industry. Its servicesinclude technology develop-ment and implementation,project management and pro-cess consultancy, as well as thesetting up of individual pro-duction processes, particular-ly in the chemicals and phar-maceuticals sector. SiemensAxiva emerged from what wasformerly Hoechst AG andsince 1 October 2000 has beena subsidiary company of theSiemens Automation and Drives Division (A&D). Witha turnover of EUR 7.9 billion(according to preliminary cal-culations) in the financial year2000 (30 September), A&D isthe world’s leading manufac-turer in this sector. C

The world’s largest plant for thedistribution of purified watersupplies 17 pharmaceuticalcompanies in the Höchstindustrial park around the clockwith purified water. Workingwith the client Infraserv, SiemensAxiva’s scientists and engineerssolved a fundamental logisticalproblem – how to maintain thequality of the water during itstransportation.

P urified (ultra-pure or sterile)water, which is water with avery high level of purity, is

one of the most important con-

stituents in the production of phar-maceuticals. The purity of this wateris of great importance because mostdrug returns are traced back to in-adequate water in the productionprocess.

Sterile system

At the start of the process at theHöchst industrial park is a centralpurified water plant which preparesspring water with a drinking waterquality of such a degree that it fulfilsthe quality standards specified in thepharmacopoeia. The major techni-cal challenge for the Siemens Axivaengineers was to distribute the waterto the various companies on the 4 km2 site without loss of quality.

With a total of 13 km of sterilepipes, the distribution system is thelargest of its kind in the world. Afterexiting the generation plant, the wa-ter is conveyed via a main closed cir-cular pipeline to four decentralized

equalizing reservoirs which regu-lates peaks in water consumption.Each of these reservoirs supplies upto five of the 17 companies via a sub-pipeline. In order to minimize thegrowth of germs, around 500 m3 ofwater is constantly circulated in thepipelines even during times of nodemand. This is done by 13 sterilepumps with five redundant pumppairs.

Revolutionary process

As a further measure to hinder thegrowth of germs, the water isozonized at several points in the cy-cle. The ozone generators work ac-cording to the process of catalyticwater electrolysis. Special through-put electrolysis cells ensure on-siteozonization which does not requireeither oxygen or cooling water. As aresult, the operating costs are lowand the process is quite safe, techno-logically speaking.

3Process News 1/2001

Doing justice to changeSiemens intensifies its process technology skills with Axiva

The purest waterSiemens Axiva produces plants for purified water

Siemens Axiva has created theworld’s largest water plant function-ing exclusively with electrolysis cells.“With certainty, we have laid thefoundation for exclusive use of elec-trolysis cells in this type of plant inthe future,” emphasizes Dr. MichaelEwers, Project Manager at SiemensAxiva.

The entire plant is controlled bythe Simatic PCS 7 process controlsystem which consists of 2 operatingand 5 process stations. These arelinked together by a fiber optic in-dustrial Ethernet network. Both theconsumer’s consumption data andthe measuring values for the in-linecontrol of the water quality run inthe control system. Data is processedfrom 260 measuring points, config-ured in 20 buildings located acrossthe site. C

Dr. Michael Ewers, Siemens Axiva, Frankfurt

position to advise customers in de-tail on all changes and to providethem with support. The bundledskills of automation and processingtechnology also enable the customerto reduce the number of partners re-quired for the implementation ofprojects.

Optimization across the entirenet product chain

All efforts are focused on supportingthe customer in every phase of theconstruction of a plant. In the devel-opment, realization or implementa-tion, as product or system supplier,in the framework of an overall pro-ject or in the optimization of indi-vidual processes, either as a consul-tant or a general contractor.

With its involvement in Axiva,Siemens is underlining its knowl-edge of the changes in the sector andits desire to be a true trendsetter and,therefore, a future-oriented partnerfor the process industry. C

Ruud Ijsselstein, Siemens Axiva Frankfurt

Laboratory development Pilot plants Process development Basic engineering Detailed engineering Construction and assembly Startup

More than 3,500 APACS+ instal-lations prove the strength of theMoore process control system,particularly in the life sciences,chemicals, petrochemicals, oil & gas, cellulose and paper aswell as energy generation sectors.Robustness, reliability, anexcellent batch concept andopenness are the excellentcharacteristics which have madeAPACS+ so successful to date.

T he versatile, scaleable APACS+process control system basedon Windows NT offers con-

tinuous control, batch control and“Fail Safe” (QUADLOG) protec-tion on one common platform. Thescalability ranges from a systemwith an operator system and 100I/Os to a system with hundreds ofclients, dozens of servers and thou-sands of process control technologypoints.

This universality and scalabilitydoes not just reduce hardware costsbut also expenditure for engineer-ing, integration and maintenance isalso considerable less. Moreover,each plant can be expanded at com-parably low cost thanks to the mod-ularity of the hardware.

Open and adaptable

An open architecture as well as flex-ible redundancy options make itpossible to adapt the control systemextremely cost effectively to individ-ual applications. The point of this:APACS+ facilitates the integration,almost without cost, of ‘best-in-class’ products via a so-called frame-work. Guaranteeing maximum avail-ability and at the same time keepingthe costs as low as possible is an artwhich few can manage. APACS+ is

With the purchase of MooreProducts, Springhouse, USA,Siemens has not only expandedits product portfolio and consid-erably increased its process con-trol technology skills. The acqui-sition of Moore has also enabledit to develop its worldwide pres-ence in the field of process au-tomation. The merging of bothcompanies meant an importantintensification, particularly inthe US, Canadian, UK and AsiaPacific markets.

M oore Products, which hasbeen owned by Siemenssince March 2000, has

long been one of the leading suppli-ers of process, measurement andcontrol technology in North Ameri-ca and is creating many new oppor-tunities for Siemens AG.

Increased skills in controltechnology

An important reason for the pur-chase of the US company with its1,200 employees was the expectedintensification of the control tech-nology expertise in all sectors ofprocess technology. Moore, founded40 years ago, has essentially alwaysbeen a supplier of process controltechnology solutions and has con-tinued to develop its expertise in thissector over the years. Moore’s em-ployees, used to providing cus-tomers with solutions and workingclosely with them, are very familiarwith the requirements of the processindustry.

One of the results of this controltechnology expertise is the APACS+

control system. The particularstrengths of this system are its open-ness and its adaptability to all sec-tors. APACS+ has particularly pro-ven itself in the chemical, life sci-ences, paper, oil & gas as well asenergy generation sectors. So it isnot surprising that Genentech Inc.,one of the US’s most important

biotech companies, has decided onAPACS+. The particular character-istics of APACS+ are the batch con-cept developed by Moore which hasachieved its current range as the re-sult of years of experience in inter-national projects, as well as theQUADLOG safety system which canbe seamlessly integrated into the

APACS+ process control system andwhich fulfils the highest safety re-quirements (up to TÜV AK6/SIL3).APACS+ expands the Siemens

4 Process News 1/2001

Protecting investmentMoore intensifies Siemens expertise in process control technology

one of the few. The system redun-dancy can be tailored precisely to theindividual application: APACS+ of-fers a wide range of redundancy op-tions from standard redundancy viaselective redundancy of criticalfunctions to full system redundancyin all networks, controllers, serversand client applications.

Comprehensive features makeAPACS+ also one of the most reli-able and robust systems which willrun trouble free for years in thetoughest industrial environments.Should a fault occur, APACS+ isequipped with comprehensive diag-nostic facilities in order to quicklyidentify and deal with the problem.

Reliable is reliable

The integrated ‘fail safe’ QUADLOGcontrol and the batch functionalityare excellent features of APACS+.QUADLOG is TÜV approved andfulfils the highest safety require-ments (up to AK6/SIL3). The sim-

Robust,reliable and adaptable

APACS+, a new addition to the Siemens family of process control technology

Siemens Moore Demo-Center

Springhouse, PA, USA

process control system Simatic PCS 7in many different ways. The Siemensprocess control system based on To-tally Integrated Automation con-tributes all Siemens’ expertise in thearea of automation technology andis the open control system whichconnects the manufacturing tech-nology world with that of processtechnology.

Guaranteed investmentprotection

With a common installed basis ofoverall 5,000 systems, Siemens feelsobliged to its customers. In ordernot only to maintain the strengths ofthis expanded product portfolio andthe skills in the field of control tech-nology, but even to consolidate it,both control systems will first of allbe further developed with the aim ofstimulating them mutually. A firststep in this direction was the equip-ping of APACS+ with a Profibus in-terface and therefore the integrationinto the Siemens automation worldof Totally Integrated Automation.All future activities are organized toprotect customer investments.

The synergies resulting from themerger are not just of benefit to thecustomer with respect to system de-velopment. Customers also benefitfrom process control and automa-tion technology skills in sales, sup-port and consulting. C

André Bouffioux, Siemens Karlsruhe

plest to implement batchfunctions cover simple batch-es to the most complex batchprocesses. As APACS+ canrun both batch and contin-ual processes, the controlsystem is best suited for allprocess technology sectors.

One of the further devel-opments of APACS+ will beits integration into the au-tomation world of Totally In-tegrated Automation. Con-nection to Profibus-DP andOPC interfaces is alreadyavailable. C

Rich Dunbar,

Siemens Moore,

Spring House, USA

Paperless Production

“What drove me was I felt we coulddo a better design,” says Hans Kon-ing-Bastiaan, Genentech AssociateDirector of Automation. “Bettercontrol over the product, a moreflexible facility, reduced cycle time,and an electronic database thatcould become the beginning of elec-tronic records.” Through the use ofelectronic signatures and records,Genentech manufactures in a pa-perless environment. Genentech’sinnovative paperless manufactur-ing, fully approved by the FDA, is atthe forefront of biopharmaceuticalproduction and an aspiration forother biopharmaceutical manufac-turers. C

Tom Patrick, Siemens Moore,

Bridgewater, USA

The Holsten Army AmmunitionPlant in Kingsport, Tennesseemanufactures high explosives formilitary purposes. With the mod-ernization of the process au-tomation, Simatic PCS 7 guaran-tees safe and clean production.

S ince 1999, the production ofexplosives in Kingsport hasbeen wholly in the hands of

RONA (Royal Ordnance NorthAmerica) which manufactures thehigh explosives HMX and RDX forthe US military at the Holsten ArmyAmmunition Plant. One of thecompany’s first tasks was to mod-ernize the entire plant from theground up in order to make theplant more efficient and flexible.

Part of this modernization wasthe installation of a new and com-pletely universal process control sys-tem. After comprehensive compari-son, RONA decided on the SimaticPCS 7 system. “One of the decidingarguments for this system was themajor operational safety and the

comprehensive performance rangeof PCS 7. With PCS 7, we have aturnkey solution including powerfulcommunications networks,” ex-plains Jeff Pierson, senior engineerat RONA.

Safety is critical

Operational safety is of critical im-portance in the manufacturer of ex-

plosives. The process which takesplace in several stages is partiallyexothermic. A failure of the processmanagement could easily lead to theformation of an explosive mixture inthe truest sense of the word – withpossible devastating results. Pre-venting such an occurrence is thetask of the Simatic PCS 7 processcontrol system.

The plant is operated via a total ofthree operator stations in a centralcontrol room and one operator sta-tion in each of the four main plants.A redundant Simatic S7-417 con-troller, four Simatic S7-416 con-trollers and a Simatic 545 PLC con-trol the plant’s processes. Thesecomponents communicate witheach other via Industrial Ethernet.

The experts at RONA were con-vinced by the easy operation of thenew system, both at commissioningand during continuing production.“With PCS 7, the production recipescan be quickly altered. We can nowalso manufacture several products inparallel which wasn’t possible be-fore,” says Roger Williams, Produc-tion Team Manager, summing upthe advantages of the new solution.

Soon to be completely universal

By the end of 2000, the moderniza-tion of the ten production linescould be successfully completed, butthey are already thinking about thenext project section at RONA. “We

also want to includethe acid plant and thewastewater treatmentplant in the new system,”says Tony Hewitt, Directorof Commercial Development

at RONA, “then all the processes willbe part of a universal automationsolution.” C

Ulrich Seidl, Siemens Moore,

Spring House, USA

5Process News 1/2001

After a successful project at theSchweizerhalle site, Novartis isnow also turning to the flexibleand modular Simatic PCS 7process control system in theUSA. A new pilot plant in EastHanover, New Jersey, was com-pletely automated from the fieldinstrumentation to the controltechnology by Siemens Moore.

T he new plant at East Hanoveris a pilot plant for the manu-facture of small amounts of

active substances, primarily used fortoxicological studies and clinical tri-als. The results of these tests formthe basis for the research and devel-opment of new drugs. The plantmust be in a situation to producethese active substances in the neces-sary quantities within the shortesttime. This means that it must bepossible to change process manage-ment and recipes quickly andsmoothly. Flexibility was also a de-ciding factor (decision criteria/re-quirement) when Novartis decidedon the automation of the plant.

A true turnkey package

With the PCS 7 process control sys-tem, Novartis decided on an au-tomation solution which had al-ready proven its quality in compara-ble systems. Typically the plant ismanually operated with the operatorable to access preconfigured stan-dard work flows such as sterilization,pressure checking or inerting.

Novartis did not just commissionSiemens with providing the processcontrol system but also the configu-ration and project engineering, test-

ing, commissioning and the fac-tory acceptance test. In addition, 170 field units are connected viaProfibus in the control system. Inaddition to the actual production,Siemens Moore also automated thesupply equipment and the connec-tion to devices of other manufac-turers.

Validation included

One of the most important issues inthe project engineering commis-sioning and operation of the plant in East Hanover was its validation.The statutory requirements such asCGMP (Current Good Manufactur-ing Practices) and Novartis’ require-ments with regard to them had to befulfilled. The knowledge and expe-rience which the employees ofSiemens Moore Process Automationcould offer herewere the decid-ing factors indeterminingthat Siemensreceived the con-tract. When thefinal work hasbeen complet-ed on the newplant, the nextgeneration of pharmaceutical activesubstances will be produced in EastHanover. With the Simatic PCS 7process control system, this pilotplant is in the best hands. C

Wolfgang Neitzke, Siemens Moore,

Spring House, USA

Genentech Inc. is a pioneer inthe field of genetics andbiotechnology. Holding morethan 3,600 patents and withanother 2,600 pending,Genentech is a truly innovativeenterprise.

G enentech was one of the firstbiotechnology companies tosuccessfully scale-up protein

manufacturing processes from thesmall quantities used for research tothe much larger quantities neededfor clinical trials and marketing.

Genentech’s new plant in Vaca-ville, California became operationalin 1999 and received FDA licensurein April 2000. Siemens Moore se-cured the contract to automate theentire manufacturing facility. Thefully redundant process automationsystem consists of the APACS+

Batch System controlling over8500 I/O. Siemens Moore alsoprovided project services in-

cluding the design, specifica-tion, integration, configuration,

test execution, validation, andstart-up assistance.

Automation with ISA S88.01

Maximum possible plant flexibil-ity was the major considerationduring all phases of the project.The system enables a flexiblebatch plant with easychangeover between multi-ple products. The imple-mentation of reusable gener-ic software modules reducedconfiguration, documenta-tion, testing and validation

efforts. According to a case studypresented at World Batch Forum,this methodology saved Genentechapproximately $4.7 million duringthe project’s implementation.

Following the recipeSimatic PCS 7 at Novartis in the USA

Batch by BatchThe APACS+ Batch Control System at Genentech

ExplosiveSimatic PCS 7 provides RONA with safe explosives production

S imatic S7400-F and S7-400FHare based on the powerfulCPUs of the redundant S7-400H

automation system and comply withthe SIL 3 safety requirements in ac-cordance with IEC 61508, Cat. 4 ac-cording to EN954-1. In addition tothe automation and communicationtasks, the CPUs also take care of thesafety cycles. The CPU program-ming tool and the fail-safe peripher-al modules provide the safety-ori-ented functionality.

The safety functions can be cre-ated using the pre-assembled fail-safe basic function modules whichare TÜV approved and supplied inthe F library. These modules can be

may be necessary for non-intrinsi-cally safe lines under some circum-stances can be omitted.

Up to 64 analog or 128 digital sig-nals can be connected per I/O de-vice. The fine modular structure ofthe device offers optimum flexibili-ty. A Simatic ET 200iS station con-sists of an explosion proof powersupply unit, an interface module forProfibus-DP according to RS 485,up to 32 electronic modules and abus termination module.

Low engineering expense

Users appreciate a consistent, simpleengineering which saves consider-able costs. As a standard slave onProfibus-DP, ET 200iS can of coursebe operated on any standard master.It goes without saying that the inte-gration is optimized for the SimaticPCS 7 process control system fromSiemens – the necessary drivers willbe part of the standard PCS 7 equip-ment. Field devices with HARTfunctions can be connected easilyand can be parameterized by Simat-ic PDM. The HART status and oth-er information will be passed on di-

6 Process News 1/2001

Our new Internet service helpsyou select the rightinstrumentation product for yourapplication quickly and easilyfrom the Siemens product rangefor process instrumentation andanalysis.

T he product selector accessiblevia Internet at http://it-spa.khe.siemens.de/default_en.htm

is a tool which supports efficientengineering and additional elec-tronic processing. The tool providesthe user with the correct orderingnumber as well as specific technicaldata without having to sift throughboring catalogues.

The integrated configurator canalso help select the correct options

for configurable products. With asimple mouse click, the selectedproducts may be placed into an elec-tronic shopping list where the prod-uct number, clear text designation,selected quantity and other detailsare displayed.

For further processing, the listcan be downloaded to your PC inWord or Excel format. Using an In-ternet acquisition tool from SAP onthe product sector, all the informa-tion can be transferred directly viathe OCI interface into your system.

Information about connecting toan Internet acquisition tool or Inter-net market places can be obtainedfrom rafael.winter@khe.siemens.de.C

Rafael Winter, Siemens Karlsruhe

Product selectorInteractive tool for product selection and configuration

accessed and interconnected usingthe CFC engineering tool, whileprogramming tasks for the SimaticS7 automation system via the usualstandard tools continue undis-turbed period.

The use of CFC greatly simplifiesproject engineering and acceptanceof the plant. This also reduces engi-neering costs considerably, particu-larly in more complex systems whichinclude HMI devices for example.

Reliable communication viaProfibus

With the new ProfiSafe safety pro-file, safety-oriented communicationtasks, which until recently required

Safe PeripherySimatic ET 200iS – Distributed I/O device for the Ex area

T he new Simatic ET 200iS I/Odevice with Eex de [ia/ib] IICT4 type of protection in ac-

cordance with CENELEC enableseven more application areas thanbefore to exploit the advantages ofdistributed I/O – the chemical andpharmaceutical industries in partic-ular but also varnishing plants, ce-ment factories and the petro-chemi-cal industry. Simatic ET 200iS relieson the number one field bus,Profibus, for communication withthe control system and the con-troller. By using a series-connectedisolating transformer to limit the ig-nition energy, the DP variant usedhere is also intrinsically safe. This al-lows transmission rates up to 1.5Mbps with several ET 200iS slavestations connected simultaneously.

The field bus in the Ex area notonly saves a great deal of wiring workbut also a large number of isolatingtransformers, marshalling distribu-tors and sub-distributors whichwould otherwise be necessary. In ad-dition, extra mechanical protectionsuch as double insulation, addition-al metal meshes or steel pipes which

rectly to the control system. The sta-tion-related properties (parameteri-zation) of the ET 200iS will be set bySimatic PDM (Process Device Man-ager) with which the HART devicesthemselves or other process devicesfor Profibus-DP or -PA are alsomanaged.

Practice-oriented design

The fixed wiring allows the productsto be connected and tested withoutelectronics. Modules can be ex-changed without disconnecting thefield wiring, even during operation("hot-swapping”). The device canbe assembled almost without tools.The width of the device is flexibleand depends on the number ofmodules required. The terminalmodules (sub-components) aresnapped onto a DIN rail, the powersupply and electronic modules arethen simply plugged on. The back-plane bus is assembled "automati-cally” by the busbars of the terminalmodules. Coding elements preventthe wrong replacement modules be-ing plugged, the terminal box andbus connector can be removed andreplaced individually. Clear modulelabeling with order number andwiring diagram as well as ruggedmechanics are an added joy to thosewho like it practical. C

Rita Müller, Siemens Nuremberg

conventional solutions (e.g. fixedEMERGENCY STOP circuitry) orspecial buses can now also be solvedusing Profibus. The user data of thesafety function can be sent within astandard data message in addition tothe safety measures.

The merging of standard technol-ogy and safety technology in one sys-tem saves considerable hardware,engineering, software and trainingcosts in automobile construction,presses and robots, in firing technol-ogy, process automation or in pub-lic transport by cable-car. C

Bernhard Woell, Siemens Nuremberg

Integrated reliabilityFail-safe S7-400F/FH and safety-oriented communication via Profibus

In a few months a newdistributed I/O device, theSimatic ET 200iS, will beavailable for connecting simplesensors and actuators, which can

be installed directly in explosionhazardous areas zone 1 or zone 2– the connected actuators/sensors may even be in zone 0.

The fail-safe S7-400F and S7-400FH Simatic Controllershave recently becomeimportant for a wide range offield applications. Inconjunction with the safety-oriented I/O modules of the ET200M peripheral system andthe Profibus-Profile Profisafe,safety-oriented, distributedapplications can now also beimplemented with a bus systemand uniform engineering. Assoon as a critical situationarises, the automated systemswitches the plant into a safecondition, thus protectingpeople, machinery and theenvironment from danger.

A new preheating furnace wasrecently installed at theCarolorégienne de Laminage(Carlam) rolling mill inChâtelineau, Belgium. Siemenswon the contract to developand implement an integratedfield bus application for thecontrol of the furnace based on Profibus and Simatic PCS 7.Profibus is able to prove itscapability with over 200connected sensors andactuators.

C arlam belongs to the Cocker-ill-Group which operates sev-eral foundries and steelworks

around Charleroi and Liège. Thesteel blanks which are processed atthe Carolorégienne mill are trans-ported from a foundry in the vicin-ity by rail. The steel blocks arebrought up to temperature in which

is now three preheating furnaces.This is required for further process-ing in the rolling mill.

Old partners – new solutions

There has been a business relation-ship between Carlam and SiemensBrussels for some time. In recentyears, several projects have been car-ried out using Simatic S7 and finallythe existing HMI system was re-placed by WinCC. Due to its goodexperience of Siemens technology,the Carlam Engineering Team, led

by Vincent Detry, welcomed the de-cision of the Heurbel planning of-fice (responsible for major infra-structure projects at Cockerill) toaward Siemens the contract to equipthe third furnace.

In addition to the automation ofthe new furnace, the project also en-compassed the replacement of the ex-

isting process control. Heurbel andSiemens favored the Simatic PCS 7process control system which inte-grates Simatic S7, WinCC andProfibus DP/PA for this complex task.

The application

At field level today, ten ProfibusDP/PA links are used to connect nu-

merous actuators and sensors. In ad-dition to 86 Sitrans T3K temperaturesensors, 52 Sitrans P-PA pressuretransmitters and 22 Sipart PS2 PAelectropneumatic positioners, 57magnetic flow meters from anothermanufacturer are integrated viaProfibus. Gas analyzers are moni-tored with 11 decentralized ET 200Mperipheral devices, devices integrat-ed with 4-20 mA or HART interfacesas well as numerous digital I/Os. Lastbut not least, drives and encoders forthe mechanical functions are alsoconnected via Profibus.

One level higher, five Simatic S7-400 controllers with a redundantWinCC server pair and an engineer-ing server are connected via Indus-

trial Ethernet. The servers are on theother hand connected via Ethernetand TCP/IP with seven operator sta-tions, four engineering stations andthe plant’s VAX system.

Fit for the future

For Vincent Detry, the decision touse Simatic PCS 7 is not just the rightdecision financially. The systemcontains all the options required forthe inclusion of further areas of theproduction site in the concept of To-tally Integrated Automation.

“With the opportunities whichSimatic PCS 7 offers, we have alreadyimplemented things which I had notdared to ask for in the planning. Forexample, the complex monitoringtasks for a mill like ours can be easi-ly managed with the integrated func-tions of the process control system.When I look at the system today, itstrikes me that even my unspokendemands have been met.”

The Profibus-PA solution hasproven itself to be very stable. This is shown particularly on the level ofsensors and actuators where noproblems at all occurred.

Vincent Detry takes stock: “Wewanted a plant which from the pointof view of technical equipmentwould be without competition, andwe’ve got it! Also our expectationswith regard to time flows and target-ed production increases were met. Italso showed that our operating andmaintenance team had no difficul-ties to speak of familiarizing them-selves with the new system.”

Although there are currently nospecific plans for further automa-tion, it is the stated aim of VincentDetry to make the concept of Total-ly Integrated Automation reality atCarlam. This will be no problemwith Profibus and Simatic PCS 7. C

Marc Laenen, Siemens Belgium

7Process News 1/2001

Steel networkProfibus in the steel industry

For more than 35 years, Canada’spetro-chemical industry has hada close working relationship withSiemens Applied Automation.This has led to numerous innova-tive developments in the field ofprocess analysis. At LambtonCollege in Sarnia, Ontario,Siemens is now supporting theeducation of qualified youngpeople in this branch of industry.

T he Siemens Analytical Tech-nology Center was recentlyopened at Lambton College in

Sarnia, Ontario. Its laboratory is

Maxum goes to collegeCanadian students work with Siemens process gas chromatographs

The following process equipment

is integrated via Profibus DP/PA:

86 Sitrans T3K temperature sensors,

52 Sitrans P-PA pressure transmitters

and 22 Sipart PS2 PA positioners

College president Terry Blundellsees the laboratory as an importantstep in rounding off the educationof his students. “Graduates of ourcollege who have completed thenew training program take withthem precisely those skills whichjobs in ‘Chemical Valley’ urgentlyrequire”.

The facilities at Lambton Collegeare also available to employees ofpetrochemical plants and refineriesfor training on Advance Maxum.General Manager Gary Waugh ofSiemens Applied Automation says:“The high-tech areas of process au-tomation and analysis have beensubjected to very rapid changes. Wehave therefore taken the opportuni-ty to support the college and our cus-tomers with the equipment and rele-vant training programs. After all, weall rely on superbly trained employ-

ees to enable us to be a match for thechallenges of the economy.” C

Angela Summers,

Siemens Applied Automation,

Bartlesville, USA

equipped with four new AdvanceMaxum process gas chromatographsfrom Siemens Applied Automation.

The analyzers are used in the educa-tion programs for process optimiza-tion and environmental protection.

P r o c e s s N e w sPublisher

Siemens AG,Automation and Drive Technology

Responsible for contentAnton S. Huber

EditorCornelia Dürrfeld, Siemens AG A&D AS PAS

Östliche Rheinbrückenstr. 50, D-76187 KarlsruheTel: +49 (0) 7 21 5 95-25 91,Fax: +49 (0) 7 21 5 95-63 70

e-mail: cornelia.duerrfeld@khe.siemens.de

Editorial committeeDr. Michael Gilluck, Achim Heim,

Walter Huber, Michael Lang, Marc Laenen,Harald Mag, Wolfgang Neitzke, Hartmut Oesten,

Manfred Schirner, Bernd Renner

Publishing housePublicis MCD, Werbeagentur GmbH

Head of periodicalsWolfgang Meyer

CoordinationSylvia Schwope

Artwork and layoutWerner Völkl

PhotosBASF, Dreher (1, 2), Degussa-Hüls AG (2),

Siemens Axiva (3), Moore Products (4),RONA (5), Genentech Inc. (5),

R. Vanden Berghe & Partners (7), Novartis (8)

ISSN 1430 2292

© 2001 at Siemens AGAll rights reserved by the publisher.

No part of this document may be reproduced without priorwritten permission from the editor. Process News is printed on

100% recycled paper.

SIMATIC, TOTALLY INTEGRATED AUTOMATION,SITRANS, SIPOS, SIWAREX, SIPART, ET 200, SIPAN,

ULTRAMAT, OXYMAT, TELEPERM, SIMOVERT, SIPOS, ELMO,PROFIBUS-DP/PA are registered trademarks of Siemens AG.

If trademarks, technical solutions or similar are not includedin the list, it does not imply that they are not included.

T he Rhodia chem-ical works inHouston, Texas

had a problem: it wasnot possible to auto-matically measure the level ina container for liquid sulfuras the heavy caking of thematerial hindered even ro-bust sensors.

With the IQ Radar 160 non-contacting radar meter fromMilltronics which uses mi-crowaves to measure levels, userscan now also gather reliable mea-surement data even where ag-gressive chemicals, strong vaporor crust formation and turbu-lence have previously hindered

T he Simatic PCS 7 process con-trol system is being used inthe extension of the polyTHF

plant at BASF’s Ludwigshafen site.Siemens was awarded the contractby the plant contractor ABB Lum-mus Global GmbH. Simatic PCS 7 isbeing used to realize the automationof the new polyTHF plant and theoperation and monitoring of the ex-isting plant in a joint control roomwithout changing the proven appli-cation. The opportunity to operateand monitor both plants in the sameway, the protection of the invest-ment in the existing plant as well asthe Simatic PCS 7 system technologywere important arguments for this

Process News 1/2001

Siemens AG, Process Automation and Instrumentation, Östliche Rheinbrückenstr. 50, D-76187 Karlsruhe, Germany

Order no. E80001-V381-A71-X-7600004900 RPE11 0201 32.Printed in Germany

Subject to change without prior noticeSiemens Aktiengesellschaft

AEF Industry Istanbul 15–18 March 2001

Inhouse fair of the Siemensbranch Nuremberg Nuremberg 22–23 March 2001

POWTECH Nuremberg 27–29 March 2001

Hanover Fair Hanover 23–28 April 2001

Achemasia Beijing 08–12 May 2001

Drinktec–Interbrau Munich 20–27 September 2001

Interkama Düsseldorf 24–28 September 2001

C A L E N D A RUpcoming shows

+++++++++++++++++++++++++++++++++++++++

Net News:Here are a few interesting websites dealing with the subjects coveredin this edition of Process News:

w w w . s i e m e n s . c o mw w w . a d . s i e m e n s . c o mw w w . f i e l d d e v i c e s . c o mw w w . g l a s s - i n d u s t r y . c o mm a l l . s i e m e n s . d ew w w . a x i v a . c o mw w w . s m p a . s i e m e n s . c o m

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• Stop Press

+++ Siemens Applied

Automation has received

an order for 21 complete

applied process gas

chromatographs from

Dow Chemical, Terneuzen

in the Netherlands +++

+++ The new RWE brown

coal power station block in

Niederaußem is fitted with

670 SITRANS P measuring

transformers for pressure/

differential pressure

measurement +++

+++ Siemens has been

awarded a contract to

provide the control

technology and field

instrumentation for the

modernization of a blast

furnace at the Kremikovzi

ironworks in Sofia +++

F r o m a r o u n d t h e w o r l d

NTER

NET

INTE

RNET

INTE

RNET

TERN

ETINTE

RNTE

RNETINTE

RNET

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Process News

on the Internet

www.processnews.de

Modernization of the Novartis PilotPlant with Simatic PCS 7

system decision. Remote I/O sta-tions are used in the field for decen-tralized recording and output of sig-nals. A connection to the BASF datanetwork facilitates the integration ofprocess data in the production plan-ning and evaluation.

With this plant extension, theproduction of polyTHF, the mostimportant raw material in the man-ufacture of elastomer fibers will beincreased from 16,000 tons to 56,000tons. After its completion at the be-ginning of 2002, this will be theworld’s largest polyTHF plant. C

Ernst-Dieter Keller, Siemens Mannheim

Simatic PCS 7 provides more PolyTHF at BASF

this. The process atmos-phere and the temper-ature conditions havepractically no effect onthe sensor.

At Rhodia, the device wasinstalled in less than 20minutes and is completelyreliable after just one cali-bration. The tolerance range

is less than 2.5 cm. At Rhodia theeasy handling and total reliabilityof the IQ radar has led to it beingrecommended for use at its sisterplant. C

Rolf Panzke, Siemens Karlsruhe

A multi-purpose device

A cer, the third largest PCmanufacturer in the world iscurrently building a new

factory in Lung Tan, Taiwan, for themanufacture of flat screens. Part ofthe project will include the installa-tion of the Siemens Simatic PCS 7process control system. In additionto the automation of the cleanroom, the PCS 7 is also used to con-trol all the other process technology(gases, water, wastewater, etc.).

In addition to references, localpresence and local expertise, a cru-cial factor in the selection of the

Simatic PCS 7 was the Siemens ‘To-tally Integrated Fab’ concept whichfacilitates general and standard au-tomation of the entire project with auniform user interface and generalengineering. The operator saw thisas a great opportunity to reduce itsoverall costs (Total Cost of Owner-ship).

The contract for the clean roomitself was awarded by the Taiwanesebranch of Meissner + Wurst, a lead-ing global supplier of technicalbuilding systems for industry andthe public sector, and the other con-tracts by the relevant OEMs fromTaiwan and Japan. C

Hannspeter Pachel, Siemens Karlsruhe

Clean room automation for Acer, Taiwan

struction phases between Januaryand August of last year. The scope ofdelivery included five AS 416 stations,one engineering station, one operatorstation and 19 local control panels inaddition to the entire field instru-mentation. The Management Infor-mation System MIS-light fromSiemens was also integrated in thecontrol structure in order to meet thestringent FDA requirements.

According to Dr. Martial Casarin,Project Manager at Novartis, thegood professional co-operation be-tween all those involved was a majorfactor in successful and timely com-pletion of the project. C

Hansjoerg Munz, Siemens Schweiz

I n the pilot plant at the Novartissite in Basle the Simatic PCS 7process control system has since

recently been making its contribu-tion to the manufacture of newdrugs which will be able to helppeople all around the world. Newingredients pass through this im-portant station on their way fromdevelopment in the laboratory tomarket maturity. Since it was ab-solutely essential to carry out plantconversions in the shortest possibletime, Siemens was contracted as a partner possessing the necessaryexperience in the re-equipping ofpharmaceutical plants.

A total of 11 reactors were con-verted and commissioned in five con-