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process news
The Magazine for the Process Industry
Partners in India
Solutions for growth and innovation
Focus on India
In 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 worlds third largest in terms of volume. The photo shows two researchers in a pharmaceutical laboratory in Mumbai.
Photo: Frederic Soltan/Corbis
Editorial
03 Past meets present
Process Instrumentation
24 Good measures A Sitrans flowmeter helps verify the supplied amount of jet fuel 25 High tech in compact design Sitrans technology in a combined wastewater treatment/biogas facility
Cover
04 Partners in progress Jubilant India benefits from modern process control
Drive Technology
26 Production sweet spot Spray Engineering Devices Ltd., India, improves energy efficiency in the sugar industry with Siemens drives
Solution Partners
28 Modernization without disruption Process control system migration at a German utility 30 Getting the most out of raw materials Simatic PCS7 supports smooth project implementation at a French sawmill 32 Turn up the gas Aegis Logistics benefits from smooth safety system operations 34 Hot stuff A tailored gas analysis solution helps improve blast furnace operations Folder inside: Competent Partners Individual solutions for the water sector
Pharmaceuticals
12 World-class efficiency Shantha Biotechnics benefits from smooth validation 14 Active and effective Teva API optimizes energy efficiency
Dialogue
35 Compliance, preview
Looking out my ofce window, I can witness just how the society and the economy in India are rapidly evolving. My ofce 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 benet from low production costs, but draw added benet 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-ofthe-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!
Siemens AG
Partners in progress
Siemens becomes a trusted partner to an Indian pharmaceutical and life science company, helping it expand and grow.
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ubilant Life Sciences Ltd., an integrated pharma- to achieve higher productivity with less manual interceutical and life science company, is one of the vention and a faster return on investment. largest custom research and manufacturing services companies in India. The company has earned a The plan for expansion reputation as a high-quality manufacturer, with approval from the US Food and Drug Administration Jubilant is currently developing a sector-specic SEZ (FDA), the Agence franaise de scurit sanitaire des (special economic zone) for chemicals on 265 acres produits de sant (AFSSAPS) in France, and the Phar- of land at Vilayat GIDC Industrial Estate, in Bharuch maceuticals and Medical Devices Agency (PMDA) in district of Gujarat. The facility dedicated to the production of specialty chemicals is located here. Japan. Jubilant has a 300-acre manufacturing facility in ThieBharuch facility consists of multiple processing Gujarat, India, which contains a state-of-the-art plant blocks, along with scrubbers, raw material tank farms, producing specialty chemicals used in the manufac- cooling towers, and the plant utilities. The plants ture of vitamins and intermediates for the pharma- have been successfully commissioned one after the other. ceutical and agricultural industries. To meet the growing demand, Jubilant wanted From the very beginning, Jubilant wanted a distribmore efcient and transparent process control, with uted control system (DCS) for the manufacturing faa high degree of exibility and expandability, in order 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
SITRANS LR250
Radar Level Transmitter
SITRANS P DS III
Pressure Transmitter
SIPART PS2-FF
Electropneumatic Positioner
SITRANS F M 6000
Magnetic Flowmeter
Siemens AG
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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.
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 research 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 Are there any plans to extend this be built in Bharuch as well as new API collaboration to other elds? (active pharmaceutical ingredient) Mr. Bang: We have a concept called plants in Mysore. Another pillar for partners in progress, where we meet growth is innovation: we are research with preferred vendors and work out a and development driven. The new spe- yearly plan for developing and upgradcialty chemical facility is proof of this, ing their technology and Siemens is as it will operate with a new environ- an important part of this concept.
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
bus technology. The customer saw this as necessary to achieve better plant and system diagnostics, enhanced safety in operations, and consistent nal product quality, along with optimum raw material consumption. Another benet of the DCS was an improvement in plant performance, thanks to a reliable data archive for the process parameters. Cost optimization in manufacturing was another key aspect, especially due to the pressure on prot 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.
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 eld instruments (mass ow, magnetic-inductive ow, radar and differential pressure-type level transmitters), installation commissioning, installation hardware, eld engineering, installation 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 conrmed the clients condence in Siemens leadership in the process control systems market.
A valuable addition
Jubilant chose the Simatic PCS7 V8.0 process control system in a redundant conguration for maximum One success leads to another availability. Siemens patented event-based synchronization technology for the Simatic PCS7 system al- The Bharuch project was not the rst successful collows hot standby operation with bumpless switching laboration between Jubilant and Siemens. Impressed within a few milliseconds and without the redundant with the on-time execution and commissioning of systems needing to be near each other. Another key Plants 4 and 5 at Jubilants Nanjangud facility, Jubifactor in favor of PCS7 was the systems ability to lant selected Siemens as the main automation venseamlessly integrate Foundation Fieldbus I/O devices. dor for Plant 6 at the Nanjangud facility as well as the In Bharuch, 400 Foundation Fieldbus I/O devices are Bharuch SEZ facility. Siemens scope of responsibility connected to a single redundant PCS7 CPU, which for the Plant 6 facility includes process automation helps reduce hardware costs. and eld instrumentation on a turnkey basis, along With the help of PCS7, Jubilant Life Sciences is im- with eld engineering, installation and commissionplementing a number of process improvements, ing, validation, and site management. thereby optimizing production costs, quality, and product safety. In addition, continuous recording of all the relevant process data not only enables rapid Info and ContaCt error analysis during servicing, but also allows for siemens.com/pcs7 clear tracking of quality issues and provides higher mahesh.parkhi@siemens.com system availability. The archiving takes place in accor7
AFP ImageForum
Fieldbus technology
Corbis
he production and process industries would be unimaginable without eldbus solutions. Fieldbuses simplify the planning, engineering, installation, and operation of plants. Instead of individual wiring, a bus feeds the information from the eld devices 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 eldbus, and the original hope for a single unied communications mechanism has not been realized. However, Simatic PCS7, which can accommodate all the major processing and production technologies (HART, Probus, and Foundation Fieldbus), offers a eldbus compatibility level that is unmatched.
Siemens AG
The Simatic PDM Process Device Manager V8 serves as a central tool for user-friendly parameterization and diagnosis of the process instrumentation
One of Indias 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
Siemens in India
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Frederic Soltan/Corbis
ne 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 expenditure 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 Pronet that monitors the status of the machine and switches it off in real time when there is no production scheduled. Such measures can enable even smaller manufacturers to benet 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 reliable quality and that it offers added benets such as increased energy efciency and cost-effectiveness, leading to higher productivity and improved margins, he says. Process automation can also help in detecting and controlling water usage, energy consumption, 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 technology partner whose expertise is completely aligned with their process requirements and that also deliv-
Siemens in India
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 companys founding in 1847. In 1922, Siemens set up branch ofces in Mumbai and Calcutta. In 1957, Siemens was incorporated as a company in India and started manufacturing switchboards; 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 development centers.
ers a superior return on investment. Because we follow a vertical market approach, we have marketspecic products and solutions for particular industries that are handled by competent sales and execution teams with extensive industry-specic application knowledge. This results in the implementation of optimum products and solutions that enable customers to increase the productivity and sustainability of their operations.
Siemens India
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World-class efciency
By monitoring and managing energy consumption with Simatic B.Data, Shantha Biotechnics is able to track and optimize the energy efciency of the utilities in its production plant and achieve signicant cost savings.
Shantha Biotechnics is the first Indian company to develop a recombinant-DNA human healthcare product in India
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frankoppermann Fotolia
hantha Biotechnics, a wholly owned subsidiary of the global Sano group, is a biotechnology company with state-of-the-art facilities in Hyderabad, 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 rst Indian company to develop a recombinant-DNA human healthcare product in India and is prequalied by the World Health Organization (WHO) to sell vaccines to United Nations procurement agencies such as the United Nations Childrens Fund (UNICEF) and the Pan American 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 conservation, the main aim of Shantha Biotechnics was to have a exible utility management solution that could calculate the cost per unit of the utility generated at the block level and generate energy-related reports.
Key points
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
Established in 1993, Shantha Biotechnics has matured into a successful pharmaceutical venture
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 fulll their legal obligations to monitor and report on greenhouse gas emissions (CO2 emissions).
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eva Active Pharmaceutical Ingredients (TAPI) is a stand-alone business unit of Teva Pharmaceutical Industries Ltd., an international pharmaceutical company headquartered in Israel. Teva Pharmaceutical Industries is the largest generic drug manufacturer in the world and one of the 15 largest pharmaceutical companies worldwide. TAPI is the
leading international supplier of active pharmaceutical ingredients (APIs). It specializes in the development, 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-
Siemens India
thetic fermentation, enzymatic synthesis, high- potency manufacturing, plant extract technology, synthetic peptides, vitamin D derivatives, and prostaglandins.
functionality, and many other diagnostic features. Wiring and maintenance were reduced by implementing the Simatic ET 200M distributed I/O system to connect signals in explosion-hazardous areas. Siemens also offered local validation expertise with qualied project teams in India who worked with dedicated engineers to execute and complete the MPP-2 and MPP-3 automation system on schedule. As Dinesh Agarwal, TAPI senior manager of procurement, explains, TAPI beneted 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 enjoyed a very good cooperation, and our engineers are comfortable with the services provided by Siemens.
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Linde AG
System in a box
In India, Siemens builds a complete cryogenic plant control system inside two shipping containers before sending them to an Indonesian steelworks.
inde India Ltd., formerly BOC India distillation. The rare (or noble) gases 2007 to 2011, Siemens India executed Ltd., a part of the Linde Group are present in the air in only trace several ASU projects for BOC India based headquartered in Germany, is one amounts of parts per million. Therefore, on the Simatic PCS7 process control of the leading companies in India sup- to extract them in viable amounts using system. In October 2011 Linde India seplying industrial gases, both in bulk for the air-separation process, large-scale lected Siemens to supply the control heavy industrial use and as high-purity units with huge air intakes, of the order system for a new 2,000 MTPD ASU to be gases for users such as hospitals and of at least 1,000 metric tons per day installed at a steelworks operated by laboratories. (MTPD) oxygen capacity, are needed. POSCO in Cilegon, Indonesia. The ASU The gases are produced in large The plants operate in a nely balanced was to be installed on a build, own, and air-separation units (ASUs) commonly closed-loop system requiring precisely operate basis. To avoid any additional located within the sites of heavy indus- calibrated analytical instrumentation to building to accommodate the ASU contrial users such as steel plants, glass ensure accurate control and safe trol equipment, a complete preengineered containerized control system manufacturing plants, petrochemical operation. complexes, reneries, and others. ASUs From its Indian manufacturing center was designed. The control cabinets, I/O separate atmospheric air into its pri- at Nashik Works, Siemens supports and marshaling cabinets, PC consoles, mary components, typically nitrogen, Linde India in ASU projects, supplying and other equipment would be comoxygen, and argon, and the rare gases and commissioning distributed control pletely housed, wired, and tested inside neon, krypton, and xenon. The separa- system panels and accessories for instal- two shipping containers at the Siemens tion process uses various technologies, lation inside control rooms, marshaling factory in Nashik prior to transporting the most common of which is cryogenic rooms, and switchgear rooms. From them to Indonesia.
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The remote operations center features the latest technology and provides all local HMI functions of the remote process control systems via terminals
The entire control system was shipped to the customer site as a containerized solution
development and assumed overall responsibility 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 PSC7 AS redundant controller tted in container 2. This unit provided control for the storage area and utilities. ET200M rack systems, both within the containers and mounted remotely, provided I/O connections to the eld. When all the work was complete, the containers were shipped to the POSCO steel site in Cilegon, where nal commissioning was carried out. Classroom training on the Simatic PCS7 was provided to the new operators at Siemens Kalwa Works in India. This groundbreaking project marked the
Linde AG
rst time that Siemens India had manufactured a complete containerized system, and the project required close cooperation between different organizations across three countries.
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Siemens India
ashik, located approximately 170km from Mumbai, is one of the fastest-growing cities in India. In 1987, Siemens established a manufacturing 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 d evelopment facility and develops many compo nents for products manufactured in the factory as well as adapting global Siemens products for local conditions.
automation cabinets for an air-separation plant in South Korea; and automation, electrical, and variable-frequency drive cabinets for a polyester line in Quality and standards are key Turkey. With its long proven record of successful projQuality has always been the key driver for this facil- ects, the Nashik factory has expertise in project deity and the factory adheres to strong quality manage- sign and execution to back up its stringent standards, ment processes. Every year the factory turns out ensuring the highest quality for every product delivmore than 4,000 engineered cabinets, meeting ered to customers in India and abroad. global standards for various industrial applications within India and across the world such as more than Info and contact 100 automation cabinets for a polypropylene plant in siemens.com/pcs7 Egypt; automation cabinets for a direct reduced iron abhijit.tambat@siemens.com plant in Bahrain via a customer in the United States;
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SiemensIndia
Process safety
A safe choice
Process safety is essential for the protection of people, assets, and the environment. It can also help safeguard 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.
ne key factor affecting the cost and performance of a safety instrumented system (SIS) is engineering. 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 TV-certified causeand-effects tool was specifically created to help users design, engineer, operate, and maintain an SIS through all phases of the safety lifecycle. The tools intuitive interface has helped hundreds of customers comply with the requirements of the ANSI/ISA 84 functional safety standard while reducing their engineering costs by automatically programming the safety logic. Users save time and reduce cost and complexity, as was recently acknowledged by Control Engineering maga-
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D. Obertreis
zine in its selection of the Simatic Safety Matrix to receive the 2011 Engineers Choice Award.
S7-400FH controller
1002 Flow
2003 PT
Simatic PCS7F 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
technologies, including Prosafe, ASIsafe, and Industrial Ethernet. This eliminates the need for additional networks, complex configuration, or costly gateways to provide safe, secure, and fault- tolerant system communication. Safe signals can be linked via Simatic ET 200ISP, the recipient of Control Engineering s 2012 Engineers Choice Award for failsafe 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 installations in hazardous areas (up to Ex zone1), extreme temperature ratings (-20 to +70C), and corrosive atmospheres (ISA-71.04 severity levels G1, G2, G3). For better integration and reduced footprints, both safety and standard modules can be installed and congured in the same backplane.
tors must test their SIS following a r igorously defined schedule. Simatic PCS7F safety performance numbers have been approved for either a 10- or 20-year proof test interval and help reduce SIL verication costs by simplifying calculations while extending test intervals. This feature removes the burden of conducting comprehensive and time-consuming system test procedures and helps reduce annual maintenance budgets, along with enabling simpler SIL verication calculations. Siemens can also use its industry and technology expertise to support customers in designing and building industry- compliant safety systems. Siemens is able to deliver complete systems that are designed and built to meet regulatory codes and safety standards. Prepackaged systems help reduce risk, simplify the scope of projects, and ensure consistent design and better service and support.
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Siemens AG
Industrial Security
Hands-on security
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.
he physical components of an automation system should be effectively safeguarded against unauthorized access, and their use should be dened by a clear set of rules. Awareness of security issues should be rmly 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 ve thematic areas: handling of mass storage media, system servicing either at the plant or by remote access, handling of communication media, how operators 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 automation systems. As in other areas of a defense-indepth security strategy, physical access protection depends upon a bundle of coordinated individual measures that
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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 organizational and personnel procedures, mechanical and physical controls, and electronic surveillance and detection.
communications infrastructure must be adapted to changes in operational requirements. These are tasks that must be performed not only by in-house personnel but also by external service partners and suppliers. Both groups need physical access to individual components of the system. Mechanical and electronic protection systems may indeed ensure that this access is only granted to explicitly authorized personnel. However, a responsible approach to these mechanisms also includes personnel procedures. Targeted duties and procedures can be de-
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)
D. Obertreis
DCS
ned for the companys own employees, can be organized into four security secwhile specic contractual arrangements tors. Sector 0 is considered to be the are an effective approach for managing area outside the property. Sector 1 is external partners. the property line itself. Sector 2 inA sense of responsibility also necessi- cludes all areas within the premises. tates practical knowledge of the signif- And nally, Sector 3 is the direct protecicance of the installed security mea- tion of the automation system itself. sures. This means that the person con- This sector concept can be exibly apcerned must have a clear awareness of plied to almost any architectural envithe far-reaching consequences of ma- ronment. The protection of sectors 0 to nipulating the system an awareness 3 is based on comprehensive surveilthat is best communicated by means of lance alarm management and a precourses and on-site training programs. cisely coordinated system of sensors In addition, the physical security sys- and alarms with different operating tem must be inspected regularly to en- principles. Such a system forms multisure its continued reliability. For this tiered perimeter protection that is process, the day-to-day experience of largely tamper-proof. everyone involved is critical in order to It is supplemented by coordinated acuncover weaknesses and identify op- cess protection, which includes securiportunities for manipulation. ty-critical oors, parts of buildings, and rooms, as well as individual switch cabSecurity begins at the site inets. Siemens relies on an integrated access concept, where interior mechaboundary tronic locking components are comIn spatial terms, a comprehensive pack- bined with online access control sysage of measures for physical security tems in the input area. At the same
time, the use of RFID technology makes it possible to equip all internal and external employees with exactly the access permissions they require for the performance of their duties. But the information system of a company is not only exposed to attacks from cyberspace; it must also be protected against physical attacks in the real world. This is why a physical component is an absolutely mandatory element of a defense-in-depth security concept. The physical component must ensure that authorized persons are able to fulll their tasks unhindered, in order to keep the system running, while at the same time having the capability to block unauthorized entry effectively.
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
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Good measures
By installing a Sitrans FUT1010 clamp-on ow metering solution, BKL A/S can now reliably verify the amount of jet fuel supplied from a nearby terminal to the companys tank storage at Copenhagen airport.
The TransLoc mounting system allows for permanent transducer installation outside the sensor
Verifying measurements
A level meter in the tank measures the fuel. BKL noticed discrepancies between 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. Because BKL needed precise, repeatable measurement, the team chose the Sitrans FUT1010 liquid ultrasonic owmeter, which offers several critical f eatures, such as 0.15 % accuracy, Peter Laybourn, General Manager, BKL A/S 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 that its meters were correct. This elim- Since the transducers are protected system, which prevents contact with inated the measurement discrepancies. from the medium and the surrounding the fuel and allows ow calibration. environment, the maintenance requireBKL installed a Sitrans FUT1010 on Signicant savings ments are almost nonexistent. These factors add up to signicant cost savthe pipeline into the storage tank, where it could measure the fuel after it Incorporating the Sitrans FUT1010 into ings for our company. was cleaned but before it entered the our fuel transfer process has proven to tank. Sitrans FUT1010 readings con- be an extremely wise investment, said rmed that BKLs level meter was accu- Peter Laybourn, general manager of Info And ContaCt rate, allowing BKL to conclude that the BKLA/S. The meters accurate and relisiemens.com/ow problem was on the supplier side. BKL able performance allowed us to reconmatt.bird@siemens.com then worked with the supplier to ensure cile our stock with ease and condence.
I ncorporating the Sitrans FUT1010 into our fuel transfer process has proven to be an extremely wise investment.
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Siemens AG
ocated at Copenhagen International Airport in Denmark, BKLA/S transports jet fuel from the Prvestenen oil terminal in eastern Copenhagen to a storage tank at the airport, and then to each aircraft stand as needed. Each day, BKL receives about 3million liters of fuel from another supplier and pipes it to a storage tank at the airport. The fuel is ltered before entering the storage tank.
Sitrans electromagnetic flowmeters monitor the inflow, outflow, and backwashing filtration cycles
The Dutch company Pharmalter 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.
he treatment of hospital wastewater is something of a challenge. Community sewage plants are primarily designed for the disposal of biodegradable materials, and not even the most modern of treatment methods can satisfactorily remove high concentrations of drug residue. Distributed wastewater treatment plants built directly on the clinic grounds constitute the most useful approach. But Pharmalters waste disposal concept goes a step further. It follows the principle Recycling instead of reuse and it pays off in a number of ways. It has been tried and tested at the R einier de Graaf Hospital in Delft. There, common reusable hospital articles were replaced by biodegradable, disposable articles made from bioplastic manufactured from renewable raw materials. The used disposables are ground down in special shredders and flushed away to the clinics sewage treatment plant where the water is treated and biogas is produced.
installation. They are responsible for the exact measurement of the substrate deployed in the fermenter.
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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 efciency in the sugar industry.
stablished in 1992, Spray Engineering Devices Ltd. (SEDL) is a leading provider of energy-efcient and cost-effective integrated technology solutions for the process industry. One of SEDLs areas of expertise is the redesign and engineering of processes and equipment, together with the coordinating process automation systems. With many satised customers in India and abroad, the company has introduced energy-efcient processes in a variety of industries. One industry in which energy efciency has recently gained momentum as a key performance indicator is sugar.
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 consumption is a key lever to reduce production costs. Evaporators generally use 2 to 2.5 bar pressure steam in four to ve effects. Using a power and heat cogeneration process, SEDL was able to use the available enthalpy and temperature of vapors for evaporation prior to condensation. Eliminating evaporation processes above 100C increased plant capacity and decreased 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 ow rate, pressure, and
Unclesam - Fotolia
The production of sugar is a resource- and energy-intensive process, where energy-saving solutions can make a large contribution to overall process efficiency
temperature to a suitable level. LTEM also helps reduce process heat requirements, making power generation more efcient. However, in LTEM, system efciency depends on precise motor control.
Excellent performance
In addition to better control and higher efciency, the Siemens drive systems provide energy savings, increased durability, higher efciency, and better monitoring of errors with the Probus network. The cost-effective solution prevents overow by controlling the speed based on the tank level. Thanks to the Profibus network, the solution provides easy plug-and-play performance with minimal maintenance. Better accessibility for remote locations is provided by built-in web servers. Impressed with the on-time execution and success of the project, SEDL has become a loyal Siemens c ustomer and regularly uses Siemens process in struments, Sinamics G130 and G120 drives, and low- voltage motors as well as switchgear.
Not only did the product help achieve commendable control of pressure and allmotors, making the LTEMsystem efcient, but promptcustomer servicealso ensured smooth installation and streamlined internal processes.
Vivek Verma, Co-founder, SEDL
SEDL
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MS supplies process and heating were of special signicance. In addition, were entered into the input modules. In steam, electricity, compressed air, existing Siemens controllers could be this way, the team was able to verify and industrial water to several in- integrated without a problem. BN Auto- whether the outputs showed the exdustrial installations locally, as well as mation AG, as a certied PCS7 special- pected switching behavior. Also, the district heating to two neighboring ist, was commissioned to implement operator graphics were completely recommunities. To do so, EMS operates the project, and the original idea of a designed due to the higher resolution. four gas-red steam generators, two 1:1 migration of the engineering from We have matured here as well, said gas turbines, and two steam turbines old to new was quickly rejected. Gunnar Fritsche, who is responsible for for the production of electricity. As cusAs there was no functional descrip- the electrotechnical equipment at EMS. tomer support for the original control tion of the control system, appropriate Subsequently, the new operator termisystem could no longer be guaranteed, specifications had to be created first nals were set out on tables in the conEMS was forced to nd a new solution. using reverse engineering. At the trol room for testing. In this way, the The standard required for the successor Migration Support Center in Cologne, system operator had a chance to try out system was very high, recalled Tino Siemens provided the BN Automation the new user interface. Our employees Danz, manager of the electrical plant. AG project manager with the corre- have really welcomed this measure, After evaluating the various options, sponding information about the exist- said Fritsche. They also had an oppormanagement decided upon the Simatic ing system. With this knowledge, it was tunity to submit their suggestions, and PCS7 process control system. then possible to work out a functional with PCS7, implementing these sugdescription of the automation. Subse- gestions was possible without any Project implementation without quently, implementation of PCS7 was problem. initiated. The new automation solution At the request of EMS, the entire condisruption of supply came into being at BN Automation AGs version was to take place without interFrom EMSs point of view, the openness premises in a matter of weeks. During rupting the steam and electricity genand easy learnability of the system the test run, realistic signal sequences eration. The concept thus made sure
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We now have a futureproof control system withwhich the pending easily implemented.
Gunnar Fritsche, Electrotechnical Equipment Manager, EMS
Hubertus Bhm, Siemens AG
only a single processing station. Thanks to intense preparation, this problem was also resolved, and the entire modernization was completed in just four weeks.
Professional implementation
EMS is very satised with the progress of the project. We now have a future- proof control system with which the pending modications can be very easily implemented, said Fritsche. The extension of the preparatory phase, in order to guarantee supply to our customers during the conversion, was the right decision and was more than offset by the rapid implementation, emphasized Thomas Fillebck, managing director of EMS. The professionalism shown during the implementation of the installation and commissioning is also reflected in the continuous dialogue that took place throughout the entire project between the project engineers from BN Automation AG and EMS and also Siemens.
www.bn-automation.com
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 companys 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 construction, 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.
that initially only one of the two large steam generators was put out of operation. During this period, the second steam generator guaranteed the supply of steam to customers. This was possible because one of the process stations
in the old system was deployed to ontrol and monitor each of the steam c generators. The auxiliary plant, which served both steam generators, constituted a challenge for technical planning, as its automation was managed using
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he Siat Braun sawmill is one of the This recycled process heat is used to vanced Process Library and dened adlargest of its kind in northeastern dry the sawdust for pellet production dress spaces and naming conventions. France. Recycling and disposing of through a heat exchanger. Thanks to these comprehensive specications, each package unit provider the bark and sawdust produced during could carry out programming and partimber processing used to be time and Multisupplier coordination tial commissioning with a temporary cost intensive. New, modern heating technologies now enable making good Siat Braun chose to use Simatic PCS7, in engineering station independently of use of these materials. Sawdust is its current 8.0 version, very early in the other packages. pressed into pellets without any further planning phase. The challenge lay in additives and is then made available as the drafting of a concept to unify sev- Individual components result in a natural product for the heating of eral technical disciplines (or subsec- amultiproject homes and for further use in industrial tions) and different suppliers so that all plants. The bark produces enough en- areas could be operated by means of a Evias GmbH supported the individual ergy in a boiler to power a steam tur- single system. To help achieve this, suppliers throughout the complete projbine. The electricity produced by a gen- Evias GmbH drafted an engineering ect. In this way, minor problems could erator is fed directly into the public guide a comprehensive document be solved immediately, without affectpower supply. In addition, the steam that species the requirements for the ing the project schedule. Apart from energy remaining after the turbine is project design in a multiproject frame- central coordination, Evias handed over utilized in a condenser to heat water. work: all packages had to use the Ad- the entire electrotechnical design, as-
The nw PCS7 control center: the operators can access all relevant process information via nine screens
SIAT Braun
sembly, and installation of a belt dryer, necessary for the drying of sawdust, tothe Swiss company Swiss Combi W.Kunz dryTec AG. The project was also created as a module of the later PCS7 multiproject. Further subprojects from Evias GmbH include the complete raw material feed system for the boiler, the supply and installation of the Simatic PCS7 network structure (including the complete operating and monitoring system), a control system for the plants central emergency stop circuit, and the control for the energy supply connection.
www.evias.de
The EVIAS GmbH was founded in 2006 in Bad Bergzabern, Germany. Since then, the company has evolved into a product- andsystemindependent engineering rm 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 wellas service, infrastructure, validation, training, and project execution.
The SIAT Braun sawmill utilizes waste sawdust as pellets for heating. The pellets are pressed without additived in an eco-friendly process
SIAT Braun
/s Aegis Logistics in India moves and distributes petroleum and chemical products from the producers to end users. At Pir Pau the company operates a 20,000 MT refrigerated liquefied petroleum gas (LPG) import terminal. The terminal has advanced safety features such as full- containment LPG storage tanks, a remote control water curtain, gas detectors, automatic shutoff systems, and remote control valves. The terminal is connected to Pir Pau Jetty by 12 low-temperature steel pipelines. The complex consists of three discrete sections: 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 PCS7 distributed control system with ber-optic links between the terminals. One key benet for Aegis was the seamless integration of the enterprise resource management system that Simatic PCS7 provides, offering improved order and materials tracking.
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Luftbildfotograf Fotolia
Our condence in the power of Simatic PCS7 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.
PCS7 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 instrumental in minimizing the development time. At Pir Pau the control of rotating machines is implemented via Probus and Simocode Pro intelligent motor control centers (MCCs). The Simocode Pro MCCs enable seamless interconnection between different 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.
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Hot stuff
Indias leading steel producer benets from a tailored gas analysis solution that helps improve blast furnace throughput and quality.
Siemens AG
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 analyzed are generally carbon monoxide (CO), carbon dioxide (CO2), oxygen (O2), and hydrogen (H2). The top gas analysis of a blast furnace is one of the most challenging applications that a continuous gas monitoring 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 rst 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.
adage-automation.com
Adage Automation is a Solution Partner Process Analytics and one of the largest exporters of gas analytical systems from India. Based in Mumbai with sevenofces across India, the company has a state-ofthe-art factory with ISO 9001:2000 certication. The facility is one of the largest analyzer system units in India and also includes a modern analyzer repair center and lab.
stages. The graphic touchscreen HMI provided greater ease of operation, and logging of the system components status facilitated preventive maintenance. The rst top gas analysis system was tted to Blast Furnace No. 3 at Bokaro and was immediately successful. With the performance and reliability conrmed, in 2010 SAIL ordered the same solution to replace 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.
Positive experiences
he 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 companys reputation. This denitely must be avoided. However, the most important thing to remember is that clear commitment to fair competition results in a consistent focus on product innovation 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 comprehensive compliance program. This year the compliance ofce of IIA and IDT once again presented positive experiences with this program 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. Andr Groe Vorholt of the law rm Luther Rechts anwaltsgesellschaft mbH at siemens- ombudsmann@t-online.de.
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Integrated Engineering
hat will the future of industrial production look like? Many experts predict that production will be increasingly characterized by networked IT systems and software tools. One key aspect of optimizing plant and product lifecycle costs are consistent engineering 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, process news will illustrate how integrated engineering will benet 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.
Siemens AG
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 thepossibilities to reduce energy costs significantly. Werelooking forward to asuccessful Drinktec see you there!