number 2 | june 2015 | siemens.com/processnews … · engineering the potential of ... we are...
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Number 2 | June 2015 | siemens.com/processnews
Integrated engineeringThe potential of digitalization: Common data management and integrated processes ensure higher quality and efficiency
Continuous quality controlSipat enables the continuous production of pharmaceuticals
More power, less consumptionIntegrated Drive Systems improve the performance of a waste incineration plant
process news The magazine for the process industry
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process news 2/2015 | Contents
16 A package for lifeMigration in the automation of rotary cycle autoclaves
18 Continuous quality controlSipat enables continuous production through research and development
Water industry20 Quality, drop by drop
Services ensure quality and availability in highly purified water plants
22 Quenching the thirstElectrical and automation solutions for water treatment
Industrial communication24 Communication for today and
tomorrowIndustrial communication as the foundation of digitalization
Integrated engineering04 Rich rewards
Wacker saves time and costs thanks to integrated engineering
08 Engineering tool as efficiency leverIneos uses Comos as a tool for computer-aided engineering
10 Step by step toward the standardIntegrated engineering as a success factor for plant design
Chemical industry12 Pilot migration
Expertise and technology safeguard investments at Columbian Carbon Europa
Pharmaceutical industry14 The digital vein
Digital processes improve plant efficiency
Drive technology26 More power, less consumption
Integrated Drive Systems improve the performance of a waste incineration plant
Process instrumentation28 Perfect down to the last detail
Integrated solution enables resource-friendly energy generation for Merck
News30 Mission: added value
The Integrated Drive Systems Roadshow tours Europe
Dialogue31 Online, Apps, Preview
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Cover photo:Silos for pyrogenic silica at the Nünchritz site, Wacker Chemie AG
Integrated engineering
at Wacker
Process instrumentation and
automation at Merck
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Editorial | process news 2/2015
“ Digitalization is the key to greater competitiveness!”
Editorial
How can companies in the process industry increase their efficiency and productivity and thus also their competitiveness? We will address this key issue this year at ACHEMA. Under the slogan “From Integrated Engineering to Integrated Operation – Discover the Potential of Digitalization,” we want to show our visitors how we promote digitalization in the process industry based on our existing portfolio of products and services for electrification and automation.
Digitalization enables the integration of individual process steps over the entire plant lifecycle, from engineering and operation to continuous optimization. We already support our customers with solutions that advance this integration – for example, with the integration of planning for electrical engineering, process engineering, and automation, which we provide with Comos and Simatic PCS 7. Companies such as Wacker, DSM, and Ineos benefit from greater efficiency and consistency in their data – as the examples in this issue of process news show.
Another important topic in the process industry is documentation. Read how the Chinese pharmaceutical company Rongshen converted its batch documentation to a paperless process using our manufacturing execution system – an important step toward operational efficiency. Other topics include new approaches in industrial communication and integrated drive solutions that ensure greater energy efficiency in the process industry. I hope these articles give you some valuable tips.
At ACHEMA we are going one step further and demonstrating how digitalization is achievable in the process industry: the digital plant, modularization, and optimizing production. In this way, we are building a bridge from the technologies of today to the process industry of tomorrow – for greater competitiveness and higher productivity. Visit us at ACHEMA 2015, June 15 to 19, in Hall 11, Booth C3. I look forward to seeing you there! If you want to find out further information in advance, please visit our website: siemens.com/achema
Warm regards,
Eckard Eberle CEO Process Automation Process Industries and Drives Siemens AG
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Eckard Eberle CEO Process Automation Process Industries and Drives Siemens AG
Wacker, Germany
Rich rewardsWacker is now one of the most intensive users of Comos, even though it was not among the very first users. The company has taken the time and effort to advance and evolve the Comos solution and set challenging benchmarks for the tool – which is one reason why the company is now richly rewarded by saving time and costs.
Manufacture of polycrystalline hyperpure silicon at Wacker’s Nünchritz site: part of the plant recycles byproducts in order to feed them back into the manufacturing process
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process news 2/2015 | Integrated engineering
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W e were founded in 1914, meaning that the documentation of the plants is in a wide variety of forms,” says Peter
Schöler, director of electrical and instrumentation for project engineering at Wacker, which is head-quartered in Burghausen, Germany. Until the early 1990s, Wacker used various tools and systems for computer-aided engineering (CAE), resulting in the familiar interface problems and data inconsisten-cies in imports and exports. “The driving force behind the introduction of a uniform CAE system was the desire for increased productivity in plant engineering,” Schöler recalls. A uniform database would minimize the number of interfaces, reducing engineering time and costs. However, the world-wide presence of Wacker required software that would enable the implementation of different stan-dards in the CAE tool. “For us, it was important for all project partners from every corner of the world to have common access to project data,” empha-sizes Schöler.
Successful CAE implementationIn 2000 Wacker selected the Comos CAE system; the first plant that was designed with Comos began operation in 2003. The holistic approach for pro-cess, electrical, and instrumentation and control engineering was a decisive factor in the choice of the system. This approach would create a global database and reduce the interfaces between these disciplines. However, the opportunity to have open and customizable interfaces to third-party systems, such as process simulation tools, SAP, or process control systems, also played a significant role at the time.
Schöler readily admits the staff experienced a learning curve with Comos. “Design engineers are not CAE nerds,” says Schöler succinctly. The CAE software should support engineers and operators in their job, and accordingly, using it needs to be simple and intuitive. Training is essential, particu-larly because design and plant engineers do not constantly work with Comos. In addition, the intro-duction of a CAE system affects the division of labor and the workflow. This is now seen as some-thing positive, because CAE ensures the workflow is very structured. However, the data models are based on idealized development models that do not always correspond to real-life project require-ments. Compromises between the modeled and the actual work procedures are absolutely neces-
sary. “In addition, the performance must feel right,” says Schöler. It was also important that despite integration, users were still able to carry out their tasks in their respective engineering disciplines independently from other teams. Other important aspects were smooth version conversion as well as rights management, which is essential for IT security.
Worldwide useToday, Comos is virtually the only tool used for IT-aided plant engineering at the German plants in Burghausen and Nünchritz, as well as in a second installation environment in Charleston, Tennessee, in the United States. Since the tool was launched, some 1,400 users have been trained using two independent redundant runtime environments, in which up to 240 users can work simultaneously on 24 terminal servers. Engineering partners and suppliers access Wacker’s site data via Citrix SQL Server. And this lays the foundations for successful
Comos at Wacker
• 2 independent runtime environments with 24 terminal
servers for up to 240 concurrent users
• 1,400 trained users
• 4,700 piping and instrumentation diagrams with a total
of 13,200 pipes, 60,000 devices, 117,000 measuring
instruments, and 47,000 actuated valves
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process news 2/2015 | Integrated engineering
integrated engineering as everyone works with the same data. The master data are continuously syn-chronized across the sites.
Wacker uses the Comos Process and Comos Auto-mation software, which include modules for pro-cess technology, electrical, instrumentation, and control technology as well as isometrics and stan-dardization. All the modules use the uniform Comos database. Open interfaces to third-party systems and an object-oriented approach facilitate integration with systems for process simulation as well as connection to the enterprise resource plan-ning and process control level, where Wacker uses Simatic PCS 7 and other systems. “The consistent object orientation makes the work easier. Plant engineers and plant operators can access the data at any time – in real time – regardless of time zones. This enables informed decision making and thus considerably greater productivity, efficiency,
and flexibility across all processes,” adds Klaus Kraml, head of CAx systems and applications at Wacker.
Almost all the EMR planning now takes place in Comos. Consistent data management means that the relevant data are also disseminated into the process control system and SAP. The CAE system also provides support for the automatic creation of the Ex i certificates, for example, as well as the function plans, and it assists with the selection of the measuring principle. In addition, Comos helps Wacker track planning and installation progress. Different norms and standards, for example for Germany and the United States, are accounted for, so there are specific runtime environments and data models for the different locations.
Integrated workflowsData from the process simulation are additionally implemented in Comos. The software manages factors such as the different operating points and material compositions for batch plants or different load situations. The tool also supports intelligent pipe specification management, providing assis-tance in selecting the correct components not only to the design engineer but also to the procurement department. From the process control device speci-fication, Comos creates a “procurement object,” provides the exact requirement data to SAP for ordering, and exchanges the corresponding data with SAP as part of the order process. The SAP document can be displayed later in Comos.
Comos also supports maintenance, because the data imported by SAP can be displayed directly in the piping and instrumentation diagram (P&ID) for maintenance planning. The objects for checking are color coded based on the chosen time period. Comos receives maintenance schedule information for each object via SAP and generates an overview of the current maintenance status by means of a colored illustration on the P&ID, and also enables quick and easy procurement of spare parts in con-junction with SAP.
A central data hubThe switch to the Comos CAE system has paid off for Wacker: the system landscape has become sim-pler, the engineering quality has improved signifi-cantly, and considerable potential savings have been identified. And a deeper commitment in the area of maintenance is also currently being investi-gated. “Comos has become the central data hub for our process design,” concludes Schöler. The common database improves engineering quality
» Comos enables informed decision making and thus considerably greater productivity, efficiency, and flexibility across all processes.«
Klaus Kraml, Head of CAx Systems and Applications, Wacker
Greater efficiency: Comos assists not only the design engineer but also the procurement department
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Happy users: the departments led by Klaus Kraml, Head of CAx Systems and Applications (left), and Peter Schöler, Director of Electrical and Instrumentation for Project Engineering, have been working with Comos for 15 years
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throughout the design phases. In addition, CAE sys-tems help store knowledge modules for the organi-zation so that the project editors have access to all the relevant information in their work – because the expertise of employees, whether they are design or maintenance engineers, or plant opera-tors, is a company’s greatest asset. That is some-thing Schöler is also certain of: “The actual engi-neering is still done by the engineers and not by the CAE system!”
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» Comos has become the central data hub for our process design.«
Peter Schöler, Director of Electrical and Instrumentation for Project Engineering, Wacker
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T he petrochemical site in Cologne, one of the largest of the Ineos Group, produces a variety of raw materials from the two main
source materials naphtha and butane. These serve
as basic building blocks for manufacturing plastics and fibers, solvents, detergents, paints, fertilizers and pesticides, as well as cosmetics and pharma-ceutical preparations.
Ineos, Germany
Engineering tool as efficiency leverAt its Cologne site, Ineos Group AG, a group of global chemical companies, relies on a new system for computer-aided engineering (CAE). Together with other tools, it manages more than 100,000 documented process control points, including safety equipment and more than 3,500 piping and instrumentation diagrams (P&IDs).
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Integrated engineering | process news 2/2015
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As different as the plants for the countless precursor products are, they have one thing in common. In the past, the essential piping and instrumentation diagrams (P&IDs) required for their engineering and ongoing operation were created with the Plant Design System (PDS) 2D from Intergraph and man-aged in close cooperation with SAP and Docu-mentum. But emerging performance problems and outdated data management in relational databases made it necessary for the plant operator to intro-duce a modern CAD/CAE system.
Selection of Comos“We need a very efficient workflow in the planning, maintenance, modification and operation of our plants,” explains Guido Gerdemann, project man-ager for central engineering at Ineos. “The new engineering tool therefore had to be seamlessly integrated in the way we work and also had to pro-vide further improvements in efficiency.”
After comparing different solutions, the project team selected Comos as an integrated software solution for efficient plant engineering and opera-tion. It is able not only to represent the various workflows and the enterprise-specific breakdown of technical equipment, but also to provide inter-faces to the SAP tools and Documentum used at Ineos.
To minimize the risks of introducing a new system, the Comos solution was first implemented in a pilot project. “With only 50 P&IDs, we decided to perform a small-scale, manageable project as a pilot. We wanted to quickly gain experience and insights that we could to apply to larger plants,” explains Ralf von der Weppen, maintenance man-ager and member of the steering committee at Ineos in Cologne. To migrate the data from the 2D plant design system, Comos provided a converter with which existing P&IDs could be automatically imported into Comos P&IDs.
The entire technical equipment is structured on four levels; the plant, the apparatus or the pipeline, the space of the apparatus, in other words, the pipe section, and the fittings, i.e. sensors/actuators or meters. “Siemens did a good job of implementing this layered structure and demonstrated that they
understood our philosophy on the one hand, and that it could be implemented in Comos on the other,” explains Gerdemann. “Siemens exceeded their contractual assurances. They had promised that importing a P&ID would take 15 minutes. Today, depending on the size of the flow diagram, it takes between six and eight minutes!”
Standardized, up to date, and efficient Once the software system had proven itself in the pilot project, the rollout was soon launched for
other plants . “Timely, consistent data are an important foundation for our system maintenance work,” says von der Weppen. “In the past, this was only achieved in part by our workflow. Changes were initially carried out purely graphically in the P&ID; this was followed by release in paper form. Then the data were entered into PDS 2D and par-tially linked to data from SAP.” With the introduc-tion of Comos, these intermediate steps can be eliminated. One employee can now carry out the preplanning, the graphical implementation and the work in the database using a single software package.
Secure asset management with Comos
At the site in Cologne, the Ineos Group uses Comos as an integrated software solution for efficient plant design and operation
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F or Niklaus Beck, who was responsible for the automation of the Vitex project, the tool
was an important success factor for this large project. The Vitex plant also was the first project to use Comos that was to be deployed for other engineering processes. Today Beck heads the Technical Services depart-ment at DSM Nutritional Products in Sisseln. “An important part of our work is support and development of configuration tools for our plants,” says Thomas Müller, who heads Beck’s
DSM, Switzerland
Step by step toward the standard
Tools and Document Management team. “Here we use Comos, which we are continuously developing along with our standards and libraries, together with Siemens.”
Pioneer in databaseaided toolsBeck is responsible in no small part for the fact that today Comos is used for the design of piping and instrumenta-tion as well as the electrical systems. He has worked for DSM in Sisseln since 1986 and began his career as an automation engineer – “still at the
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» Both our team and the engineering partners concluded that we would not have completed the Vitex project so successfully without a database-aided engineering tool.«
Niklaus Beck, Head of Technical Services department, DSM Nutritional Products
With approximately 800 employees and several large plants, Sisseln in Switzerland is one of the largest production sites of the Dutch company DSM. One of the key Swiss plants is for the production of vitamin E, which DSM manufactures exclusively in Sisseln. This plant was the first major project in which electrical engineering and automation technology were planned using the Comos engineering software.
drawing board,” he recalls with a smile. The first computer-based tools were quickly adopted, but at the time there were still many different tools for tasks ranging from plant engi-neering to electrical engineering. “In the mid-1990s, I took over manage-ment of engineering, and it was already then our goal to clean up the landscape of multiple software solu-tions,” says Beck. “After a few interme-diate steps, we evaluated Comos and were soon impressed by the possibili-ties.” Initially, Comos was used only as
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» With Comos, we provided the plant operation staff with a solution for accessing data and information for configuration that offers them real added value.«
Thomas Müller, Head of Tools and Document Management, DSM Nutritional Products
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an engineering tool for automation planning; however, later it was addi-tionally used for electrical engineering planning. “And then the Vitex project arrived,” Beck says.
Key plant for a key productDSM’s Nutritional Products division is the largest manufacturer of vitamins A and E – and both vitamins are pro-duced exclusively in Sisseln. With the Vitex project, which was completed in 2004, DSM has further consolidated its leading position in the market for vitamin E. The new production facility was equipped with Simatic PCS 7 as a process control system.
To complete the planning for the large Vitex project on schedule, many teams had to work in parallel. “Back then we decided that all partners involved in the planning of the elec-trical and automation technology for this plant would work with the same tools in Comos. Looking back, we were taking on a certain risk, but it has really paid off,” says Beck.
Ten years after commissioning, the plant is a mainstay of production at
DSM. The processes are continuously optimized, which has allowed the plant yield to be significantly increased in recent years. In addition, the level of automation has increased steadily, reducing the number of manual interventions in the process. These changes are, of course, con-stantly updated in Comos, says Müller: “Here, too, we see the advantage of object-oriented work in a unified data-base – we can easily create new com-ponents or visuals.”
Orderly and uniform data simplify auditsUniform document management facilitates not only the engineering, as Müller clarifies: “Especially in view of applications in the pharmaceutical and food industries, we need to ensure that our data are maintained and stored in accordance with good manufacturing practice guidelines. In some cases, we need to store the same information and data at 20 loca-tions – in the engineering system, in the system for the management of production information, and so on – and that is simply not possible without a uniform tool.” Beck confirms this: “At
the site, we have a weekly system or process audit, so it is crucial that our documents are always up to date. A tool such as Comos is a tremendous help with this.”
After Comos survived its baptism by fire, so to speak, with the successful deployment of the Vitex project, its use has been gradually extended. In the meantime, the planning of piping and instrumentation is also being carried out with Comos. Müller out-lines the next steps: “Our application engineer maintains and expands our Comos standard continuously, so that our engineering partners have a good toolbox for their work. But of course we are already thinking one step ahead. For example, we are also evaluating how we can benefit from integrated engineering with Comos and Simatic PCS 7.”
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C olumbian Carbon Europa S.r.l. is part of the multinational Aditya Birla Group, which comprises
several industrial conglomerates. This includes Birla Carbon, a leading global manufacturer and supplier of carbon black, found in many everyday items such as tires, black plastics, paint, cables, and kitchen utensils. Creating carbon black requires automation technology with high-precision con-trol loops. Birla Carbon installed its first automatic control system in one of its factories in 1987. In 1994 the company added the APACS series from
Moore, which eventually replaced the first system altogether.
Siemens became responsible for the maintenance of the Moore distributed control system (DCS) following its acquisition of Moore in early 2000. In 2012 Columbian Carbon Europa decided that a revamp of the Moore APACS system was needed to expand its network of I/O devices and to man-age the technology obsolescence phase. Automazioni e Sistemi, a Siemens Solution Partner and inte-grator specialized in process control
systems, had previously collaborated with Columbian Carbon Europa in the implementation of its DCS lifecycle management system. It also made the migration from APACS/QUADLOG to Simatic PCS 7 on the FPSO Mystras offshore tanker and on the Okpoho platform in Nigeria in 2010. These migrations required an application to be successfully hot swapped, switch-ing the LAN from Modulnet to Industrial Ethernet by introducing new interface cards and replacing 5 pairs of redundant servers and 10 operator stations with new Simatic PCS 7 units.
Birla Carbon is a leading global manufacturer and supplier of carbon black
Columbian Carbon Europa, Italy
Pilot migrationA leading chemical manufacturer wanted to migrate its entire control system while keeping its APACS cards installed. This would be the first migration of its kind. Siemens Solution Partner Automazioni e Sistemi was happy to accept the challenge.
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Chemical industry | process news 2/2015
» We have an open, reliable architecture that can communicate with third-party systems. Our operators immediately appreciated the user-friendly interface.«
Massimo Beccaglia, Maintenance Manager, Columbian Carbon Europe
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Based on the success of these previous projects and the company’s links with Siemens, Columbian Carbon Europa decided to partner with Automazioni e Sistemi for the migra-tion of its old Moore APACS system to the latest version of Simatic PCS 7.
The first migration of its kindThe upgrade was motivated by the technological and economic benefits resulting from having a state-of-the-art solution and an extended system lifecycle. This was the first time in the world that an entire control system was to be replaced while keeping the APACS I/O cards installed and con-nected to the system using DP/IO-Link boards. In addition to supplying the CPU 417H and the ES/AS/OS stations, the project included a web server solution for monitoring the system online.
When selecting the new control sys-tem, the main issue for Columbian Carbon Europa was minimizing the downtime while implementing the new installation. So Automazioni e Sistemi proposed not to remove the installed I/O cards already connected
to the system but to update the CPUs with the latest state-of-the-art ver-sions instead.
Migrating for successThe transition to the new configura-tion, system architecture, and Simatic PCS 7 all took place on schedule and as planned. Close cooperation among Columbian Carbon Europa, Automa zioni e Sistemi, and Siemens ensured that any unexpected technical communica-tion problems were addressed and re-solved promptly.
Columbian Carbon Europa’s mainte-nance manager, Massimo Beccaglia, hailed the project’s success: “Since last year we have been working with an updated, modern control system. Finally we have an open, reliable
architecture that can communicate with third-party systems via standards. Our operators immediately appreciated the user-friendly interface, complete with system information and intuitive alarms, and the versatile operations controlled by authorized access.” Following the successful migration at Columbian Carbon Europa, Automazioni e Sistemi has been providing similar solutions to other APACS/QUADLOG users and is cur-rently involved in the implementation of a migration from APACS to Simatic PCS 7 in Settala, Italy.
The userfriendly interface, complete with system information and intuitive alarms, effectively supports daily operation
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process news 2/2015 | Pharmaceutical industry
C hengdu Rongsheng Pharmaceutical Co. Ltd. wanted a manufacturing execution system (MES) to cover the entire scope of operations
at its plasma processing factory in Chengdu. This included production planning, equipment status management, process monitoring, and manu-facturing declaration of finished goods to the warehouse. The switch to electronic records and signatures would enable the plant to meet good
Rongsheng, China
The digital vein
manufacturing practice (GMP) guidelines for pro-duction procedure standardization and lean manu-facturing management. The MES would also support strict control requirements and more effective pro-duction procedures, in compliance with GMP speci-fications. Because implementing the entire MES at once could have caused complications and risked downtime, the project was split into two phases to ensure a smooth implementation.
Experts in blood: Rongsheng employs more than 400 people in one of the largest
plasma fractionation facilities in China, producing plasma derivatives such as
albumin and intravenous immunoglobulin as well as hepatitis B and tetanus
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A Chinese pharmaceutical company recently replaced all paper-based processes with a manufacturing execution system. This took the plasma processing plant in Chengdu into the digital age – with improved efficiency and reduced risk.
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Pharmaceutical industry | process news 2/2015
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Project highlights
• Electronic workflows replace paper-based
workflows and processes.
• Enhanced quality assurance and data integrity
improve patient safety.
• Detailed digital tracking ensures no cross-
contamination between batches.
• Only the correct equipment that meets strict
requirements is used.
• The system enables the controlled release of
production parameters.
• Electronic instructions and bar code
technology enable improved compliance.
Project phases for a smooth implementationPhase 1 focused on the weighing and distribution of materials as well as buffer solution preparation. Phase 2 covered the entire production workflow, including thawing, main trunk fractionation, paste refining, purification, work in progress and finished product compounding, filling, and packaging. Implementing the MES also required complete inte-gration of data for the process control system (PCS) layer with the enterprise resource planning (ERP) layer, as well as real-time communication. This resulted in a three-layer structure of automation, MES, and ERP – the foundation of a truly digital factory.
The project comprised more than 50 client termi-nals, 200 different materials, and 250 pieces of equipment. Additionally, more than 250 users were trained on the new solution. Following its successful implementation, the MES now performs more than 50 work orders and 1,000 tasks daily. The project strictly followed GMP requirements, with both implementation and validation com-pleted in compliance with GAMP 5 guidelines. Key to the project’s success was close collaboration between various Rongsheng teams (quality assur-ance, manufacturing, IT) and the industry software teams from Siemens. All aspects and steps of the implementation, from the unique requirements specification, functional specification, and design specification to the factory acceptance test, site acceptance test, installation qualification, and operational qualification, were meticulously carried out following validation guidelines.
Improved efficiency and reduced riskAlong with improved efficiency, switching from paper-based workflows to the MES has improved patient safety, pharmaceutical quality assurance, and data integrity. The Rongsheng plant now has a full complement of real-time electronic batch records, electronic signatures, batch designs and execution, reviews by exception, full audit trails, and genealogy to support all its activities. This meticulous digital tracking ensures, for example, that there is no cross-contamination between batches and that only the correct equipment, which meets strict sterilization or cleaning and calibration requirements, is used. The MES also controls the release of production quality parame-
The contract between Siemens and Chengdu Rongsheng Pharmaceutical Co. Ltd, has been successfully completed
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ters, production schedules, and plans, as well as the expiration date, accuracy, and genealogy of production materials. This significantly decreases the risks that can arise from managing these tasks manually and improves compliance through strict process control with the reliable precision of elec-tronic instructions and bar code technology.
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T he extensive product portfolio of Fresenius Kabi includes medi-cines and technologies for infu-
sion, transfusion, and clinical nutri-tion. At the Friedberg site, Fresenius Kabi operates a highly modern pro-duction facility for infusion solutions with some 600 employees. From Friedberg, the company delivers infusion solutions in plastic bags or bottles to pharmaceutical wholesalers,
pharmacists, and hospitals. Infusion solutions include, for example, elec-trolyte and glucose solutions as well as low-concentration carbohydrate solutions, electrolyte-containing infu-sion solutions, and carrier solutions for pharmaceuticals. Just as important as the standard infusion solutions are volume replacement solutions based on hydroxyethyl starch. These are used for blood loss and stabilizing the
Caring for life – with this philosophy, the healthcare company Fresenius Kabi develops and distributes medicines and medical technologies for the therapy and care of critically and chronically ill patients. A key element of the production is the rotary cycle autoclave unit for sterilization of infusion solutions. The system was recently upgraded with Simatic PCS 7.
circulating blood volume. At the fully automated high-bay storage ware-house, the staff of the on-site logistics center handles 2,000 orders every day, which are delivered worldwide.
Smooth sterilization operationsAn important function in the produc-tion chain is the rotary cycle autoclave. Inside the autoclave, bags with infu-sion solutions are sterilized. The
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A package for life
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content of the bag determines which autoclave program must be run and the corresponding temperatures and rotation times. The rotary cycle auto-clave is divided into 24 compartments, which are loaded in sequence with bags by a robot. The bags undergo a cycle in the autoclave where they are sterilized and then transported to the packaging area. A conveyor belt with several light barriers delivers the bags. Loading and unloading is carried out by a robot, and the bags are removed on conveyor belts.
New project with proven expertiseAs a result of the positive experience with the current Siemens SCADA system, as well as a general policy to invest sustainably in existing equip-ment, Fresenius Kabi decided to fit its rotary cycle autoclave with the latest
automation technology from Siemens. The first project has been completed – a rotary cycle autoclave was migrated to the process control system Simatic PCS 7. Since the rotary cycle autoclaves play a central role in the production process and additional plants will soon be mod-ernized, this project was closely monitored by those responsible in Friedberg.
The greatest challenges of the project were both the complexity and the size of the plant, as well as working under adverse ambient conditions caused by high temperatures and high humidity. The communication between the con-troller and the rotary cycle autoclave needed to work over a wireless con-nection. The project at Fresenius Kabi was also the first implementation of RFID systems, Simocode motor control units, and the PM Quality tool for the traceability of the entire production process. It was necessary to ensure that the system met current good manufacturing practice (GMP) regula-tions to guarantee that the final product would fulfill the medical product requirements demanded by various regulators. For the Siemens project team, it was necessary to con-sider a number of new features for the
new automation solution. In order to aid the transition for employees at the plant, the operation and appearance of the system were to be as close as possible to those of the previously used system. The existing on-site package units, such as the rotary drive or conveyor belts for delivery and removal, had to be connected to the system – and of course had to func-tion in accordance with GMP.
» With migration of our SCADA solution to Simatic PCS 7, we ensure the availability and extensibility of production for the future, and thanks to the new production documentation for the batch log, we now benefit from seamless batch archiving. This order and batch-oriented archiving and logging system has been a significant factor in meeting the FDA requirements.«
Birgit Becker, Project Engineer, Technical Services,Fresenius Kabi Deutschland GmbH
Reaching a new solution togetherIn collaboration with Fresenius Kabi, Siemens developed an automation solution with an engineering station, an operation single-user station, an AS400 controller for controlling the autoclave, a panel for operation, and a panel in the packing to provide infor-mation to employees. The existing hardware was completely replaced. Before and after commissioning, Siemens also supported the customer during the factory acceptance test (FAT) and the site acceptance test (SAT). In the four weeks during the plant start-up, the Siemens employees were available through an on-call ser-vice. Fresenius Kabi and the Siemens team of pharmaceutical and automa-tion experts had a smooth and close cooperation from the very beginning. Modernization and configuration of
automation solutions in a regulated environment are areas in which Siemens has developed expertise over many years.
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process news 2/2015 | Pharmaceutical industry
When an international research-based pharmaceutical company needed a software solution that would enable it to use hot-melt extrusion to continuously produce high-quality pain-relief medication, Siemens was ready to assist. Sipat process analytical software now helps to reduce time to market.
Grünenthal, Germany
Continuous quality control
Project highlights
• The new hot-melt
extrusion line was
finished on time and
on budget
• Continuous production
with real-time quality
checks increased
output and product
quality
• The Sipat software
enabled data on
product quality to be
analyzed during the
process rather than
weeks afterward
T he Grünenthal Group is an international pharmaceutical company with headquarters in Aachen, Germany. It specializes in new
pain treatments and invests heavily in research. The company’s commitment to innovation led to the development of the market-leading INTAC tamper- resistant formulation technology. Grünenthal‘s INTAC technology is featured in FDA-approved products that help prevent prescription drug abuse due to the tablets’ exceptional crush resistance and the low extractability of the active drug.
Grünenthal’s INTAC technology is based on hot-melt extrusion (HME). First used in plastics pro-cessing, HME has rapidly grown in popularity in
pharmaceuticals manufacturing, particularly over the last 10 years, for embedding active pharmaceu-tical ingredients into tablets. HME enables the cre-ation of continuous production lines, with product quality tested throughout the process rather than at the end. This helps dramatically to reduce the time it takes to bring new drugs onto the market.
A continuous production line with realtime quality checksGrünenthal had previously set up an HME line at its production site in Origgio, Italy. This line was focused on production, with fixed operating condi-tions. A second HME line at the company’s head-quarters in Aachen is focused on research and development. To support operation according to
A view of the stateoftheart INTAC production line in Aachen
Grü
nen
thal
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Pharmaceutical industry | process news 2/2015
INFO AND CONTACT
siemens.com/[email protected]
quality-by-design principles, with real-time quality checks, Process Analytical Technology (PAT) would be required to combine and assess data at various stages.
Grünenthal had previously collaborated with Siemens on the Italian HME line, and the quick rollout encouraged the company to partner with Siemens again. Grünenthal had been impressed by Sipat software and knew it could rely on the Siemens consultants’ expertise. “During the pre-sales phase, different solutions were analyzed and demonstrated. Siemens showed the best solution,
and the experience shown by the involved consul-tant gave us confidence in the Siemens offering,” says Grünenthal’s head of production, Origgio, Italy.
Weeks of data analysis performed in real timeSiemens’ implementation of the Sipat system on Grünenthal’s HME line included the integration of control panels and ongoing support. The Sipat soft-ware collects data at different locations and then combines it with univariate and multivariate data (near-infrared spectra). Principal component anal-ysis of the spectral data is performed to check product composition, along with mathematical modeling to determine the amount of active ingredient in the mix. Real-time data evaluations (Western Electric Rules) of the time-trended results then check for quality issues.
Based on the measurements, feedback controls for the extruder line can be executed to divert any defective products, ensuring that only quality medi-cation leaves the production line. “In the past it took us weeks to prepare the process data for analysis after designing experiments. Now we can start analyzing even during the runs,” says the head of Grünenthal’s PAT Group, Aachen headquarters, Germany.
Ongoing highquality collaborationThe rollout of the HME line with Sipat began in Aachen in mid-October 2013 and was completed
in June 2014 – on time and on budget. As during the Italian project, the project’s success hinged not only on the technology but also on close collabora-tion between the Siemens and Grünenthal project teams. “The people from Siemens did a great job. They showed high engagement and performed well to finish the project as specified,” says the head of Grünenthal’s PAT Group, Aachen head-quarters, Germany.
Feeder
APIMatrix
Feed rateoutput
Barreltemperatures
output
Barreltemperatures
inputTorque Screw
speedoutput
Material temperature
Spectrum
Die
Material pressure
Feed rateinput
Screwspeedinput
Motor
Motor
The hot melt extrusion process
The Sipat solution monitors all relevant output parameters (light blue) and controls process values (dark blue)
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process news 2/2015 | Water industry
H ighly purified water (HPW) and water for injection (WFI) are used in the pharmaceu-tical industry as basic media and cleaning
agents in many manufacturing processes. The rules of the European Pharmacopoeia and the United States Pharmacopoeia must be strictly adhered to at all times. HPW meets all the important criteria of WFI with strict limits on electrical conductivity, total organic carbon, aerobic bacteria, and pyrogens.
From conceptual design to commissioningSiemens supports its customers in the design, plan-ning, engineering, project management, and implementation of HPW systems. Interdisciplinary expert teams of chemists, process technicians, and engineers, along with qualified technical staff, work closely with the future operator. HPW is pre-pared at room temperature from drinking water. For HPW production, the operator and the planning team usually select the most mature and modular-ized standard systems, known as package units. The complete processing line can be sanitized against microorganisms from the drinking water connection to the final process step.
Engineering down to the last detailAfter the drinking water has been analyzed, the Siemens experts recommend suitable systems from established manufacturers for the required cleaning and processing steps. These include particulate fil-ters, ion exchangers, and membrane processes for residual desalination, such as electrodeionization and ultrafiltration. If the operator also wishes to produce WFI, in Europe it is mandatory that this be carried out by distillation. WFI is usually stored and distributed at temperatures of 80°C to 85°C in order to counteract microbiological contamination. For the preparation of WFI, Siemens offers manufacturer- independent consulting to ensure that the operator finds the best possible technical solution.
Highest quality throughout the systemIn order to deliver water with impeccable quality, the storage and distribution system is custom built for the operator. The Siemens specialists provide all the necessary planning services, based on the indi-vidual system requirements and all pharmaceutical and technical regulations. For optimum results in terms of the given plant size, the team calculates the previously planned consumption points, their
Highly purified water for the pharmaceutical industry
Quality, drop by dropIn the planning and implementation of highly purified water systems for pharmaceutical applications, many factors must be considered in detail and with foresight in order to ensure that the high purity requirements are met. Siemens helps companies achieve consistent product quality and high plant availability while also taking cost-efficiency into account.
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Water industry | process news 2/2015
reference quantities, the duration and frequency of daily withdrawals, and their impact on the plant pressure. The team observes and implements the general guidelines of good manufacturing practice throughout. Suitable simulation programs take into account the amounts consumed and the time of consumption, and also support the hydraulic design with individual loops for optimal pipe routing. Software tools and internal material data-bases assist the Siemens experts in the detailed design of all systems as they specify the required parts and components in terms of function, size, suitable materials, and manufacturer.
Quality assurance in ongoing operationPlanners are also on site at the factory acceptance test (FAT) and site acceptance test (SAT), providing support together with the supplier for the review and approval of design documents up to the accep-tance of the package units and the overall system. Even in the commissioning and qualification, the operator can rely on the Siemens planners. They
provide assistance in preparing test plans, in veri-fying the specifications of all components, and in transitioning the system into continuous operation.
For continuous quality assurance, the planners and the operator jointly determine the required mea-suring points in the system. The quality-relevant measurements are then continuously performed in the operating plant and the measured values are critically analyzed and documented. The project is brought to a successful conclusion with the final preparation of the technical as-built documentation from the suppliers and the commissioned installa-tion companies. In this way, consistent product quality and plant availability are ensured from the initial planning phase to ongoing operation.
Drinking water
Analysis
Cation and anion exchanger(Ultrafiltration)
Ultrafiltration
Reverse osmosis
SofteningReverse osmosis
ElectrodeionizationUltrafiltration
SofteningReverse osmosis
(2-stage) Evaporation Pure steam
PWHPW WFI
EvaporationDistillation
Manufacturing process for highly purified water from drinking water
INFO AND CONTACT
siemens.com/ec [email protected]
W ater for industry is not just water – it is a vital production factor that must meet specific requirements depending on the
type of use, from process water for mining equip-ment to highly purified water for pharmaceutical purposes. Furthermore, the regulations for the discharge of wastewater are very strict and require special treatment of the water. All applica-tions have two things in common: conditioning, distributing, and treating the water often requires substantial technical effort and consumes a great deal of energy. Managing water supply and dis-posal has become a major challenge, not only in arid regions where water is scarce – even in Europe, companies face growing difficulties in providing the right water quantity for production without overexploiting natural resources.
Size matters: efficient solutions for cutting costsThe major issues in water treatment – no matter what the application – are controlling energy con-sumption, improving service quality, and increasing plant availability. Choosing the right technology can help address all these issues. Take wastewater treatment plants, for example: by making the process more efficient, a plant can treat more water with the same or even less consumption of energy, and an existing plant can treat larger quantities of water. Integrated tools for engineering and process control can help optimize the operation of key components in water treatment and distribution such as pumps.
Electrical and automation solutions for water treatment
Quenching the thirst
Comos and Simatic PCS 7 not only help streamline the design and engineering process but can also support process optimization during operation.
Solutions for telecontrol systems such as Sinaut reliably and securely monitor distributed systems. They also assist flexible and efficient drive systems to optimize the operation of pump stations. Low-maintenance process instruments such as the bat-tery-operated Sitrans FM Mag flowmeters and leak detection systems ensure that every drop of water will reach its destination with minimum cost.
Critical to quality: solutions for measuring and conditioningBecause water impurities can seriously affect the overall process performance, monitoring and recording water quality is an important aspect of water management. For this purpose, Siemens provides an aligned set of systems for monitoring process parameters with its range of process instru-ments and process analyzers, and supports the industry with broad expertise in water treatment and disinfection along with tailored solutions for recovering and treating process water in the oil and gas industry.
Water expertiseIn addition to a broad set of systems and solutions, Siemens also emphasizes the role of industry know-how. Siemens water experts have developed
Along with energy, water is the most used resource in industrial processes. Treating water for the specific type of use is a substantial cost factor, but it is often essential for process efficiency and product quality. However, by deploying a set of aligned systems and solutions, the process industry can quench its thirst for water both sustainably and economically.
process news 2/2015 | Water industry
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Industry-specific solution: Treating water for oil production
Water is not only an important resource for the
manufacturing and processing industry – it is also
vital for the exploitation of natural deposits in the
oil and gas industry. For example, large amounts
of water are used to extract and pump crude oil.
Depending on the crude oil viscosity, as many as
nine barrels of water can be needed to pump one
barrel of oil.
In the Castilla oil field in the Acacias township in
Colombia, Siemens has partnered with Ecopetrol
to create a system that will purify approximately
40 million gallons of water daily, equal to the
average water consumption of a city of 100,000
people.
To make production water clean enough to be piped
back into the local Guayuriba River, Siemens has
installed systems that consist of three basic compo-
nents. The first is a corrugated plate separator, which
removes the thickest concentration of oils and
suspended solids. Then the water passes through
flotation cells, where injected gas or oxygen adheres
to oil drops and suspended particles, enabling them
to be skimmed off. Last, the water is pushed through
a Monosep filtration unit that uses walnut shells
to absorb oil and other remaining impurities. The
Monosep system features a simple yet compact
design, saving space and reducing costs. “Siemens
was selected after a rigorous screening process
addressing both technical and economic consider-
ations,” states Jorge Bustamante, Ecopetrol’s project
mechanical installation manager. “Their service has
been excellent. We knew that if there were a problem
with engineering or project management, Siemens
was the right partner to help us fix it. It’s important,
because we can’t do it all ourselves.”
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dedicated water-specific libraries and templates for the Simatic PCS 7 process control system that supports standardization and efficient system engi-neering. The company also supports the water industry with engineering and consulting teams that identify potential energy savings or perfor-mance improvements in plants and systems. By using this combination of technology and expertise,
the water industry will be able to quench the growing thirst for water while preserving resources for the future.
INFO AND CONTACT
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Water industry | process news 2/2015
23
A chemist at Ecopetrol examines a sample of heavy oil to analyze how effective the water dehydration process has been
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process news 2/2015 | Industrial communication
Network solutions for the process industry
Communication for today and tomorrow
this context, data transfer between the corporate IT system and the automation network is becoming increasingly important. The transition of automa-tion into the IT environment is a very sensitive area that demands safe and reliable data transfer on the technical level, but it also raises organizational questions: does the responsibility for industrial communication lie with IT or automation? As would be expected, the criteria and solutions that are used differ greatly.
For Ewald Kuk, head of product management at Siemens Industrial Communication, industrial com-munication is not only essential to digitalization strategies (see box) but also to process automation. “Network components must meet the same require-ments as other automation components: they need to be robust, easy to maintain, and reliable,” says Kuk. “We take this into account when developing our systems for industrial communication – for example, with simple solutions for industrial secu-rity that can be configured without specialized IT knowledge, or with network components that a service technician can easily replace in the plant. At the same time, our communications products also meet all IT requirements.”
Comprehensive and integratedIn recent years, Siemens has steadily expanded its product and service offerings for industrial net-works and now covers virtually all industries and applications – from oil platforms to car manufac-turing. This enables the implementation of
Modular plants are among the new optimization and digitalization concepts currently being discussed in the process industry. A key prerequisite for these modular plants is secure, flexible, and above all easy-to-use solutions for industrial communication.
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O ne of the most important projects involving the modularization of production plants was the F3 Factory, in which the European
chemical industry worked until 2013 on the modu-larization of chemical plants. The concept includes container modules with microreactors as the building blocks of small-scale production plants, especially for fine and specialty chemicals. A further aim is the “plug and produce” capability: intelligent components that can be assembled into production units individually and without signifi-cant effort or specialist knowledge. In this context, there is much discussion of standardization and interfaces – and observers often forget that a strong communication network is a prerequisite for the digitalization and modularization of plants and processes. If processes are to be configured and ini-tiated based on specific customer orders, informa-tion must be seamlessly exchanged between pro-duction and the enterprise resource planning system. And in order for modular plants to operate safely and efficiently, the individual components must be networked horizontally.
Specific industry requirementsAlthough it will certainly be years before self- configuring process units come into large-scale use in the process industry, the integration of informa-tion technology into the process environment and the creation of an efficient communication infra-structure are key issues today. The availability of large networks and secure data communication are prerequisites for efficient automation systems. In
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Industrial communication | process news 2/2015
INFO AND CONTACT
siemens.com/[email protected]
Ewald Kuk, Head of Product Management, Siemens Industrial Communication
comprehensive and innovative solutions that meet customers’ individual requirements. The products rely on standards complemented by industry-spe-cific functions. For example, Siemens developed the Rapid Roaming solution for safety-related com-munication via Industrial Wireless LAN. Even for connectivity and wiring, an industrial environment has special requirements for the ruggedness of plugs and the simple assembly of cables.
The Scalance and Ruggedcom product lines per-fectly complement each other in their areas of use: Scalance is specially designed for use in industrial environments that require efficient, flexible, and reliable communication. The products enable redundant communications solutions for very high network availability and rapid fault diagnosis and repair through enhanced diagnostic functions. The
Ruggedcom products are the specialists for particu-larly harsh environmental conditions, for example in energy transmission or oil and gas development.
Siemens’ comprehensive portfolio of industrial com-munication products and services has impressed many companies that have used them in rather unusual applications. For example, Kuk’s project list includes Europe’s largest container port in Alten-werder, Germany, as well as Europa-Park in Rust, Germany, and Disneyland Paris, which automates its attractions with Siemens technology.
The approaches discussed with terms such as “digita-lization” or “big data” also involve intelligent networking of information. For manufacturing operations, these approaches bring new ways to optimize processes and systems – as well as new challenges. Availability and stability must be reconciled with greater flexibility; in addition to appropriate software solutions, these manu-facturers need a strong communications network that transfers the necessary information and data between all areas of the company. Siemens is developing all the necessary building blocks for digitalization, ranging from industry software to industrial identification to industrial communication. Our products and systems for industrial communication provide enterprise-wide efficiency. They enable the implementation of integrated, high- performance data networks that meet the needs of today and tomorrow.
Digitalization is only possible with industry-standard solutions for communication
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S leco in Belgian Doel was estab-lished in 2006 for the construc-tion and operation of a plant
with three fluidized bed incinerators of sludge and nonhazardous industrial waste including energy valorization. The plant is the largest of its kind in Europe and currently has a capacity of 580,000 tons per year. The energy valorization consists of the production of steam, which it generates using a turbine. Both the increase in capacity and the optimization of energy effi-ciency were carried out by the Belgian company Svex. After intensive study and planning in August, the capacity
Sleco, Belgium
More power, less consumptionA capacity increase of more than 10 percent, and then trimming the plant for maximum energy efficiency: that was the task that Sleco, a joint venture of Indaver and Suez Environment, carried out in collaboration with Siemens. A solution based on Integrated Drive Systems is providing the performance necessary for these requirements.
of the air condenser system was increased during the major operational shutdown of Sleco‘s fluidized bed plant.
Capacity expansion of air condensersFor this purpose, the drives of six air condenser fans were replaced. The drive trains consist of a frequency controller, a 60 Hz AC motor, and a mechanical reducer. Siemens was chosen as a supplier for the solution because the complete drive trains could be delivered within a single project. A Dutch engineering office
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calculated that with 20% more air flow, the air condensers would again generate their vacuum of 100 mbar at temperatures up to 15°C. This calcula-tion revealed that the expansion could be achieved with the fans, but not with the existing drives with a respec-tive capacity of 80 kW. Instead, a Sinamics drive with 132 kW was required, which led Svex to investi-gate how the drive train could be con-verted as cost-effectively as possible. One result: the existing electrical cables should be reused. There are about 250 meters of cable per motor currently meandering through the
process news 2/2015 | Drive technology
27
Drive technology | process news 2/2015
INFO AND CONTACT
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building and plant. These cables can be used for the power supply of 132-kW motors – but only if the motors are started with frequency control to limit the starting current.
Drives from a single sourceAnother advantage of this solution: the pressure at the outlet of the tur-bine is easier to control. A speed con-troller to the fans guarantees a con-stant or slow-varying vacuum, while the previous on/off control for switching the air capacitor cells generated pressure surges. The old cables are powering the frequency controllers that are installed close to the motors, which simplified the installation of the additionally required cables.
Siemens suggested an alternative con-ceptual approach that better fitted the technical requirements of the plant. For the desired operating area, a smaller and more standard Simotics 132-kW AC motor wound for 60 Hz can also deliver the required torque.
Strict schedule metThe new drive train had to be installed according to an exact schedule. In just three days, all the wiring needed to be connected and the first motors and gearboxes installed so that the first incinerator and the first turbine – that is, the first two air condensers – could be started up. During this period the fluidized bed incinerators were shut down for maintenance of the steam plant that takes place every four years. In the two weeks that followed, the remaining work was completed to start up the other lines afterwards. Thanks to the cooperation of all those involved, everything went according to plan – and the result proves this: the air velocity measurements showed that the fan‘s capacity increased by 23%, exceeding the target of 20%.
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A smaller Simotics threephase 132kW AC motor delivers the required torque
Luc Mampaey, Project Manager E&I from Svex, checks the settings on the Sinamics frequency controllers
Increase of plant capacityby more than 10 percent
Increase of fan capacityby more than 20 percent
+ 20 %+ 10 %
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process news 2/2015 | Process instrumentation
M erck is a global market leader in pharma-ceutical, chemical, and life science products. The headquarters of three of
the company’s four divisions are in Darmstadt, Germany, where 9,000 people are employed and important production and research facilities are also located. Merck has generated its own power in-house for quite some time. “We decided several years ago that, in addition to the existing combined heat and power plant that supplies nearly 60% of our electricity and our heat, we wanted to increase the proportion of power produced in-house using a modern power plant,” says Ralf Schmeisser, head of infrastructure planning and development and former head of energy production at Merck in Darmstadt. The new combined heat and power plant (CHP) generates 3.12 MW of electricity and 3.16 MW of thermal energy from natural gas as an energy source. Through cogeneration, the plant achieves an overall efficiency of 87%, which is sig-nificantly higher than with separate generation. This makes the CHP very resource-efficient and raises the climate-friendliness of the entire energy generation, reducing carbon dioxide emissions by approximately 2,500 t per year.
Merck, Germany
Perfect down to the last detailA comprehensive solution for automation and process instrumentation enables resource-friendly energy generation for Merck KGaA. The company was able to significantly reduce carbon dioxide emissions and increase the in-house power production rate to 70 percent.
An essential component in the two power stations: a Sitrans P DS III pressure
gauge
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Process instrumentation | process news 2/2015
INFO AND CONTACT
siemens.com/[email protected]
Until recently, the company supplied the energy to all divisions centrally. But the requirements of chemical production and pharmaceutical produc-tion are diverging. For example, the demand for cooling in the pharmaceutical industry has increased significantly in recent years, and the pressures of the compressed-air systems are dif-ferent. “It therefore makes little sense to produce the compressed air in a single plant. The new power stations now provide electricity and steam as well as refrigeration and compressed air directly where they are needed,” says Schmeisser.
Load management made easyTo minimize losses in the provision of process cooling, Merck built the power station for pharma-ceutical production and research near the plants. But energy efficiency was also the central guide in choosing the technology. Normally, power stations use a single method for refrigeration. Not at Merck. The plant uses compression refrigeration, using electricity for refrigeration, and absorption refrig-eration, using a heat source for refrigeration, and converts cooling energy into ice. “We utilized all available methods,” says Schmeisser proudly. When there is excess power, the plant uses compression refrigeration to freeze water in two refrigerated containers to store energy. If the price of electricity is high at peak load times, Merck uses the filled ice storage, thus reducing the load on the power grid.
For power station PH34/35 for pharmaceutical pro-duction, Siemens supplied automation components as a package solution: a Simatic PCS 7 Version 8.0 process control system with four Simatic PCS 7 CPU 410 automation systems. As subordinate con-trollers, Merck uses Simatic S7-300 controllers. The main argument for this automation strategy was the ease of operation and the efficient engi-neering of Simatic PCS 7. “The plant was to go into operation on August 1, 2014. Making this deadline
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would not have been possible without the prefabri-cated modules in the process control system,” says Schmeisser.
Reliable data from the processProcess instrumentation from Siemens provides the data for efficient and safe operation of the plant. A total of 25 Sitrans FM magnetic inductive flowmeters, 37 Sitrans P DS III pressure and differ-ential pressure transmitters, and 40 PT 100 resis-tance thermometers with built-in Sitrans TH 300 temperature transmitters are installed in the plant. “We have standards from Siemens that we like to use, such as magnetic inductive flowmeters for water measurements. We have had positive experi-ences and are very satisfied with the equipment. The support and price/performance ratio are also right,” says Schmeisser.
The Sitrans FM MAG 5100 W sensor is particularly suitable for flow measurement of water, whether groundwater, drinking water, cooling water, sewage, or sludge. The complete flowmeter con-sists of a sensor and transmitter – Merck opted for the combination of Sitrans FM MAG 5100 W and Sitrans FM MAG 5000, a low-cost transmitter with an accuracy of +0.4% of the flow rate.
More inhouse production, lower emissionsWith the new power station, Merck made its in-house power generation much more efficient and now generates 70% of its electricity itself. For the company, this not only contributes to securing the future but is also in a sense part of an internal energy revolution.
» We are very satisfied with the Siemens devices. The support and price/performance ratio are also right.«
Ralf Schmeisser, Head of Infrastructure Planning and Development, Former Head of Energy Production, Merck Darmstadt
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process news 2/2015 | News
W ith IDS, Siemens offers integrated drive solutions to ensure high performance,
reliability, and efficiency of machinery and equipment. The integration takes place on three levels: the optimal interplay of drive components, their integration into the automation envi-ronment, and lifecycle integration.
Specific applications and examples The IDS Roadshow Truck features a wide variety of exhibits and anima-tions for various applications – from
Integrated Drive Systems Roadshow
Mission: added value
rack feeders to pumps to the latest software – that show how users can reduce energy consumption with IDS, utilize plants more efficiently, stream-line processes, and increase avail-ability. The truck’s displays also show in detail how drive solutions can be integrated into various automation and control system environments.
Services offer additional benefitsAnother key aspect of IDS is tailor- made services for the entire lifecycle of a plant. These services help
The Integrated Drive Systems Roadshow is touring Europe, bringing innovative technologies and interesting applications directly to users and allowing them to discuss relevant issues with experts in drive technology. The focus: the added value that Integrated Drive Systems (IDS) brings to applications.
manufacturing companies save energy, achieve a level of high avail-ability, and implement cost-effective maintenance. Condition monitoring services prevent unplanned outages in a targeted manner and can extend the life of the machinery and equipment.
MORE ON THE ROADSHOW AND TOUR DATES
siemens.com/ids-roadshow
From Nuremberg throughout all of Europe: the IDS Roadshow was at SPS IPC Drives on November 25, 2014
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Dialogue | process news 2/2015
process news 2/2015
Publisher:Siemens AGDivision Process Industries & DrivesDivision Digital FactoryGleiwitzer Str. 55590475 Nuremberg, [email protected]
Editorial responsibility according to the German press law:Winfried Wittmann
Responsible for technical content:Cornelia Dürrfeld
Editorial committee:Mareike Blettner, Elisabeth Desmet, Ute Forstner, Petra Geiss, Birgit Gottsauner, Andrea Kerber, Andrea Lüdecke, Alma Mirojevic, Doina Pamfilie
© 2015 by Siemens Aktiengesellschaft, Munich and Berlin.All rights reserved.
Publishing house: Publicis Pixelpark Publishing,P.O. Box 32 40, 91050 Erlangen, GermanyEditor-in-Chief: Kerstin PuruckerPrint: Passavia Druckservice, Passau, GermanyCirculation: 26,000Volume 20, process news is published quarterlyISSN 1430-2284 (Print)IWI: TPOGArticle number: CGMC-M10007-00-7600
Printed in Germany.
The following are registered trademarks of Siemens AG: COMOS, PCS 7, S7-300, SCALANCE, SIMATIC, SIMOCODE, SINAMICS, SINAUT, SIPAT, SITRANS
If trademarks, trade names, technical solutions, or similar are not listed above, this does not imply that they are not registered.
The information provided in this magazine contains merely general descriptions or characteristics of performance, which in the case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall exist only if expressly agreed in the terms of contract.
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Preview
The future of resources: oil and gas
to address the challenges to remain successful in this complex market envi-ronment. To control costs and raise availability, efficiency, and flexibility in its operations, the industry needs the right technology.
You can read more about this in the next issue of process news with a focus on the oil and gas industry.
Fossil fuels, especially oil and gas, will continue to be the foundation for ener-gy generation and chemical processing for many years to come. The markets for oil and gas have recently become less solid: prices are subject to drastic fluctuations, and developing and ex-ploiting known and new deposits re-quires a steadily growing investment in technology. All this is paired with slow demand and overproduction.
The times are over when profitability in the oil and gas industry was subject to just a few factors. The industry needs
process news 3/2015 will appear in October 2015.
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siemens.com/achema
Digitalization, our central topic at ACHEMA 2015, is the key to increase your competitiveness. The integration of individual process steps across the lifecycle leads to higher efficiency along the entire value chain – from engineering and operation to continuous optimization. Experience first-hand how we can accompany you as your partner on the path to integrated production.
Discover the potential of digitalization
From integrated engineering to integrated operation
June, 15–19Frankfurt/Main
Hall 11.0 Booth C3
ACHEMA2015