Trends in Process Automation - Siemens · 2011-08-10/11 Industry Sector Trends in Process Automation. ... New plants especially in China, ... (total cost of ownership)

© Siemens AG 2011. All Rights Reserved.

Industry Sector2011-08-10/11

Trends in Process Automation

Prof. Dr. Michael Bruns

Vice PresidentProcess AutomationIndustrial Automation Systems

SRAES @ Goa 2011



Indu

strie

sIndustrial Automation Systems stands for…

...products and solutions with highest level of customer valueSo

lutio

nsPr

oduc

ts

Design & execution of plants

Ener

gy

Ref

iner

y

Wat

er

Che

mic

als

Oil

& G

as

Pulp

& P

aper

Cem

ent &

Gla

s

Met

al /

Min

ing

Sola

r

Phar

ma

Food

& B

ev

Aut

omot

ive

Elec

tron

ics

Process Discrete

Plant Engineering Software

MES SIMATIC IT

SIMATIC Automation Designer, COMOS

SIMATIC PCS 7SIPAT, Batch,

Asset Management,Redundancy, Ex(i)

SIMATIC WinCC, SIMATIC Panels,Panel PC

SIMATIC S7PC-based, LOGO!Remote I/O, Safety

DCS HMI PLC/ IPC



Global Trends in Verticals

Chemical&

BioFuels

Chemical Industry will grow around 6% per year

New plants especially in China, Near Middle East, India, Brazil

Modernization/specialization of plants in North America, Europe

Food&

Beverages

Continuous market growth especially in developing countries

Increased demand in tracking & tracing and product safety

Global Standardization of production

India: Non Alcoholic Drinks grow fastest (15% CAGR)

Pharma-

ceutical

Biggest market growth is expected in India (over 15%)

India will be in the top 10 of biggest pharmaceutical markets

Regional regulators will become increasingly important



Global Trends in Verticals

Glass &

Solar

Water&

Wastew.

Environmental protection (carbon emissions)

Energy efficiency

Capital efficiency TCO (total cost of ownership)

Cement

Water scarcity (mega cities, e.g. in Asia Pacific)

High degree of industrialization on a global base

Major growth in APAC/India –

evolution from M3 to M1

High economic pressure and complex value chain

Solar: Rapid Growth and evolving technology

Glass: Environmental protection and product innovation



Customers are driven by life cycle costs

and operational efficiency

Customer Requirements Solutions

Lower Project costs

Increase flexibility

Decrease life cycle costs

Reduce resource consumption

Digital enterprise and optimized en-

gineering

workflow

Comprehensive Fieldbus

solutions

Life cycle services

Operational efficiency

1

2

3

4

Global Trends

New plants especially in Brazil, China, India, NME

"Brown fields" in EU / NAM

India with biggest market growth in pharmaceutical

Global standardization of products

Regional regulators will become increas-

ingly

important

Environmental protection

Energy efficiency

Capital efficiency TCO



Solutions

2 Comprehensive Fieldbus

solutions

3 Life cycle services

1 Integrated Engineering

©

Siemens AG 2011. All Rights Reserved.

4 Operational Efficiency



Only an integrated view across all levels of production enables faster time to market!

Process serial serial, shortened by tools

parallel

Further optimization

by individual tools is widely exhausted

time time time

ProductProcessMechanicalElectricalAutomation

Level

yesterday today tomorrow

Integration of Process Planning and Automation Engineering…

enables parallel Planning Process …



… save valuable time

… based on a new engineering workflow

Engineering workflow on the basis of one engineering model for configuration of plant-, electrical-

and automation aspects

parallel

time

tomorrow

Electrical Design

Piping 3D

design

P&ID Instrument

ation

•

Assembly•

Commissioning•

SOP

Document-Mgmt.

DCSConfigu-

ration

Function-

oriented engineering

model

I&C planning:

Plant & Process related planning:



Integrated Engineering with COMOS and PCS 7 Today's Situation Using a Motor as an Example

P&ID

3-D model

Circuit diagram

PCS 7 Software Configuration

PCS 7 Hardware ConfigurationSingle-pole representation

COMOS SIMATIC PCS 7Object,

e.g., motor

Configurations and structures are transferred as objects between COMOS and SIMATIC PCS 7





solutions




©




Short-circuit or wire break on trunk line

AFD

PROFIBUS PA

/

FOUNDATION Fieldbus

H1

bus termination

Active

Field

Distributor (AFD)

Link

(redundant)Field Device Coupler, redundant (M = master)

Higher availability and robustness

due to intelligent fieldbus

Infrastructure



Foundation

Field

Bus

All required configuration with one Foundation Field bus Link for a scalable availability

PROFIBUS PA and FOUNDATION Field bus FF Use the same Physical Layer

FF-H1 ring redundancy

No 3rd party components required

No interoperability issues

PRO

FIB

US

DP

back

bone

FF Link

FF-H1

FF Link

FF-H1

FF Link

FF-H1

FF Link

FF-H1

Ideal Link with Highest availability !!! Only at Siemens





solutions




©




Life Cycle Services (LCS) for SIMATIC PCS 7

Life Cycle Service

For Operation and Serviceability of plants

Are maintaining the existing functions of DCS for minimized costs

As per Standards & Recommendations



Life Cycle Services (LCS) for SIMATIC PCS 7

Specific Characteristics

Planning and management of Product Obsolescence in-house

PCS 7 components ~100% by Siemens

Integrated in PCS 7 PLM (Product Life-Cycle Management)

Siemens = OEM for MS –

delivery of PCs w. MS operating sys.

Worldwide Product Service Infrastructure (SIMATIC)

Regional Service Organization

Common Remote Service Platform

Benefits

Increased plant availability

Modernization and service costs can be planned –

over years

Investment protection & securing of serviceability

Ensuring the delivery capacity of spare parts

Reduction of the Total Cost of Ownership (TCO)





solutions




©




Optimization

Advanced Process Control (APC)

Intelligent and energy efficient maintenance of electronic and mechanical plant components

SIMATIC PCS 7 offers not only corrective but also preventive Plant Asset management

Reduction of the decision and reaction time -

high plant availability, cost effective

Energy Management acc. to Standards Advanced Process Analytics

Model based predictive control (MPC)Typical applications:

Two component distillation (2x2)

Cement mill (3x4)Benefits

Less process deviations

Increased yield

Higher throughput

Plant Asset Management Advanced Process Control

SIMATIC

PCS 7

Electrical

EnergySteam

Cooling

HeatCompressed

Air

Gas

Water

SIPAT -

key Enabler for Continuous Manufacturing & Real Time Releases



Thank you for your attention!

©


Documents

Trends in Process Automation - Siemens · 2011-08-10/11 Industry Sector Trends in Process Automation. ... New plants especially in China, ... (total cost of ownership)