Process News 2-2013 En

process newsThe Magazine for the Process Industry

Number 2 | August 2013 | siemens.com/processnews

Partners in IndiaSolutions for growth and innovation

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process news 2/2013 | Contents

Cover photo: Frederic Soltan/Corbis

Process Instrumentation24 Good measures

A Sitrans flowmeter helps verify the supplied amount of jet fuel

25 High tech in compact designSitrans technology in a combined wastewater treatment/biogas facility

Drive Technology26 Production sweet spot

Spray Engineering Devices Ltd., India, improves energy efficiency in the sugar industry with Siemens drives

Solution Partners28 Modernization without disruption

Process control system migration at a German utility

30 Getting the most out of raw materialsSimatic PCS 7 supports smooth project implementation at a French sawmill

32 Turn up the gasAegis Logistics benefits from smooth safety system operations

34 Hot stuffA tailored gas analysis solution helps improve blast furnace operations

Folder inside: Competent PartnersIndividual solutions for the water sector

Dialogue35 Compliance, preview

Editorial03 Past meets present

Cover04 Partners in progress

Jubilant India benefits from modern process control

Process Control Technology08 Flexibility in the field

Fieldbus integration made simple and cost-effective

10 Going strong togetherSiemens in India is focused on offering optimum solutions

16 System in a boxA complete control system in two containers for Linde India

18 World-class skills and expertiseThe Siemens Nashik Works supplies cabinets to customers all over the world

20 A safe choiceAchieving better safety with less hardware and costs

22 Hands-on securityIndustrial Security with access protection, guidelines, and instructions

Pharmaceuticals12 World-class efficiency

Shantha Biotechnics benefits from smooth validation

14 Active and effectiveTeva API optimizes energy efficiency

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

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Editorial | process news 2/2013

Looking out my office window, I can witness just how the society and the economy in India are rapidly evolving. My office is located in Thane adjacent to the Mumbai metropolis, which is one of the oldest and greenest cities in India and at the same time a booming suburb with shopping malls, entertainment centers, business parks, and industrial areas.

Clearly a country of contrasts, India has made the leap from a predomi-nantly agrarian society to a global player in many industries, from food and beverage to pharmaceuticals and chemicals. Companies are no longer just investing in India to benefit from low production costs, but draw added benefit from a skilled workforce and a growing domestic market. This is complemented by many Indian enterprises making the move onto the world stage, with a focus on their own research and development and state-of-the-art production standards.

Automation technology, in general, and process control technology, in particular, are considered key drivers to improve quality and performance. This is where Siemens, as a supplier for automation and drive systems, stands ready to help companies in India address the challenges of a global market. We can provide the technology and the expertise required to improve operations – both locally and globally. Our first multinational project was the construction of the telegraph line from London to Calcutta in 1867 – which made us a global player even before there was such a term.

Siemens has been a reliable partner to India and its economy and infrastructure for more than 100 years. I consider myself very fortunate to be part of this long and successful partnership, and I hope that with this issue of process news, you will gain some interesting insights into this booming economy.

Enjoy the read!

Sascha MännlHead of VSS Process AutomationSouth Asia

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Siemens becomes a trusted partner to an Indian pharmaceutical and life science company, helping it expand and grow.

Partners in progress

Jubilant Life Sciences Ltd., India

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Jubilant Life Sciences Ltd., an integrated pharma-ceutical and life science company, is one of the largest custom research and manufacturing ser-

vices companies in India. The company has earned a reputation as a high-quality manufacturer, with ap-proval from the US Food and Drug Administration (FDA), the Agence française de sécurité sanitaire des produits de santé (AFSSAPS) in France, and the Phar-maceuticals and Medical Devices Agency (PMDA) in Japan.

Jubilant has a 300-acre manufacturing facility in Gujarat, India, which contains a state-of-the-art plant producing specialty chemicals used in the manufac-ture of vitamins and intermediates for the pharma-ceutical and agricultural industries.

To meet the growing demand, Jubilant wanted more efficient and transparent process control, with a high degree of flexibility and expandability, in order

to achieve higher productivity with less manual inter-vention and a faster return on investment.

The plan for expansion

Jubilant is currently developing a sector-specific SEZ (special economic zone) for chemicals on 265 acres of land at Vilayat GIDC Industrial Estate, in Bharuch district of Gujarat. The facility dedicated to the pro-duction of specialty chemicals is located here. ThieBharuch facility consists of multiple processing blocks, along with scrubbers, raw material tank farms, cooling towers, and the plant utilities. The plants have been successfully commissioned one after the other.

From the very beginning, Jubilant wanted a distrib-uted control system (DCS) for the manufacturing fa-cility with about 400 I/O devices on Foundation Field-

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

Simatic PCS 7

SITRANS LR250

Radar Level Transmitter

SITRANS P DS III

Pressure Transmitter

SIPART PS2-FF

Electropneumatic Positioner

SITRANS F M 6000

Magnetic Flowmeter

SITRANS F C MASS 6000

Mass Flowmeter

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Standards and quality

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

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Shyamsundar Bang coordinates manu-facturing, supply chain, and new proj-ects for Jubilant and has been instru-mental in upgrading existing technolo-gies, introducing new technologies, and developing and managing projects for Jubilant.

In an interview, Bang states that be-sides a best-in-class manufacturing fa-cility and competitive advantages, it is necessary to comply with all regulatory guidelines and adhere to the highest quality standards. Following best prac-tices for engineering and automation is a must.

Mr. Bang, what strategy does Jubilant pursue on the road to growth?Mr. Bang: “Jubilant Life Sciences is an integrated pharma and life science company, and the largest custom re-search and manufacturing player in India. We are proud to say that we have been growing consistently for many years now, and we intend to maintain annual growth of 20 to 25 percent. A solid manufacturing base is vital in achieving this goal. At present, we operate seven manufacturing locations in the country. New chemical plants will be built in Bharuch as well as new API (active pharmaceutical ingredient) plants in Mysore. Another pillar for growth is innovation: we are research and development driven. The new spe-cialty chemical facility is proof of this, as it will operate with a new environ-

mentally friendly process we have de-veloped.”

And what is the role of Siemens in this strategy?Mr. Bang: “Siemens enjoys an excellent reputation in India. First known for its power generation systems, Siemens has successfully introduced its automa-tion products and expertise into the In-dian market. At Jubilant, we have sev-eral plants at our Nanjangud and Bha-ruch facilities that are equipped with Siemens automation systems, and we are very satisfied with them. As an in-ternational company, we value partners that can offer globally accepted solu-tions, and Siemens can provide this. Plus, Siemens can support us with knowledgeable teams whose members have both automation and process ex-pertise. All in all, we have had an excel-lent experience with Siemens as a sup-plier, and on the operational level the service Siemens provides is always flaw-less, which is very important for the op-erating team. Consequently, we con-sider Siemens a preferred supplier.”

Are there any plans to extend this collaboration to other fields?Mr. Bang: “We have a concept called ‘partners in progress,’ where we meet with preferred vendors and work out a yearly plan for developing and upgrad-ing their technology – and Siemens is an important part of this concept.”

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Cover | process news 2/2013

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

A valuable addition

Jubilant chose the Simatic PCS 7 V8.0 process control system in a redundant configuration for maximum availability. Siemens’ patented event-based synchro-nization technology for the Simatic PCS 7 system al-lows hot standby operation with bumpless switching within a few milliseconds and without the redundant systems needing to be near each other. Another key factor in favor of PCS 7 was the system’s ability to seamlessly integrate Foundation Fieldbus I/O devices. In Bharuch, 400 Foundation Fieldbus I/O devices are connected to a single redundant PCS 7 CPU, which helps reduce hardware costs.

With the help of PCS 7, Jubilant Life Sciences is im-plementing a number of process improvements, thereby optimizing production costs, quality, and product safety. In addition, continuous recording of all the relevant process data not only enables rapid error analysis during servicing, but also allows for clear tracking of quality issues and provides higher system availability. The archiving takes place in accor-

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

Complete service

In addition to being the main automation vendor for the plant, Siemens was responsible for supplying and commissioning the field instruments (mass flow, magnetic-inductive flow, radar and differential pres-sure-type level transmitters), installation commis-sioning, installation hardware, field engineering, in-stallation of Siemens and third-party instruments, and site management.

The successful commissioning of the plant with such a large Foundation Fieldbus I/O device count confirmed the client’s confidence in Siemens’ leader-ship in the process control systems market.

One success leads to another

The Bharuch project was not the first successful col-laboration between Jubilant and Siemens. Impressed with the on-time execution and commissioning of Plants 4 and 5 at Jubilant’s Nanjangud facility, Jubi-lant selected Siemens as the main automation ven-dor for Plant 6 at the Nanjangud facility as well as the Bharuch SEZ facility. Siemens’ scope of responsibility for the Plant 6 facility includes process automation and field instrumentation on a turnkey basis, along with field engineering, installation and commission-ing, validation, and site management.

INFO AND CONTACT

siemens.com/[email protected]

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

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Fieldbus solutions provide a simple, cost-effective way to combine devices in an automation system. But differing fieldbus standards can make integration difficult. With Simatic PCS 7, users can integrate HART, Profibus, and Foundation Fieldbus, as well as Industrial Ethernet devices, enabling them to choose a fieldbus solution that offers maximum return on investment.

Flexibility in the field

Fieldbus technology

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Process Control Technology | process news 2/2013

The production and process industries would be unimaginable without fieldbus solutions. Field-buses simplify the planning, engineering, instal-

lation, and operation of plants. Instead of individual wiring, a bus feeds the information from the field de-vices via one cable into the central control system. This reduces the required number of cables and saves time in planning and installation.

A further important feature is diagnostics, making the plant more transparent so that plant shutdowns can be avoided. Many technologies compete with the fieldbus, and the original hope for a single unified communications mechanism has not been realized. However, Simatic PCS 7, which can accommodate all the major processing and production technologies (HART, Profibus, and Foundation Fieldbus), offers a fieldbus compatibility level that is unmatched.

Planning for the long term

Process plants are operated and maintained over long periods; 15 to 20 years is common. This creates a demand for longevity in the automation systems, including fieldbus solutions. A good fieldbus choice must satisfy several requirements: It must be able to use field devices from different vendors. It should be simple and quick to engineer, commission, maintain, and modify. Installation should be cost-efficient. It should provide a high level of reliability and availabil-ity, and transmit diagnostic information for preven-tive maintenance. And it should link the management level to the field level.

The Simatic PCS 7 process control system with HART, Profibus, and Foundation Fieldbus communication capabilities offers the best combination for meeting all the requirements of the process industry. All plant information is collected in one system, evaluated centrally, and then used for the open- and closed-loop control of the plant.

A flexible and scalable system

To accommodate the huge variety of different plants and requirements, Siemens provides a flexible and scalable system for linking the field level to the man-agement level. HART devices can be easily integrated by means of distributed input modules. The integra-tion has been standardized by the Profibus user orga-nization in the profile for HART on Profibus. In addi-tion, Profibus PA fieldbus systems and Foundation Fieldbus and WirelessHART field devices can be seam-lessly incorporated via links.

Enabling the optimum choice

The openness and support of different fieldbus sys-tems enable planners to select the best field device for their purposes. Expansions present no problems, even during operation. Simatic PCS 7 enables easy troubleshooting through user-friendly diagnostics to support fast commissioning and improve the effec-tiveness of the plant. With Profile 3.02, the Profibus user organization has created a profile that complies with NAMUR Recommendation NE107, which will also simplify the replacement of devices, as it speci-fies that upgraded field devices must be capable of adapting to a previous version. The device automat-ically adjusts itself to the version defined in the de-vice description used and is transferred during parameterization.

The Simatic PCS 7 process control system allows all fieldbuses used in the process industry to be con-nected in the same manner in the best possible way. This integration enables the planner to have a free choice of fieldbus system and field device.

The standardization of proxies for Profinet is al-ready well advanced and guarantees the future capa-bility of fieldbus solutions – not replacing Profibus PA and Foundation Fieldbus, but integrating them. This means protection of the user’s investment.

INFO AND CONTACT


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

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mailto:[email protected]

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

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

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One of the major challenges Indian companies face is improving productivity, says Mandal. “The automation level in India is approximately

50 % lower than the automation level in developed economies and approximately 30 % lower than in China,” he explains. “Larger, well-known companies in the market are eager to implement automation technologies, but smaller players view it as an expen-diture rather than an investment. Our approach has always been to optimize lifecycle costs. For example, from a machine perspective, a company can use an automation system with Profinet that monitors the status of the machine and switches it off in real time when there is no production scheduled. Such mea-sures can enable even smaller manufacturers to ben-efit from increased productivity and reduced costs.”

Due to the inherent operational and maintenance advantages of a distributed control system (DCS), there is a clear trend toward horizontal and vertical integration, Mandal continues. “There is growing awareness that a DCS can provide consistent and re-liable quality and that it offers added benefits such as increased energy efficiency and cost-effectiveness, leading to higher productivity and improved mar-gins,” he says. “Process automation can also help in detecting and controlling water usage, energy con-sumption, emission levels, and waste generation in the production process, leading to more sustainable production. However, more than the technology, manufacturers need to choose an automation tech-nology partner whose expertise is completely aligned with their process requirements and that also deliv-

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

Siemens in India

ers a superior return on investment. Because we fol-low a vertical market approach, we have market- specific products and solutions for particular indus-tries that are handled by competent sales and execu-tion teams with extensive industry-specific applica-tion knowledge. This results in the implementation of optimum products and solutions that enable cus-tomers to increase the productivity and sustainabil-ity of their operations.”

Strength through innovation

A nation like India cannot afford to slow the pace of its industrialization. There are still massive require-ments in the infrastructure, healthcare, housing, food, and other sectors – sectors that need to keep pace with the rate of population growth and that are critical for the nation’s development. Siemens will continue to support India’s growth, says Mandal. “Our partnership with Indian industry will strengthen thanks to our innovative products, solutions, and ser-vices,” he concludes. “We will also continue to strengthen our portfolio for vertical markets. I fore-see our Indian customers riding the globalization wave and Siemens India partnering on more and more offshore developments for our customers from India.”

INFO AND CONTACT

[email protected]

“ Our approach has always

been to optimize lifecycle

costs.”Bhaskar Mandal, Sector Cluster Lead, SAS Industry

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process news 2/2013 | Pharmaceuticals

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

World-class efficiency

Shantha Biotechnics Ltd., India

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

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

The complete package

In addition to the utility management system, Siemens’ project scope also included the supply and commissioning of field instruments for mass flow and magnetic inductive flow, and radar and differential- pressure level transmitters from the versatile Sitrans portfolio of process instruments. Additionally, Siemens supported Shantha during construction and commis-sioning, hardware installation, field engineering, and site management.

Shantha Biotechnics was impressed with Siemens’ innovative products and solutions for the process and manufacturing industry, the company’s lifecycle approach to projects, the continuous project reviews and updates by the dedicated local execution team, and the fact that Siemens abides by the principles of ethical, optimized, highly efficient, and sustainable business, just like Shantha Biotechnics.

Shantha Biotechnics, a wholly owned subsidiary of the global Sanofi group, is a biotechnology company with state-of-the-art facilities in Hy-

derabad, India. Shantha Biotechnics was established in 1993 to develop effective, affordable vaccines and therapeutics within the reach of the common man. Shantha Biotechnics is the first Indian company to develop a recombinant-DNA human healthcare prod-uct in India and is prequalified by the World Health Organization (WHO) to sell vaccines to United Na-tions procurement agencies such as the United Na-tions Children’s Fund (UNICEF) and the Pan Ameri-can Health Organization (PAHO).

Utilities such as chilled water, hot water, and steam play a major role in vaccine production and represent a large share of production costs. As the company was placing increasing emphasis on energy conser-vation, the main aim of Shantha Biotechnics was to have a flexible utility management solution that could calculate the cost per unit of the utility gener-ated at the block level and generate energy-related reports.

A comprehensive energy management solution

Shantha Biotechnics chose Siemens as the turnkey provider for its utility energy management system. The utilities are now monitored by a Simatic B.Data energy data management system that forms the basis for cost-effective and optimized energy man-agement. B.Data helps Shantha Biotechnics under-stand the utilities in its plants, which enables the company to plan future utility use and reduce costs.

Simatic B.Data readily supports current interface standards such as OPC, ODBC, ASCII, and XML. This enables communication and data exchange between multiple systems, which facilitates functionality such as long-term archiving, energy accounting, and de-termination of characteristic data (key performance indicators, efficiency figures, etc.) with direct refer-ence to production (batches, quantities, etc.). It also enables consumption forecasts based on production- related factors (production planning) and basic load profiles.

The Simatic B.Data system manages the entire en-ergy management portfolio of the Medchal and Mup-pireddypalli plants via a virtual private network (VPN), so their top management has remote oversight and control of the company’s overall energy consumption. This shows the real flexibility Simatic B.Data can pro-vide in an energy and utility management system.

The Simatic B.Data system provides a variety of benefits such as combined technical and business data processing, balancing of power generation and consumption, and generation of variables for reports to help increase the efficiency of systems involving power generation, distribution, and consumption. Other benefits include connecting energy costs to the enterprise resource planning system, forecasting

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

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• Shantha Biotechnics’ prime goal is to provide effective vaccines at an affordable price

• Controlling energy costs is a key factor in minimizing production costs

• Simatic B.Data helps Shantha control its energy costs by enabling the company to monitor and understand its energy use

Key points

http://www.siemens.com/pharma


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process news 2/2013 | Pharmaceuticals

Teva Active Pharmaceutical Ingredients (TAPI) is a stand-alone business unit of Teva Pharmaceu-tical Industries Ltd., an international pharmaceu-

tical company headquartered in Israel. Teva Pharma-ceutical Industries is the largest generic drug manu-facturer in the world and one of the 15 largest pharmaceutical companies worldwide. TAPI is the

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

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

Active and effective

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

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

The TAPI manufacturing campus has a state-of-the-art multipurpose plant in Malanpur, India, that man-ufactures a wide range of APIs for use in Teva phar-maceuticals, with a major portion sold to third par-ties. The plant specializes in producing advanced intermediates for various APIs for the United States and other regulated markets. TAPI needed a trusted and dependable automation vendor for a tank farm system, reactor automation, and solvent transfer sys-tem in its MPP-2 and MPP-3 facilities. Automation was desired for the primary processes, since efficiency and quality depend on management of those pro-cesses.

TAPI chose the Simatic PCS 7 process control sys-tem for its MPP-2 and MPP-3 plants. The key criteria for choosing Siemens were that the technology was state of the art and also offered a cost-effective solution. The integrated redundant system design and reliable proven components provide high system availability, a key factor in API manufacturing. If a controller or server fails, the redundant component takes over immediately without loss of data, result-ing in a bumpless transfer. This substantially reduces downtime and plant and batch losses. The user- friendly Simatic PCS 7 interfaces make the system easy to engineer and maintain.

Teva chose Siemens’ pressure transmitters with the HART protocol for the blind calibration capability, integrated loop-checking functionality, default square root extraction, local re-ranging, calibration

functionality, and many other diagnostic features. Wiring and maintenance were reduced by imple-menting the Simatic ET 200M distributed I/O system to connect signals in explosion-hazardous areas.

Siemens also offered local validation expertise with qualified project teams in India who worked with dedicated engineers to execute and complete the MPP-2 and MPP-3 automation system on sched-ule. As Dinesh Agarwal, TAPI senior manager of pro-curement, explains, TAPI benefited greatly from this: “We did not have the right in-house capabilities, and hence needed support from outside. It adds to the value of the Siemens solution that they can provide such added value support. During the project, we en-joyed a very good cooperation, and our engineers are comfortable with the services provided by Siemens.”

Fully compliant system

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

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INFO AND CONTACT


http://www.siemens.com/pharma


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process news 2/2013 | Rubrik

Linde India Ltd., formerly BOC India Ltd., a part of the Linde Group headquartered in Germany, is one

of the leading companies in India sup-plying industrial gases, both in bulk for heavy industrial use and as high-purity gases for users such as hospitals and laboratories.

The gases are produced in large air-separation units (ASUs) commonly located within the sites of heavy indus-trial users such as steel plants, glass manufacturing plants, petrochemical complexes, refineries, and others. ASUs separate atmospheric air into its pri-mary components, typically nitrogen, oxygen, and argon, and the rare gases neon, krypton, and xenon. The separa-tion process uses various technologies, the most common of which is cryogenic

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

System in a box

distillation. The rare (or noble) gases are present in the air in only trace amounts of parts per million. Therefore, to extract them in viable amounts using the air-separation process, large-scale units with huge air intakes, of the order of at least 1,000 metric tons per day (MTPD) oxygen capacity, are needed. The plants operate in a finely balanced closed-loop system requiring precisely calibrated analytical instrumentation to ensure accurate control and safe operation.

From its Indian manufacturing center at Nashik Works, Siemens supports Linde India in ASU projects, supplying and commissioning distributed control system panels and accessories for instal-lation inside control rooms, marshaling rooms, and switchgear rooms. From

2007 to 2011, Siemens India executed several ASU projects for BOC India based on the Simatic PCS 7 process control system. In October 2011 Linde India se-lected Siemens to supply the control system for a new 2,000 MTPD ASU to be installed at a steelworks operated by POSCO in Cilegon, Indonesia. The ASU was to be installed on a build, own, and operate basis. To avoid any additional building to accommodate the ASU con-trol equipment, a complete preengi-neered containerized control system was designed. The control cabinets, I/O and marshaling cabinets, PC consoles, and other equipment would be com-pletely housed, wired, and tested inside two shipping containers at the Siemens factory in Nashik prior to transporting them to Indonesia.

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

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

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first time that Siemens India had manu-factured a complete containerized sys-tem, and the project required close co-operation between different organiza-tions across three countries.

24/7 uptime with remote operation center

Linde had developed the capability to link its ASU plants to a remote opera-tion center (ROC) from which the plants could be monitored and controlled on a continuous basis. As an extension to its Simatic PCS 7 process control system, Siemens developed an ROC solution to meet Linde’s requirements, together with a customized block library. This en-abled Linde to present a consistent HMI graphics interface in its ROCs through-out the world. Two containers were pro-cured and delivered to Siemens Nashik Works, where all the automation system hardware, software, and accessories were installed. Siemens undertook all the hardware engineering and software

development and assumed overall re-sponsibility for the project management. The ASU installation at Cilegon consisted of two different areas (i.e., core plant and storage area). Two redundant PCS 7 AS controllers were provided in container 1 for core plant, with a third PSC 7 AS re-dundant controller fitted in container 2. This unit provided control for the storage area and utilities. ET 200M rack systems, both within the containers and mounted remotely, provided I/O connections to the field. When all the work was com-plete, the containers were shipped to the POSCO steel site in Cilegon, where final commissioning was carried out. Class-room training on the Simatic PCS 7 was provided to the new operators at Siemens Kalwa Works in India. This groundbreaking project marked the

Client server architecture

• 3 redundant automation systems (AS 417-4H)

• Simatic PCS 7 V7.1 SP3: 2,056 I/Os (ET 200M I/Os)

• 1 engineering station

• 2 operator stations, 2 OS servers, 1 OS client with dual monitors, 1 APC

• 2 ROC servers with 2 clients

• I/O and system panels: 13 panels (2,200H × 1,200W × 800D) in container, 8 RIO panels (2,200H × 800W × 800D) in field

• Communication: 30 iMCCs (Simocode), 7 VFDs with H-System on Profibus DP

• Third-party communication over Modbus RS 485

System details and architecture

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

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Nashik, located approximately 170 km from Mumbai, is one of the fastest-growing cities in India. In 1987, Siemens established a manufac-

turing facility for electronic components at Ambad, one of the industrial areas of Nashik. With its focus on growth, continuous innovation, and high-quality standards, the facility has become an outstanding global manufacturing location. To fuel continuous innovation, the factory has its own research and development facility and develops many compo-nents for products manufactured in the factory as well as adapting global Siemens products for local conditions.

Cabinets for process control

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

Quality and standards are key

Quality has always been the key driver for this facil-ity and the factory adheres to strong quality manage-ment processes. Every year the factory turns out more than 4,000 engineered cabinets, meeting global standards for various industrial applications within India and across the world – such as more than 100 automation cabinets for a polypropylene plant in Egypt; automation cabinets for a direct reduced iron plant in Bahrain via a customer in the United States;

automation cabinets for an air-separation plant in South Korea; and automation, electrical, and vari-able-frequency drive cabinets for a polyester line in Turkey. With its long proven record of successful proj-ects, the Nashik factory has expertise in project de-sign and execution to back up its stringent standards, ensuring the highest quality for every product deliv-ered to customers in India and abroad.

• Established in 1987

• 4,900 m2 state-of-the-art electronics manufacturing hall

• Skilled workforce of 300 Siemens employees

• ISO 9001 and ISO 14001 certification

• Ships more than 4,000 engineered cabinets per year

The Nashik Works

Core cabinet components such as controllers and I/O modules are sourced from Siemens manufacturing locations around the world

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INFO AND CONTACT




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One key factor affecting the cost and performance of a safety in-strumented system (SIS) is engi-

neering. The design and programming of safety logic can be quite time-consuming and complex. With the Simatic Safety Matrix tool, this task has been greatly facilitated. This TÜV-certified cause-and-effects tool was specifically cre-ated to help users design, engineer, operate, and maintain an SIS through all phases of the safety lifecycle. The tool’s intuitive interface has helped hundreds of customers comply with the requirements of the ANSI/ISA 84 func-tional safety standard while reducing their engineering costs by automati-cally programming the safety logic. Users save time and reduce cost and complexity, as was recently acknowl-edged by Control Engineering maga-

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

A safe choice

Process safety

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S7-400FH controller

Triple Simplex Dual

1001 LS

1002 Flow 2003 PT

Profibus

technologies, including Profisafe, ASI-safe, and Industrial Ethernet. This elim-inates the need for additional networks, complex configuration, or costly gate-ways to provide safe, secure, and fault- tolerant system communication. Safe sig-nals can be linked via Simatic ET 200ISP, the recipient of Control Engineering ’s 2012 Engineers Choice Award for fail-safe I/O systems. Certified to SIL 3, the systems are replaceable online (under Ex conditions). Simatic ET 200ISP is the perfect I/O solution for remote installa-tions in hazardous areas (up to Ex zone 1), extreme temperature ratings (-20 to +70°C), and corrosive atmo-spheres (ISA-71.04 severity levels G1, G2, G3). For better integration and re-duced footprints, both safety and stan-dard modules can be installed and con-figured in the same backplane.

Packaged savings

While Simatic PCS 7 provides immedi-ate benefits during the design and im-plementation of an SIS, it also helps reduce lifecycle costs, for example, through prolonged testing intervals. In order to claim SIL levels, plant opera-

tors must test their SIS following a rigorously defined schedule. Simatic PCS 7F safety performance numbers have been approved for either a 10- or 20-year proof test interval and help re-duce SIL verification costs by simplify-ing calculations while extending test in-tervals. This feature removes the bur-den of conducting comprehensive and time-consuming system test proce-dures and helps reduce annual mainte-nance budgets, along with enabling simpler SIL verification calculations.

Siemens can also use its industry and technology expertise to support custom-ers in designing and building industry- compliant safety systems. Siemens is able to deliver complete systems that are designed and built to meet regula-tory codes and safety standards. Pre-packaged systems help reduce risk, sim-plify the scope of projects, and ensure consistent design and better service and support.

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

Flexible, modular, redundant

The problem with conventional pro-grammable logic controllers (PLCs) is that they need redundancy to achieve safety – which comes at a cost in terms of system availability. Traditionally, physically redundant hardware compo-nents were thought to be the only means of achieving SIL 3. However, modern safety systems contain special safety-related function blocks with fail-ure control measures that make them independent of hardware redundancy, eliminating the need for extensive re-dundant logic circuits such as those used in triple modular redundancy or similar approaches. Simatic PCS 7F pro-vides the highest level of safety (SIL 3) without the need for redundancy. The flexible modular redundancy (FMR) concept supports single, dual, and even triple modular redundancy, helping plant owners achieve their availability targets and providing a cost-effective, scalable solution without compromis-ing safety for any size of safety applica-tion.

Simatic PCS 7 also supports the Safety Integrated concept. While the benefits of integrated solutions are widely ac-knowledged (common engineering, HMI, communications, etc.), this ap-proach provides additional benefits by incorporating energy and asset man-agement to help lower plant lifecycle costs. For specific applications in which this tight integration is not required, the PCS 7F safety system can operate as a stand-alone SIS and still interface with any third-party system via a vari-ety of communication options.

A safer reach into the field

To easily and safely bring intelligent field devices directly into the SIS, Simatic PCS 7F supports the broadest range of protocols certified for the transmission of safety-critical data over open bus

InFo And ContACt


Simatic PCS 7F can provide safety levels of up to SIL 3 without the need for redundancy, providing a cost-effective and scalable solution for optimum safety and availability

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The physical components of an au-tomation system should be effec-tively safeguarded against unau-

thorized access, and their use should be defined by a clear set of rules. Aware-ness of security issues should be firmly embedded in the consciousness of those who are in direct contact with the plant. This is precisely the subject of sections 9 and 10 of IEC 62443, Part 2-1, titled “Physical Security Measures for Installations, Including Guidelines and Procedures.” The chapter highlights five thematic areas: handling of mass stor-age media, system servicing either at the plant or by remote access, handling of communication media, how opera-tors are to recognize and properly deal with an attack, and what is to be done about technical malfunctions in order to guarantee the security of automa-tion systems.

As in other areas of a defense-in-depth security strategy, physical access protection depends upon a bundle of coordinated individual measures that

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

Hands-on security

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

Define and internalize rules

Every information system requires con-stant support and monitoring. Defec-tive components must be replaced, software must be updated, and the

Industrial Security

communications infrastructure must be adapted to changes in operational re-quirements. These are tasks that must be performed not only by in-house per-sonnel but also by external service part-ners and suppliers. Both groups need physical access to individual compo-nents of the system.

Mechanical and electronic protection systems may indeed ensure that this ac-cess is only granted to explicitly autho-rized personnel. However, a responsi-ble approach to these mechanisms also includes personnel procedures. Tar-geted duties and procedures can be de-

23

Defense in Depth

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

Physical access protection

Guidelines and instructions

Cell protection and perimeter network

Firewalls and secured connections (VPN)

System hardening

User management

Patch management

Protection from malware (antivirus, intrusion detection)


fined for the company’s own employees, while specific contractual arrangements are an effective approach for managing external partners.

A sense of responsibility also necessi-tates practical knowledge of the signif-icance of the installed security mea-sures. This means that the person con-cerned must have a clear awareness of the far-reaching consequences of ma-nipulating the system – an awareness that is best communicated by means of courses and on-site training programs.

In addition, the physical security sys-tem must be inspected regularly to en-sure its continued reliability. For this process, the day-to-day experience of everyone involved is critical in order to uncover weaknesses and identify op-portunities for manipulation.

Security begins at the site boundary

In spatial terms, a comprehensive pack-age of measures for physical security

can be organized into four security sec-tors. Sector 0 is considered to be the area outside the property. Sector 1 is the property line itself. Sector 2 in-cludes all areas within the premises. And finally, Sector 3 is the direct protec-tion of the automation system itself. This sector concept can be flexibly ap-plied to almost any architectural envi-ronment. The protection of sectors 0 to 3 is based on comprehensive surveil-lance alarm management and a pre-cisely coordinated system of sensors and alarms with different operating principles. Such a system forms multi-tiered perimeter protection that is largely tamper-proof.

It is supplemented by coordinated ac-cess protection, which includes securi-ty-critical floors, parts of buildings, and rooms, as well as individual switch cab-inets. Siemens relies on an integrated access concept, where interior mecha-tronic locking components are com-bined with online access control sys-tems in the input area. At the same

DCS

INFO AND CONTACT


time, the use of RFID technology makes it possible to equip all internal and ex-ternal employees with exactly the ac-cess permissions they require for the performance of their duties.

But the information system of a com-pany is not only exposed to attacks from cyberspace; it must also be pro-tected against physical attacks in the real world. This is why a physical com-ponent is an absolutely mandatory ele-ment of a defense-in-depth security concept. The physical component must ensure that authorized persons are able to fulfill their tasks unhindered, in order to keep the system running, while at the same time having the capability to block unauthorized entry effectively.

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

http://www.siemens.com/industrialsecurity


http://www.siemens.de/industrialsecurity

24

process news 2/2013 | Process Instrumentation

Located at Copenhagen Interna-tional Airport in Denmark, BKL A/S transports jet fuel from the Prø-

vestenen oil terminal in eastern Copen-hagen to a storage tank at the airport, and then to each aircraft stand as needed. Each day, BKL receives about 3 million liters of fuel from another sup-plier and pipes it to a storage tank at the airport. The fuel is filtered before entering the storage tank.

Verifying measurements

A level meter in the tank measures the fuel. BKL noticed discrepancies be-tween the volume of fuel arriving from the supplier and the readings in the tank, so the company wanted to verify the readings with a different meter. Be-cause BKL needed precise, repeatable measurement, the team chose the Sitrans FUT1010 liquid ultrasonic flow-meter, which offers several critical features, such as ± 0.15 % accuracy, since even small measurement errors can result in major monetary losses; ±0.05 % – 0.1 % reading repeatability, since fuel shipments are transferred through the pipeline on a regular basis; and an innovative TransLoc mounting system, which prevents contact with the fuel and allows flow calibration.

BKL installed a Sitrans FUT1010 on the pipeline into the storage tank, where it could measure the fuel after it was cleaned but before it entered the tank. Sitrans FUT1010 readings con-firmed that BKL’s level meter was accu-rate, allowing BKL to conclude that the problem was on the supplier side. BKL then worked with the supplier to ensure

By installing a Sitrans FUT1010 clamp-on flow metering solution, BKL A/S can now reliably verify the amount of jet fuel supplied from a nearby terminal to the company’s tank storage at Copenhagen airport.

Good measures

The TransLoc mounting system allows for permanent transducer installation outside the sensor

Siem

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BKL A/S, Copenhagen, Denmark

that its meters were correct. This elim-inated the measurement discrepancies.

Significant savings

“Incorporating the Sitrans FUT1010 into our fuel transfer process has proven to be an extremely wise investment,” said Peter Laybourn, general manager of BKL A/S. “The meter’s accurate and reli-able performance allowed us to recon-cile our stock with ease and confidence.

Since the transducers are protected from the medium and the surrounding environment, the maintenance require-ments are almost nonexistent. These factors add up to significant cost sav-ings for our company.”

INFO AND CONTACT


“ Incorporating the Sitrans FUT1010 into

our fuel transfer process has proven to

be an extremely wise investment.”Peter Laybourn, General Manager, BKL A/S

http://www.siemens.com/flow


25

Process Instrumentation | process news 2/2013

The treatment of hospital waste-water is something of a chal-lenge. Community sewage plants

are primarily designed for the dis-posal of biodegradable materials, and not even the most modern of treat-ment methods can satisfactorily re-move high concentrations of drug residue. Distributed wastewater treat-ment plants built directly on the clinic grounds constitute the most useful approach. But Pharmafilter’s waste disposal concept goes a step further. It follows the principle “Recycling in-stead of reuse” – and it pays off in a number of ways. It has been tried and tested at the Reinier de Graaf Hospi-tal in Delft. There, common reusable hospital articles were replaced by bio-degradable, disposable articles made from bioplastic – manufactured from renewable raw materials. The used disposables are ground down in spe-cial shredders and flushed away to the clinic’s sewage treatment plant where the water is treated and biogas is produced.

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

High tech in compact design

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Pharmafilter, the Netherlands

High-precision measurement technology guarantees efficiency

The combination of wastewater treat-ment and biogas production presents a number of challenges, especially for measurement technology. For both pro-cesses, a continuous stream of data re-garding temperature, flow, level, and pressure is required. In Delft, trust was therefore placed in process instrumenta-tion from Siemens. High-precision Sitrans TH head transmitters operate as tempera-ture measuring devices. Eight Sitrans Probe LU compact transmitters provide continuous level monitoring using ultra-sound in the membrane bioreactor (MBR) intake or in the activated carbon filters. Twenty electro magnetic flowmeters of the Sitrans FM MAG 5100 type were deployed for the inflow, outflow, and backwashing filtration cycles. The Sitrans P DS III digital pressure transmitter is used for monitor-ing MBR activity, and the multicompo-nent Ultramat 23 gas analyzer for the pro-cess control of biogas production. Siwarex weighing modules are also in use at this

installation. They are responsible for the exact measurement of the substrate de-ployed in the fermenter.

A convincing concept all the way down the line

Thanks to the new waste management concept, the amount of waste at the Reinier de Graaf Hospital has been sig-nificantly reduced, and the facility’s wastewater is practically free of con-taminants. At the same time, the stan-dard of hygiene has been raised with the use of disposable products. Over and above water purification, the sus-tainability of this concept is based upon the use of waste material as a source of energy. The efficiency and fail-safe per-formance of the installation is guaran-teed by the measurement technology that has been implemented.

INFO AND CONTACT


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

http://www.siemens.com/processinstrumentation


26

Established in 1992, Spray Engineering Devices Ltd. (SEDL) is a leading provider of energy-effi-cient and cost-effective integrated technology

solutions for the process industry. One of SEDL’s areas of expertise is the redesign and engineering of processes and equipment, together with the coordi-nating process automation systems. With many sat-isfied customers in India and abroad, the company has introduced energy-efficient processes in a vari-ety of industries. One industry in which energy effi-ciency has recently gained momentum as a key per-formance indicator is sugar.

Adoption of better technologies

Owing to a decline in the price of sugar and an in-crease in sugarcane prices, the sugar industry’s focus

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

Production sweet spotSpray Engineering Devices Ltd., India

has recently revolved around cost reduction, quality improvement, and energy conservation. Conserving energy and identifying new or renewable energy sources has emerged as the need of the hour.

In sugar production, reducing process steam con-sumption is a key lever to reduce production costs. Evaporators generally use 2 to 2.5 bar pressure steam in four to five effects. Using a power and heat cogen-eration process, SEDL was able to use the available enthalpy and temperature of vapors for evaporation prior to condensation. Eliminating evaporation pro-cesses above 100 °C increased plant capacity and de-creased the cost of evaporation. This low-temperature evaporator module (LTEM), a unique, innovative product from SEDL, can reduce scaling, inversion, color formation, and heat loss. With LTEM, a plant can reduce the process steam flow rate, pressure, and

27

Drive Technology | process news 2/2013

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

Search for a high-quality drive solution

For this project, SEDL was searching for a reliable, energy-efficient, and high-quality drive solution for its evaporator module. After evaluating the avail-able systems, the company opted for technology from Siemens. Vivek Verma, co-founder of SEDL, said: “Having experienced Siemens’ range of high- performance auto mation products, we decided to use Sinamics variable- frequency drives on a Profibus network for the evaporators. Not only did the prod-uct help achieve commendable control of pressure and all motors, making the LTEM system efficient, but prompt customer service also ensured smooth installation and streamlined internal processes.”

For ease of use, all field device data gathered by the control system are available on a single screen. Profibus communication ensures reliability and better control. Additionally, BICO technology (with binectors for digital signals and connectors for analog signals), along with system configuration and programming that includes a built-in PID (proportional-integral- derivative control loop feedback mechanism), pro-vides ease of use and improves process control.

Excellent performance

In addition to better control and higher efficiency, the Siemens drive systems provide energy savings, increased durability, higher efficiency, and better monitoring of errors with the Profibus network. The cost-effective solution prevents overflow by con-trolling the speed based on the tank level. Thanks to the Profibus network, the solution provides easy plug-and-play performance with minimal mainte-nance. Better accessibility for remote locations is pro-vided by built-in web servers.

Impressed with the on-time execution and success of the project, SEDL has become a loyal Siemens customer and regularly uses Siemens’ process in-struments, Sinamics G130 and G120 drives, and low- voltage motors as well as switchgear.

SED

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

“ Not only did the product help

achieve commendable control

of pressure and all motors,

making the LTEM system

efficient, but prompt customer

service also ensured smooth

installation and streamlined

internal processes.” Vivek Verma, Co-founder, SEDL

INFO AND CONTACT


http://www.siemens.com/drives


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process news 2/2013 | Solution Partners

EMS supplies process and heating steam, electricity, compressed air, and industrial water to several in-

dustrial installations locally, as well as district heating to two neighboring communities. To do so, EMS operates four gas-fired steam generators, two gas turbines, and two steam turbines for the production of electricity. As cus-tomer support for the original control system could no longer be guaranteed, EMS was forced to find a new solution. “The standard required for the successor system was very high,” recalled Tino Danz, manager of the electrical plant. After evaluating the various options, management decided upon the Simatic PCS 7 process control system.

Project implementation without disruption of supply

From EMS’s point of view, the openness and easy learnability of the system

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

Modernization without disruption

were entered into the input modules. In this way, the team was able to verify whether the outputs showed the ex-pected switching behavior. Also, the operator graphics were completely re-designed due to the higher resolution. “We have matured here as well,” said Gunnar Fritsche, who is responsible for the electrotechnical equipment at EMS. Subsequently, the new operator termi-nals were set out on tables in the con-trol room for testing. In this way, the system operator had a chance to try out the new user interface. “Our employees have really welcomed this measure,” said Fritsche. “They also had an oppor-tunity to submit their suggestions, and with PCS 7, implementing these sug-gestions was possible without any problem.”

At the request of EMS, the entire con-version was to take place without inter-rupting the steam and electricity gen-eration. The concept thus made sure

Energie- und Medienversorgung Schwarza GmbH, Germany

were of special significance. In addition, existing Siemens controllers could be integrated without a problem. BN Auto-mation AG, as a certified PCS 7 special-ist, was commissioned to implement the project, and the original idea of a 1:1 migration of the engineering from old to new was quickly rejected.

As there was no functional descrip-tion of the control system, appropriate specifications had to be created first using reverse engineering. At the Migration Support Center in Cologne, Siemens provided the BN Automation AG project manager with the corre-sponding information about the exist-ing system. With this knowledge, it was then possible to work out a functional description of the automation. Subse-quently, implementation of PCS 7 was initiated. The new automation solution came into being at BN Automation AG’s premises in a matter of weeks. During the test run, realistic signal sequences

Energie- und Medienversorgung Schwarza (EMS) at

Rudolstadt in Thuringia, Germany

29

Solution Partners | process news 2/2013

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

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

Optimized operating procedures

In conjunction with the TIBS plant data collection software, a product from BN Automation AG, the system has grown into a comprehensive multifunctional solution. This has led to significantly optimized operating workflows and energy savings at EMS. The functions provided by PCS 7 allow TIBS to perform signal connections and calculations, as well as innovative analyses, which are of special interest to management. Now, shift protocols can be created from real-time data and compared with the accounting-relevant data from flow metering. The detailed reports are pre-pared on the office network for users and made available to be called up at any time. Remote maintenance has been set up with the same standard of IT security architecture.

Professional implementation

EMS is very satisfied with the progress of the project. “We now have a future- proof control system with which the pending modifications can be very eas-ily implemented,” said Fritsche. “The extension of the preparatory phase, in order to guarantee supply to our cus-tomers during the conversion, was the right decision and was more than offset by the rapid implementation,” empha-sized Thomas Filleböck, managing di-rector of EMS. “The professionalism shown during the implementation of the installation and commissioning is also reflected in the continuous dia-logue that took place throughout the entire project between the project en-gineers from BN Automation AG and EMS and also Siemens.”

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The control room at EMS after the conversion

“ We now have a future-

proof control system

with which the pending

modifications can be very

easily implemented.”

Gunnar Fritsche, Electrotechnical Equipment Manager, EMS

INFO AND CONTACT

www.ems-schwarza.desiemens.com/[email protected]

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

BN Automation AG has developed and implemented solutions for the automation of technical processes since 1990. BN Automation AG employs more than 100 people at its headquarters in Ilmenau. The company’s specific focus is on systems for energy generation and distribution, such as combined cycle gas turbine power stations or biogas plants, water processing and wastewater treatment facilities, and technological processes in industry. Specialists in switchboard construc-

tion, automation and process control engineering, information technology, service and software development, and manufacturing execution systems work together to form a strong foundation for successful projects worldwide.

www.bn-automation.com

http://www.ems-schwarza.de



http://www.bn-automation.com

process news 2/2013 | Solution Partner

The Siat Braun sawmill is one of the largest of its kind in northeastern France. Recycling and disposing of

the bark and sawdust produced during timber processing used to be time and cost intensive. New, modern heating technologies now enable making good use of these materials. Sawdust is pressed into pellets without any further additives and is then made available as a natural product for the heating of homes and for further use in industrial plants. The bark produces enough en-ergy in a boiler to power a steam tur-bine. The electricity produced by a gen-erator is fed directly into the public power supply. In addition, the steam energy remaining after the turbine is utilized in a condenser to heat water.

Together with optimally organized preliminary planning, the performance and modularity of PCS 7 have ensured trouble-free project implementation at a new pellet production plant with an adjacent biomass power station.

Getting the most out of raw materials

vanced Process Library and defined ad-dress spaces and naming conventions. Thanks to these comprehensive specifi-cations, each package unit provider could carry out programming and par-tial commissioning with a temporary engineering station independently of other packages.

Individual components result in a multiproject

Evias GmbH supported the individual suppliers throughout the complete proj-ect. In this way, minor problems could be solved immediately, without affect-ing the project schedule. Apart from central coordination, Evias handed over the entire electrotechnical design, as-

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Siat Braun, France

This recycled process heat is used to dry the sawdust for pellet production through a heat exchanger.

Multisupplier coordination

Siat Braun chose to use Simatic PCS 7, in its current 8.0 version, very early in the planning phase. The challenge lay in the drafting of a concept to unify sev-eral technical disciplines (or subsec-tions) and different suppliers so that all areas could be operated by means of a single system. To help achieve this, Evias GmbH drafted an engineering guide – a comprehensive document that specifies the requirements for the project design in a multiproject frame-work: all packages had to use the Ad-

The nw PCS 7 control center: the operators can access all relevant process information via nine screens

Solution Partner | process news 2/2013

sembly, and installation of a belt dryer, necessary for the drying of sawdust, to the Swiss company Swiss Combi – W. Kunz dryTec AG. The project was also created as a module of the later PCS 7 multiproject. Further subprojects from Evias GmbH include the complete raw material feed system for the boiler, the supply and installation of the Simatic PCS 7 network structure (including the complete operating and monitor-ing system), a control system for the plant’s central emergency stop circuit, and the control for the energy supply connection.

Optimal utilization of Simatic PCS 7

Many of the functions and options that PCS 7 offers were used of throughout the project. Special mention must be made of the seamless integration of more than 50 Sinamics G120 drives and all the emergency stop technology using Simatic F engineering, which was built into seven S7-400 controllers and four additional S7-300 controllers. Al-most the entire signal exchange be-tween the subsections was realized using a communication bus in a ring to-pology, which saved considerable ef-fort in terms of additional cabling. Op-timal operation of the plant is enabled by a redundant WinCC server, which is connected to four clients. A total of nine new monitors have been made available to the operating personnel in the control room. The extensive range of functions is rounded off with the Alarm Control Center, which sends op-

erators important fault messages di-rectly to their cell phones. The operat-ing manager and on-call duty person-nel are automatically informed of more major incidents by means of the cell phone network.

Around-the-clock operability achieved

Under the coordination of Evias it was possible to integrate not only the most varied system components but also the individual subsections of the different suppliers into one great multiproject. The time-consuming preliminary plan-ning paid off with the smooth integra-tion of the subsections. A total of six in-dividual projects have been integrated,

which enabled a uniform library and uniform operating concept to be used and inventory management reduced. “We were able to achieve optimal oper-ability around the clock by integrating all subsections,” said Jérôme Sittler, project and operations manager at Siat Braun. “In addition, we have now housed all relevant archive data in one system, with the result that we can, at any time and without any further effort, produce cross-process analyses and reports.”

INFO AND CONTACT


The EVIAS GmbH was founded in 2006 in Bad Bergzabern, Germany. Since then, the company has evolved into a product- and system-independent engineering firm for automation technology and serves process automation customers at home and abroad. EVIAS can rely on expert staff and a high level of automation expertise to provide tailored solutions to international customers, from process and

factory automation solutions to power supply design, custom migrations, and MES, solutions as well as service, infrastructure, validation, training, and project execution.

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The SIAT Braun sawmill utilizes waste sawdust as pellets for heating.

The pellets are pressed without additived in an

eco-friendly process

www.evias.de

http://www.siemens.com/solutionpartner


http://www.evias.de

32


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

Turn up the gas

M/s Aegis Logistics in India moves and distrib-utes petroleum and chemical products from the producers to end users. At Pir Pau the

company operates a 20,000 MT refrigerated lique-fied petroleum gas (LPG) import terminal. The ter-minal has advanced safety features such as full- containment LPG storage tanks, a remote control water curtain, gas detectors, automatic shutoff sys-tems, and remote control valves. The terminal is con-nected to Pir Pau Jetty by 12’’ low-temperature steel pipelines. The complex consists of three discrete sec-tions: the gas terminal, the liquid terminal, and the Sealord terminal. The processes and parameters in all three terminals are monitored and controlled from a central control room, and, of course, safety is paramount. As part of a plant upgrade, Aegis decided to migrate from the existing S5-155H programmable logic controllers (PLCs) to the latest Simatic PCS 7 dis-tributed control system with fiber-optic links between the terminals. One key benefit for Aegis was the seamless integration of the enterprise resource man-agement system that Simatic PCS 7 provides, offering improved order and materials tracking.

Simatic PCS 7 advantages

To assist with the upgrade, Aegis hired Control Auto-mation Projects Pvt. Ltd. (CAPPL), a certified Siemens Solution Partner based in India. The project team se-lected the AS417H CPU, the most powerful in the Simatic PCS 7 line, along with four operator stations. The AS417H is a fault-tolerant one-out-of-two redun-dant system, built for ultrahigh reliability. PCS 7 fea-tures centralized data monitoring, data reduction, and data analysis, together with access to global in-formation via a web server.

Aegis Logistics, India

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Solution Partners | process news 2/2013

PCS 7 includes an Advanced Process Library (APL) that can be used to provide improved functions and visually attractive graphical user interfaces. These preprogrammed functions were used to great effect during the software engineering phase and were in-strumental in minimizing the development time.

At Pir Pau the control of rotating machines is imple-mented via Profibus and Simocode Pro intelligent motor control centers (MCCs). The Simocode Pro MCCs enable seamless interconnection between dif-ferent systems and handle the protection, control, and monitoring of motor drives. The MCCs monitor key operating parameters of the motor drives and are able to perform autonomous actions based on those measurements.

Meeting the challenges

The actual changeover posed another challenge, as the shutdown time allowed was only six hours. To complete the implementation in this short time frame, a new approach of using S5 to S7 adapters was proposed. The adapters enabled the software to be thoroughly tested during the short shutdown pe-riod and allowed the option of switching back to the S5 system should any serious problems arise. To pre-pare for these challenges, CAPPL undertook the basic groundwork off-site. The S5 logic was decoded and converted to PCS 7, and the HMI was regenerated in the PCS 7 OS. When preparations were complete, a full simulation was carried out on-site prior to the shutdown.

On the day of the changeover, the work was fin-ished in just two hours. The Simatic PCS 7 system at Pir Pau has gone on to operate problem-free for two years.

Different industry sectors present their own unique processes and operational challenges. As a result, solution providers often need in-depth industry knowledge and experience to deliver the optimum automation solutions.

Siemens Solution Partners are carefully selected systems integrators that are qualified as expert providers in the fields of automation and drive technology. More than 1,200 certified Siemens Solution Partners operate in over 60 countries. In India, Siemens has 85 systems integrator partners. The Process Automation PCS 7 Solution Partner Program was rolled out in 2008 in India and now includes 10 Solution Partners.

The same worldwide standards apply to all partners, with training programs and workshops providing alignment with Siemens Germany. The partners undertake certification testing following

training and are subject to requalification every two years. This ensures that Siemens customers receive the same level of specialist technical competence and service wherever they are in the world.

Siemens Solution Partner network

“ Our confidence in the power of

Simatic PCS 7 grew at every stage

of the project. We can see that the

OS makes it easy for the operator

to manage the processes safely.” Nitin P. Patil, Manager, Instrumentation, Aegis Logistics Ltd.

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A vital technique for monitoring the performance of a blast furnace is continuous analysis of the gases at the top of the furnace. From these

analyses the conditions in the heart of the furnace can be determined and appropriate measures taken to control throughput and quality. The gases ana-lyzed are generally carbon monoxide (CO), carbon di-oxide (CO2), oxygen (O2), and hydrogen (H2). The top gas analysis of a blast furnace is one of the most chal-lenging applications that a continuous gas monitor-ing system can perform. The gas monitors must work in an environment of extremely high moisture, high pressure at the sample takeoff point, and very high dust load.

SAIL is a leading steel producer in India, and its largest plant is at Bokaro. The first blast furnace at Bokaro started production in 1972, and now five 2,000-m3 blast furnaces are at the site. SAIL Bokaro has used various kinds of top gas analysis systems over the years but experienced problems with limited availability and performance compounded by high maintenance requirements. In 2009, Bokaro asked Siemens to develop a better solution.

Designing a robust solution

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

India’s leading steel producer benefits from a tailored gas analysis solution that helps improve blast furnace throughput and quality.

Hot stuff

stages. The graphic touchscreen HMI provided greater ease of operation, and logging of the system compo-nents’ status facilitated preventive maintenance.

The first top gas analysis system was fitted to Blast Furnace No. 3 at Bokaro and was immediately suc-cessful. With the performance and reliability con-firmed, in 2010 SAIL ordered the same solution to re-place the top gas analysis system on Blast Furnace No. 2 at Bokaro. SAIL now has a proven reference at Bokaro forming the basis for replacement of earlier systems at other SAIL steel plants with the proven solution from Siemens and Adage Automation.

Adage Automation, India

INFO AND CONTACT


Adage Automation is a Solution Partner Process Analytics and one of the largest exporters of gas analytical systems from India. Based in Mumbai with seven offices across India, the company has a state-of-the-art factory with ISO 9001:2000 certification. The

facility is one of the largest analyzer system units in India and also includes a modern analyzer repair center and lab.

adage-automation.com

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http://www.siemens.com/processanalytics


http://www.adage-automation.com

Dialogue | process news 2/2013

process news 3/2013

Integrated Engineering

What will the future of industrial produc-tion look like? Many experts predict that production will be increasingly

characterized by networked IT systems and soft-ware tools. One key aspect of optimizing plant and product lifecycle costs are consistent engi-neering data. These topics will also be the focus of the next issue of process news that will focus on integrated engineering and the integration of plant design and process control.

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

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Publisher: Siemens Aktiengesellschaft,Gleiwitzer Str. 555, 90475 Nuremberg, Germanysiemens.com/automation

Drive Technologies DivisionIndustry Automation DivisionCustomer Services Division

Editorial Responsibility in Accordance with the German Press Law:Ralf Schmitt

Responsible for Technical Content:Cornelia Dürrfeld

Editorial Committee:Lalit Bangera, Thomas Bartsch, Gustavo Bombillar, Charles Fialkowski, Ute Forstner, Petra Geiss, Sourav Ghosh, Punita Kathote, Rajesh Nair, Bipin Pagaria, Doina Pamfilie, Mahesh Parkhi, KM. Sundaram, Pai Sunil, Abhijit Tambat, Roland Wieser

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Circulation: 27,100

Volume 18, process news is published quarterly

ISSN 1430-2284 (Print)IWI: TPOGOrder No.: E20001-M6213-B100-X-7600

© 2013 by Siemens Aktiengesellschaft Munich and Berlin.All rights reserved by the publisher.

This edition was printed on environmentally friendly chlorine-free paper. Printed in Germany

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If trademarks, trade names, technical solutions, or similar are not listed above, this does not imply that they are not registered.

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process news July 2013

Compliance and Business

Positive experiences

The basic rules for responsible entrepreneurship are integrity and compliance with all applicable laws and regulations. This is also true for sustainable economic activity since it creates

new business opportunities that ensure profitable long-term growth. Our Business Conduct Guidelines, containing the basic rules and principles for our actions and our behavior within the company and in relation to external partners and the public, are of great importance in this respect. The consequences of improper and unlawful behavior can be enormous: horrendous penalties, loss of orders, penal consequences, and not least, the resulting damage to the company’s reputation. This definitely must be avoided. How-ever, the most important thing to remember is that clear commit-ment to fair competition results in a consistent focus on product in-novation and the customer. In order to continue to do justice to this claim and to strengthen the trust of the customers in the company and its products, Siemens has successfully introduced a compre-hensive compliance program. This year the compliance office of I IA and I DT once again presented positive experiences with this pro-gram to its customers and business partners at Hannover Messe.

siemens.com/compliance

We kindly ask all our customers to contact us in the event of any compliance-related problems with relevant business partners (e.g., distributors, sales agents, or business consultants) via the “Tell us” compliance help desk at siemens.com/tell-us or our attorney Dr. André Große Vorholt of the law firm Luther Rechts-anwaltsgesellschaft mbH at siemens- [email protected].

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http://www.siemens.com/automation


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Answers for industry.

siemens.com/drinktec

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

Visit us at Drinktec and learn how to make your production more flexible and cost-effective. We will demonstrate the monitoring of energy flows and the possibilities to reduce energy costs significantly. We‘re looking forward to a successful Drinktec – see you there!

Visit us at Drinktec!

September 16 - 20, 2013, Munich, Germany

Booth 107 in Hall A4

Smooth processes for higher productivityA comprehensive approach for beverage plants

http://www.siemens.com/drinktec

Documents

Process News 2-2013 En