TL3 1

In time and In
Budget Project
execution for new
sugar factory
projects
Siemens AG 2009 - Subject to modifications
Industry Sector In time and In Budget Project execution for new sugar factory projects
2009-03-01 Langhans, ISO Conference, 2009, Luxor Egypt Slide 2/4
Demands for successful new sugar projects
On the long road to a new sugar processing plant,
you want to go the
straight forward, straight forward,
fast and fast and
Most efficient Most efficient
path to success
Your Target, 100% Quality ??? It sounds trivial, is it?
Quality = Meet the expectations
Quality = Meet the expectations
Sugar Colour, meet the expectations of your customers
Capacity, meet the expectations of your suppliers
Capital cost, meet the expectations of your investors
Investment Budget, meet your own expectation
Efficiency is generated out of 100% fullfillment of the expectations
Quality 100%
Quality 100%
100% Project Quality, how can it be achieved?
Two possible ways to achieve:
Make sure to employ:
Skilled plant managers
Expierienced operators to run the plant
Expierienced engineers for planning and design
Staff which has handled big projects before
World-Class project Management
Select technical and technological partners for:
Project design and plant layout
Supply of machinery with technological background
Supply of components based on technological needs
Automation and Instrumentation solutions to
achieve the technological advantage.
= 100% responsibility for Quality on yourself = 100% responsibility for Quality on yourself
but cheapest initial invest but cheapest initial invest
High risk for project success ( High risk for project success (time&cost time&cost ) )
= Share responsibilities for Quality = Share responsibilities for Quality
and achieve your Budget and achieve your Budget
Very low risk for project success Very low risk for project success
Process Sections of a Sugar Factory & the Siemens View
Industry Sector Know-How
Innovations
Integrat ed
Process
Development
Operation
&
Maintenance
Conceptual
Desi gn
Engineering
Construction
&
Installation
Process Know-How
Maintenance &
Life-Cycle-Service
Engineering Procurement
Installation,
Commissioning,
Start-up
Project Management
100% Quality, how can it be achieved?
Sugar Production Process from Beet / Cane Yard up to Packing and Dispatching
Owner
Environment
Authorities Standards EVU
Civil works
Machinery
Piping
MV-
Switchgear
Earthing,
Lighting
Cables
Emergency
Power
Field
Equipment
Erection/
Supervision
Transformer
LV-
Switchgear
Process
Control Sys.
Motors &
Drives
HW-
Design
Commiss-
ioning
SW
Engineering
Power
Generation
MIS
Instrument.-
Engineering
Process Section which requires a certain amount of Sugar Technological Know How
Technology Performance
L1
L2
L3
N
PE
-F1
-Q1
-K2
-K3
-K1
-F2
1
1U1V 1W
2W 2U 2V
-S1
-S2
-K1
-K1 -K3
-K4
-K2
-K2 -K2 -K3
-K3 -K2 -K4 -K1 -F3
1
-K1 -K1 -S3 -F2 -F3
E
i
n
A
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s
A
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o
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l
a
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T
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e
r
m
i
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t
o
r
S
t
r
o
m
w
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M
3~
4-20
mA
-Q1
-F2
-F3
-S3 Auto
Manual
-K41
-K41
-K40
-K40
Messages
Automation level
Application
Utilization
Interlocks
Marshalling tier / Allocation
Control commands
Sto
p
Sta
rt
The advantage of introducing
Simocode into MCCs
Motor branch star-delta, Conventional
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3UF50
L1
L2
L3
N
PE
-Q1
-K2 -K3
-K1
1U 1V 1W
2W 2U 2V
-K1
Protection
Overload
Thermistor
Earth fault
-K2 -K3
1
PROFIBUS-DP
M
3~
1
Automation level
Utilization
Control
Monitoring
Interlock
part. application
Communication
Control commands
Operation data
Diagnosis data
Al location
Ready
Gen. Fault
Test/
Reset
ON
OFF
Simocode into MCCs
Motor branch star-delta, with SIMOCODE-Pro
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5% hardware cost saving
conventional style, all signals hardwired
TIA style, almost all signals through Profibus
30% space saving
Simocode into MCCs
SIMOCODE-Pro in the MCC offers advantages
Smaller cubicles
Intelligent cubicles
Cheaper cubicles
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>50% installation time saving
Convertional Wiring
Up to 1993
Bus Technology
Since 1999
Decentral Peripherie
From 1993 to
Transformer
losses
Motor
losses
Pump
losses
Throttle valve
losses
Utilized output power
Power fed in, 285 %
Benefit of replacing throttle valves by speed controlled VFD
Energy requirement of a pumping system
285 %
281 %
265 %
160 %
100 %
M
Power fed in, 160 %
Motor
losses
Pump
losses
Transformer
losses
VFD
losses
Utilized output power
160 %
158 %
152 %
142 %
100 %
M
~
~
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p
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First Class Products & Process Know How
The combination of first class products for
Instrumentation,
Control,
Drives
Motors
Electrical distribution systems
&
Know How for Know How for
Interfacing with
Partners for the Main Process Areas
Process Know How for Process Know How for
Design
Software engineering
Commissioning
Fine Tuning
= Project Success
Green-Field Sugar Factory Klein Wanzleben, Germany
Green-Field Sugar Factory Cumra,
Turkey
Sugar Factory Mirza Kuckek Khan, Khoozestan Province, Iran
Sugar Factory Santa Ana, Guatemala
Our Strength since many years
Sugar technological know-how, which results from more than 50 years of experience
in the sugar industry, as a base for Customized Solutions , for drive applications,
instrumentation-, automation- and IT-solutions for complete sugar factories or single
process sections.
Technologically oriented solutions (sugar solution suite) which were / are developed
in close collaboration with our Lead Customers.
Modular packages, coming out of a.m. developments, for the core-sections of the
sugar production process as in entrance to new customers and / or as a base for
partnerships with EPCs.
Worldwide presence, local infrastructure to provide a high
content of local supplies and services.
Approach:
Pre-tested solutions for process optimization (energy
consumption, sugar quality, )
risk-minimization due to standardization.
Time optimized project execution
Process Know How
Electrical Infrastructure
Process Control Systems
Process Instruments
Motors & Drives
Life Cycle Services incl.
Project Engineering
Project Management from
Start to After Sales
SIEMENS Scope of Supply and Services
Instrumentation and Valves (Non-Ex and EX)
Level Flow
Pressure Weighing Control Valves On/Off Valves
Temperature
Siemens - Electrical Supplies and Services for the Sugar Industry
>1000 AC converter-fed
centrifugal drives -
and still counting
Standardised automation
solutions to meet your
sugar needs
Power generation &
power distribution
Specialised sugar information
systems for best optimisation
Project success is sweet
Interfaces between suppliers:

Scope,
Technological data
Standards
Instrumentation concepts
Automation concepts,
Operation concepts
Reduction of interfaces to reasonable numbers,
reduces the project cost without increasing the risc.
Reduction to only one supplier will increase the
overall project cost for the investor.
No co-ordination will lead to chaotic project execution,
highest cost and a compromosed time line from
the beginning.
Thank you

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In time and In

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