processnews 3/2010 englisch - siemens global website · pdf file26 supply chain security...

The Magazine for the Process Industry

Volume 15, Number 3, 2010

newsprocess

Food and Beverage

Quality Package

C o n t e n t s

Braumat Compact helps the Unser Bier brewery achieve higher process quality and continuity – at much lower operational costs

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2 process news | 3-2010

p Cover

Food and Beverage 4 It’s Teatime

PepsiCo, Russia

6 Eco-MotorKraft Foods, Germany

9 Wastewater ControlTechnischer Industrie Service, Germany

10 “Beer from Here, Not Beer from There”Unser Bier, Switzerland

12 Taste TailorBraumat Compact

13 A New BrewSABMiller, United Kingdom

14 Fresh MilkValsad District Cooperative Milk Producers’ Union Limited, Vasudhara Dairy, Gujarat, India

16 A Smooth TransitionBestfoods, France

18 Freshness Quality AssuranceTetra Pak, Sweden

20 Cream of the CropRosen Eiskrem, Germany

22 Sweet SolutionIngenio El Viejo S. A., Costa Rica

23 Level AccuracyKinmen Kaoliang Liquor Inc., Taiwan

p Technology

Process Control 24 Up and Running – Faster

Simulation

Industrial Identifcation 26 Supply Chain Security

British American Tobacco, Poland

Process Analytics 28 Analytics Integrated

Analyzer Device Integration

Process Instrumentation 29 Even Flow Operation

Flow Metering

p Industry

Chemical Industry 30 Safe and Economical

Linde AG, Germany

32 Paramount AvailabilityAtanor, Argentina

34 In Brief

35 Dialogue

Linde Gas in Leuna, Germany, benefi ts from a modern, future-safe control system with Simatic PCS 7 and from an extraordinarily short changeover time

Page 30

“We offer an effi cient, stable, and attractive automation platform,” says Anders Fridh, development manager for the Tetra PlantMaster platform at Tetra Pak

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E d i t o r i a l

process news | 3-2010 3

Dear Readers:

Sustainability, quality, productivity, fl exibility: these terms are all part of the lexicon of the modern food and beverage manufac-turing environment. Providing quality products at a competitive price while using resources both responsibly and effi ciently is no small feat – and our customers in this industry need the very best equipment for this.

To effectively support our customers in reaching their goals, we have drawn on our broad expertise and portfolio to create a specifi c set of solutions for the food and beverage industry. Our automa-tion and drive solutions help operate processes more effi ciently, more reliably, and more fl exibly. The foundation is the continuous innovation behind our technological platforms, such as our process automation platform Simatic PCS 7, which has been proven in thou-sands of deployments worldwide. We build on top of these plat-forms using our industry expertise in the form of industry-specifi c libraries and solutions that tailor our offering to the unique needs of the vertical market. Further, we work closely with leading equip-ment suppliers and solution partners to satisfy our customers’ specifi c requirements. These activities are coordinated through our global account management approach, with the ultimate goal of providing you, our customers, with a sustainable competitive advantage.

This issue of process news focuses on the food and beverage industry and highlights some projects in which we supported our customers with our offerings and expertise. I do hope that you fi nd the articles highlighting our approach thought provoking and that we can make a valuable contribution to your daily work.

Enjoy the read!

Yours,

Gunther Walden

Siemens AG

Senior Vice PresidentMarket DevelopmentFood and Beverage


C o v e r F o o d a n d B e v e r a g e

PepsiCo, Russia p

It’s TeatimeSiemens and PepsiCo developed

a sophisticated automation plant

concept in the Russian capital,

where Pepsi has begun

producing Lipton teas to

meet the booming

product demand.

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infocontact

www.siemens.com/[email protected]

PepsiCo is a global enterprise, and no matter where it locates its bottling facilities, its goal is to produce the same product as it does else-

where in the world. The company’s south Moscow facility was designed as a sophisticated greenfi eld plant, but PepsiCo needed to automate processes that ranged from discrete packaging systems to batch and continuous tea-brewing processes, and a variety of hybrid processes in between.

The collaboration beginsSiemens was chosen as the plant process automa-tion supplier. “We started by asking Siemens to look at the way we do business and tell us what an opti-mized plant would look like,” explains Yury Bokov, director of the PepsiCo plant in Domodedovo. Siemens reviewed several existing Pepsi plants in different countries and returned with formal recom-mendations. PepsiCo further requested that Siemens recommend hardware, network architecture, and an overall package of equivalent components offering optimal performance at a reasonable cost. PepsiCo’s goal was to standardize the equipment and ensure complete interoperability between components, based on the OMAC (Organization for Machine Automation and Control) standards.

The Optimized Packaging Plant conceptSiemens recommended an approach that became known as the Optimized Packaging Plant (OPP) concept. Over the course of three years, PepsiCo and Siemens worked together to defi ne the OPP concept. Both companies recognized the signifi cance of standardizing the information stored in every data block. In order to serve as a buffer between the machine and the network, the data block must have the correct information. PepsiCo requires all vendors to standardize the information entered into each data block in every controller. This allows the com-pany to seamlessly collect real-time information and then aggregate it over the network.

This interoperability and seamless communication also give the south Moscow plant high operational visibility. At any given moment, the plant manager can examine every line of operations on a screen. Touch controls on the graphical user interface (GUI) allow the user to zoom in on a malfunction, even down to the level of an individual valve on a fi lling machine.

Overall improved plant results

The impact of the OPP concept was seen quickly throughout the south Moscow plant. There were immediate improvements in training, diagnostics, maintenance, and productivity when measured against the metrics of the north Moscow PepsiCo plant. Bokov states, “The OPP concept improves our operations across the board because the information is much better.” By standardizing the equipment used by all suppliers, PepsiCo allows plant operators to spend far less time in training. In addition, work-ing repeatedly on one type of equipment gives operators the opportunity to deepen their knowl-edge and increase their positive contribution to overall plant operations.

The improved level of self-diagnostics that PepsiCo required allows for instantaneous troubleshooting of problems as soon as an alarm occurs, averting the risk of a potential shutdown of an entire line. Signifi -cant improvements in maintenance are also possible because the operators and plant managers can track and archive downtime information in a single data-base. “We measure uptime through effi ciency,” says Bokov. “The effi ciency of the south Moscow plant is 5 percent higher than that of the north Moscow plant.”

Reduced environmental impactLike most consumer companies, PepsiCo is concen-trating on sustainability. PepsiCo has requested that Siemens continue its collaboration by focusing on monitoring and reducing energy consumption on large drives, as well as looking for other ways to reduce environmental waste. Increasingly, PepsiCo customers are demanding that their products be produced with as little impact on the environment as possible. p

» We started by asking Siemens

to look at the way we do business

and tell us what an optimized

plant would look like. « Yury BokovDirector of the PepsiCo Plant in Domodedovo


Kraft Foods, Germany p

Eco-Motor

Kraft has been producing decaffeinated coffee at its site in Bremen/Holzhafen for many years. Production is based on a process in

which the caffeine is removed from the coffee beans under high pressure with carbon dioxide (CO2). Four high-pressure pumps at the site press the CO2 through the coffee at 250 bar. Until recently, these pumps were operated by 10 kV high-voltage motors with a power of 650 kW.

The goal: 30 percent reduction in energy costs

Approximately three years ago, Kraft introduced a company-wide energy-saving program with the goal of reducing energy costs by 30 percent through modernization. One of the guidelines was that priority should be given to measures whose costs could be amortized in three years or less.

The food producer Kraft has converted its decaffeination pumps in

Bremen, Germany, to variable-speed operation with Sinamics drives.

The modernization was amortized in just three years.


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The electrical drives in the decaffeination plant were examined in this context. Kraft collaborated with Siemens on this analysis. The expected savings potential was demonstrated effectively on real exam-ples by using the SinaSave software. The analysis and a thorough factory inspection identified the four high-voltage drives as a suitable starting point.

The key measure of the retrofit project was the changeover of the decaffeination pumps from a combination of fixed-speed drive and hydraulic adjustment to an electric variable-speed drive with frequency converters. Unlike traditional control methods in which the motor always runs at the speed designed for the maximum fl ow volume and the excess fl ow volume is throttled by mechanical means such as throttle valves, drive systems with frequency converters adapt the speed and therefore the energy consumption to current operational requirements. The energy savings potential is partic-ularly high in fl ow machines such as pumps because

here the power consumption is proportional to the cube of the speed. In the course of the moderniza-tion project, the high operating voltage was also to be adapted to 690 V, which is normal for the given power range today, and the wiring of the new motors was to be optimized for easier maintenance. In the future, continuous operation of the pumps at very low speed was also to be possible, to preserve the pump shaft seals.

Adapted systemA new adapted system consisting of a transformer, Sinamics G150 frequency converters, and low-

voltage motors of the N-compact series was suggested as an energy-saving alternative. The Sinamics G150 cabinet converter devices are spe-cially designed for individual high-power drives that require no mains feedback, for example, pump drives. Sinamics G150 devices are highly reliable, quiet, compact, and user-friendly – and economical, from planning right through to service. The robust, low-maintenance low-voltage N-compact motors feature small power-related dimensions and high effi ciency.

The comparative value of the previous pump drive was determined for the new drive system, and the motor was dimensioned accordingly. A two-pole 1LA8 motor with an output of 485 kW in converter mode with 690 V is now used in Bremen. With this choice of motor, all the parameters for safe opera-tion are satisfi ed and a power reserve of 11 percent is installed. The power reserve allows safe operation of the motor even on hot summer days when the temperature in the production halls rises above 40 °C.

The solution with the Sinamics G150 frequency converters also offers numerous advantages for this particular application with regard to simple integration into the plant and a system that is as maintenance-friendly as possible. These converters have drive-internal block transformers, so no special conversions were necessary on the high-voltage switchgear. The mains choke in the input to the frequency converters was omitted as well. The combination with the Geafol cast-resin transformers allows a fl exible choice of installation sites for the transformers and ensures maintenance-free opera-tion.

Based on real operating values with the old drives and the nominal data of the motors, which all had to be designed identically with a view to spare parts

D e c a f f e i n a t i o n o f c o f f e e

Decaffeinated coffee is made by extracting the caffeine from the still green and unroasted beans by a solvent. The aim is to remove the caffeine without removing too much of the fl avor from the beans. At the same time, no residue of solvent may be left behind in the coffee.

A gentle process that is used especially for the production of high-quality and aromatic decaffeinated coffee is the carbon dioxide (CO2) method that Kraft also uses for decaf-feination. Here, coffee beans pretreated with steam are rinsed at a pressure exceeding 200 bar with supercritical CO2 to extract the caffeine. The caffeine is then extracted from the CO2 in a carbon fi lter. The caffeine-free CO2 can then be recycled into the process.

T e c h n o l o g y o v e r v i e w

Sinamics G150 frequency converters 3

Two-pole 1LA8 low-voltage motors of the 3

N-compact series with an output of

485 kW in converter mode with 690 V

Geafol cast-resin transformers 3


infocontact


stocks, the project team fi nally carried out a precise calculation of the cost-effectiveness. This analysis revealed that the amortization time for the conver-sion of all four drives would be approximately three years and therefore within the time frame for energy-saving measures at Kraft. The project could therefore be implemented.

Thanks to the compact dimensions, the new con-verter cabinet could simply be installed in an exist-ing cavity near to the drive, allowing short motor cables to be used. The wiring layout was chosen so that maintenance work can be carried out in the future without disconnecting the cables. This consid-erably reduces setup times.

Several special mechanical measures were necessary for the connection of the motor. The connecting fl anges of the old hydraulic coupling were designed identically at the input and output and adapted to the axle height of the old 10 kV motors. The axle height of the new 1LA8 motors is lower due to the much lower power.

This problem was solved with an adapter fl ange that has the dimensions of the hydraulic coupling on the pump side and the dimensions of the new 1LA8 motors on the motor side. This avoids further con-versions to the units.

Step by step from idea to realization

Initially, only one conversion, namely that of the drive for the HE1 pump, was ordered. The decision as to whether to convert the other three pumps was to be made later, based on operating experience with this fi rst pump. The operating values were measured regularly after conversion.

After the pump had been in operation with the new drive concept for approximately six months, it became evident that the new device fully met all expectations. The successive conversion of the other three drives was then ordered. Commissioning of the last drive was completed without problems on September 16, 2009. The idea of the operation managers to have the pumps run at very low speed in “nonoperation” to prevent the shaft seals from sticking was also implemented with no great effort by using the converter drives. This should prolong the life of the expensive seals and reduce the associ-ated replacement costs. p

After the conversion: the new drive system features reduced

setup times and much lower energy consumption

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The speed of the decaffeination pumps was

controlled by hydraulic couplings before modernization

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TIS Technischer Industrie Service, Germany p

Wastewater Control

State-of-the-art radar measurement controls the foam

development of dairy wastewater and prevents plant

failures and operation disturbances.

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A new application of the Sitrans LR260 radar fi lling-level transmitter was used by Tech-nischer Industrie Service GmbH & Co. KG

(TIS) in Erftstadt, Germany, for controlling the foam development in a compensation tank for dairy wastewater. The tank is 20 m high with a diameter of 4 m and operates at a process temperature of 30 °C to 70 °C. The composition of the wastewater varies, and there is more or less foam development depending on the production.

Since neither the quantity nor the composition of the foam can be predicted, the foam often over-fl owed, stuck, and led to disturbances in the opera-tion due to the malfunctioning of the level switches.

Ideal for demanding applicationsThe engineers at TIS solved the problem with a noncontacting level measurement using the Sitrans LR260 radar fi lling-level transmitter. The radar level instrument has a long measuring range (up to 30 m) and can fade out interference echoes thanks to intelligent signal processing so that the instrument can provide reliable measured values even under diffi cult installation conditions. The LR260 also has a fl ush connection for cleaning the antenna and can be parameterized and monitored centrally via HART and the Simatic PDM process device manager. The remote control functionality offers signifi cant advan-tages in this application in particular because the LR260 is installed on the top of the tank, which can only be reached from an elevator platform.

Easy installation and strong performanceIn March 2009, the TIS specialists installed the instrument and additional spray nozzles, which are activated when the Sitrans transmitter detects extreme foaming. The subsequent instrument con-fi guration was performed conveniently from the ground by the Quick-Start wizard via the HART protocol. The installation of the new instrument has already paid off in operation by considerably reduc-ing plant faults and clearing costs caused by over-fl owing foam. The plant owners therefore decided in June 2009 to also equip the second tank with a Sitrans device. Both systems have been working absolutely reliably and without faults since being commissioned. p

The Sitrans LR260 level meter features a long range and is insensitive to interference echoes


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Unser Bier, Switzerland p

“Beer from Here, Not Beer from There”

The Unser Bier brewery in Basel, Switzerland, chose Braumat Compact for the

expansion of its plant and achieved higher quality as well as continuity of the

brewing process at much lower operational costs.


In the middle of a fi ne brew: brewer and beer sommelier Jan Czerny (left) and managing director Luzius Bosshard from Unser Bier


Since its founding in 1997, Unser Bier has become the largest regional brewery in Basel. After moving to premises formerly owned by

Sulzer-Burckhardt in mid-March 2010, production started with a larger plant, additional brewing vessels and storage tanks, and a new bottle cleaning and fi lling plant.

Regional strategy requires qualityThe company slogan “Beer from here, not beer from there” is typical of the strategy of many micro and craft breweries. Regional anchoring is a success factor. Another factor is getting away from “standard brews” to beer types with a unique character and high individual quality. Jan Czerny, brewer and beer sommelier, puts it this way: “Our beer is brewed according to the standards of Bio-Suisse: naturally cloudy, unfi ltered, and unpasteurized. We cover market niches and satisfy the taste of our regular customers of many years.” However, a prerequisite is that the beer is brewed with a continuously high quality.

The basis for this, apart from the experience of the brewers, is a process control system that ensures the reproducibility of the recipes and the continuity of the brewing process.

Process control system supports product improvements In the course of relocating and renewing the brew-ing equipment at Unser Bier, the old process control, which was based on Windows 95, was replaced by the Braumat Compact process control system. Braumat Compact is based on the Simatic PCS 7 process control system and is specially adapted to the requirements of micro and craft breweries.

The libraries integrated into the Braumat Compact process control system provide predefi ned solutions for the production processes in micro and craft breweries, such as brewing, fermenting, storing, and fi ltration. Energy-optimized control functions ensure reduced energy consumption during heating and cooling and therefore reduce operating costs. Brews

and cleaning jobs can be organized effi ciently with the production planner. In addition to the actual process control, Braumat Compact also offers other functions that make the brewer’s life easier, such as process data monitoring and recording, the creation of automatic batch reports, and the planning and inspection of the production process of the current week. The bottle cleaning and fi lling plant, with its own control system, is also connected to Braumat.

It is important for the beer brewer to be able to intervene anywhere in the process and to make minor corrections, either by changing the tempera-ture curves or by making adaptations to the lauter pump. If these corrections have a positive infl uence on the quality of the end product, the changes can easily be transferred to the recipe.

This fl exibility in the process control system simpli-fi es the development of new recipes and the chang-ing of existing recipes, as well as the testing of new beer types, and is therefore critical for continuous product improvement. “A great advantage is that the entire operation and monitoring of the processes is based on a simple graphical user interface,” Czerny explains. “Beer brewers are craftsmen and not com-puter specialists. And if anything does go wrong, it is comforting to know that we are linked with the systems integrator in Munich via remote service.”

“The brewing process has become much more reli-able with the new system,” Czerny concludes. “We used to have a lot of operating trouble. If, for exam-ple, the temperature control fails during the fermen-tation process, this results in heating up and there-fore a noticeable drop in the quality of the beer.” p

infocontact

www.siemens.ch/[email protected]

» The brewing process has become much

more reliable with the new system.«Jan Czerny, Brewer and Beer Sommelier, Unser Bier

The brewing house has a capacity of 22 hl per brew (top left)

Braumat Compact enables simple process control and monitoring (top right)

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Braumat Compact p

Taste Tailor

Braumat Compact was designed to enable effi cient automation of brewing processes in micro and craft breweries. The compact,

modular process control system offers an attractive and fl exible approach to integrated automation for breweries with a capacity starting at 20,000 hl per year. Since its introduction in 2007, Braumat Com-pact has been successfully implemented at many breweries.

Privatbrauerei Welde: truly uniqueOne brewery that is reaping the benefi ts of Braumat Compact is the private brewing company Privat-brauerei Welde in Plankstadt, Germany. The brewery director, Dr. Hans Spielmann, and his 40 employees produce 100,000 hl of beer per year. The company’s main brand is Welde No. 1 Premium Pils pilsner, but Welde also produces many other beers such as WeldeEX, WeldeGold, and several wheat beers as well as mixed trend beverages.

The production processes are characterized by a state-of-the-art approach and innovation. When the company wanted to prepare itself to meet current

The Braumat Compact process control system targets micro and craft

breweries and offers a set of features that help brewers tailor the taste

of their beer to exactly meet the expectations of their customers.

and future challenges, Welde needed a powerful, reliable, and economical process control system – and found a corresponding solution in Braumat Compact. The Siemens Solution Partner PSA Gesell-schaft für Automatisierungs- und Integrationstech-nik mbH from Heidelberg implemented the new system and integrated additional units such as the gravel fi lter and the refrigerator plant. Now, the chief brewer can monitor and control the entire process, and Welde benefi ts from a uniform and effi cient process automation solution that increases productivity and protects the company’s investment.

Privatbrauerei Eibau: premium beerThe private brewing company Privatbrauerei Eibau i. Sa. has been brewing exquisite local beer special-ties for 200 years. The company’s favorite and best-known beer specialty is the award-winning dark beer Eibauer Schwarzbier. To optimize the processes in the brewhouse, Eibau was looking for a suitable automa-tion solution. Braumat Compact offers excellent usability and online operation options, allows the chief brewer to monitor the process and set param-eters, and includes an integrated weekly program – features that Eibau found very convincing.

During the modernization of the automation sys-tems, Eibau also optimized the process technology systems and some of the process equipment. The fi rst project unit was commissioned at the end of 2009. Now, Eibau benefi ts from integrated produc-tion planning and documentation and reliable pro-cesses with batch control and batch management of the brewing process. In the next few years, the brewing company intends to also optimize the fi ltration unit, the fermentation and conditioning units, the malt handling, and the cleaning-in-place (CIP) systems. p

infocontact

www.siemens.com/[email protected]@siemens.com


Braumat Compact was specifi cally designed for the requirements of micro and craft breweries

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SABMiller, United Kingdom p

A New Brew

The 10 hl microbrewery, located in the School of Biosciences at Sutton, will open its doors in 2011. The facility will be used to develop and

rigorously test new technologies and processes to improve beer quality, shelf life, and brewing sustain-ability as well as to train brewers in the production of beer and for the university’s fl agship master’s degree in brewing science.

A microbrewery for maximum innovationProfessor Barry Axcell, SABMiller chief brewer, says: “Having monitored full-scale processes, we have identifi ed areas where improvements could be

made. Our research in the lab has been really excit-ing, but to succeed in developing new technologies it’s essential to have access to this kind of facility so that our ideas can be tested at a suitable scale. It will be just like walking into a small brewery with its stainless steel plant and its own packaging line. We will be able to develop novel brewing processes, and beer produced at the plant can even be put through our sensory panel for tasting.”

In collaboration with experts from the university’s Faculties of Science and Engineering, a series of leading-edge technologies will be developed to optimize the brewing process. The brewing research facility will be a complete brewery with a plug-and-

play structure, thus allowing SABMiller to experi-ment with new technologies and processes by simply removing one piece of equipment and replac-ing it with another.

A matching automation systemThe brewing research facility will be less automated than a typical commercial brewery and will use an automation solution with a Simatic WinCC Super-visory Control and Data Acquisition (SCADA) system. The tender for the facility has been awarded to Briggs of Burton. Briggs of Burton is a long-established and highly regarded brewery engineering company with

headquarters in Burton-on-Trent, the heartland of traditional English brewing. The architecture of the fi nal control system and the philosophy behind it will deliver a system that is robust, reliable, modular, and easily understood. It will be as simple as possi-ble while still providing the required functionality and allowing future expansions in functionality. p

SABMiller is commissioning a brewing research facility at the University of

Nottingham that will push the boundaries of conventional brewing technology.

The research brewery is equipped with automation technology from Siemens.


infocontact


» We will be able to develop novel

brewing processes, and beer

produced at the plant can even be

put through our sensory panel.«Professor Barry Axcell, SABMiller Chief Brewer

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R u b r i k U n t e r r u b r i k

Valsad District Cooperative Milk Producers’ Union pLimited, Vasudhara Dairy, Gujarat, India

Fresh MilkVasudhara Dairy benefi ts from reduced operating

costs, more consistent product quality, and fl exible

expansion capabilities thanks to a process control

solution with Simatic PCS 7.

Milk and milk products are a growing market sector in India: the country has emerged as the largest producer of milk in the world.

The rising demand for fresh and packaged dairy products and ethnic dairy specialties is broadening the base of India’s modern dairy sector, accounting for almost 17 percent of India’s expenditure on food.

Gujarat Cooperative Milk Marketing Federation (GCMMF) is India’s largest food product marketing organization. As a body of milk cooperatives in the state of Gujarat, the company aims to serve the

interests of consumers by providing high-quality products that are a good value for the money yet also provide profi table returns for the farmers. In early 1990, Vasudhara Dairy (Valsad District Cooper-ative Milk Producers’ Union Ltd.) became a full member of GCMMF alongside 12 other district cooperative unions.

Increasing production capacityIn 2005, Vasudhara Dairy planned to set up a new milk processing plant with a capacity of 200,000 l per day at Boisar, Maharashtra, to increase production



infocontact


capacity and to meet the growing market demand. Initially, the Boisar Dairy plant was envisaged with manual operation. After extensive considerations, Vasudhara Dairy decided to go for plantwide automa-tion to reduce operating cost, and to provide consis-tent product quality. The complete scope of the automation contract was awarded to GEA Process Engineering (India) Pvt. Ltd., Vadodara, Gujarat. After reviewing a number of automation solution provid-ers, GEA appointed Siemens to work on the Boisar contract, largely because of the Totally Integrated Automation product portfolio. The plant was com-missioned in October 2006, and Vasudhara Dairy was completely satisfi ed with the system performance and its integrated functions.

Advanced process functionsThe Simatic PCS 7 process control system provides advanced engineering tools for dairies and cheese makers with the Advanced Process Functions (APF) engineering tool and the Dairy Functional Toolset tailored specifi cally to dairy operations. The main steps controlled by the PCS 7 system are safe mate-rial transfer, reliable tank management, traceable material movements, and consistent product specifi -cations. Online instrumentation and powerful pump drives ensure that the correct quantity and quality of material are provided at each process, be it cleaning and separating skimmed milk and cream, setting the fat content, pasteurization, homogenization, steril-ization, or cooling.

Plant expansion projectShortly after the successful completion of the initial automation project at Boisar, Vasudhara Dairy decided to double the plant capacity to 400,000 l per day. As the company was satisfied with the results of the fi rst automation project, it decided to work again with the same partners. So in 2009, Vasudhara awarded the expansion project again to GEA and Siemens. As part of the expansion, Vasud-hara Dairy also decided to upgrade the existing system to incorporate the Dairy Functional Toolset.

Moreover, Siemens was also selected to provide the plant automation solution for Motaponda Dairy Plant at Vapi, Gujarat, another dairy in the same group. For this project the OEM contractor was IDMC Ltd., an Indian company specializing in turnkey projects for the dairy, brewing, and beverage industries.

Building on trust and performanceWith these projects, Siemens has built an impressive track record in the Indian dairy industry. The Dairy Functional Toolset is clearly a differentiating factor for Siemens, and more projects for India’s dairy industry are sure to follow. Vasudhara Dairy is satis-fi ed with Siemens’ expertise and product portfolio, and has recently specifi ed Siemens as its preferred automation solution provider. p

T o t a l l y i n t e g r a t e d a r c h i t e c t u r e

Dairy Functional Toolset, the proven and tested 3industry-specifi c process management toolset

Central monitoring and calibration of all fi eld 3devices via Profi bus

Seamless integration of existing third-party devices 3

All electrical HV and LV and VFDs integrated with 3plantwide PCS 7 system

Integrated power factor control system to optimize 3electricity consumption

Main control system integrated to APC and MIS 3reporting systems and diagnostic functions with central monitoring stations

» I appreciate the sincere efforts

of Siemens in working with

Vasudhara Dairy. My faith in

Siemens’ capabilities has been

well justifi ed.« Darshan Mehta, Vasudhara Dairy

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Bestfoods, France p

A Smooth Transition

Bestfoods France Industries is part of the Uni-lever Group. One of the major production locations for aseptic soups in bricks is in

Duppigheim, France, where the company produces soups and sauces in different formats. In order to ensure optimum product quality and a long shelf life, the entire production process is operated under aseptic conditions, from raw materials processing to the packaging of fi nished goods. Brands include the well-known Knorr line of convenience foods.

Upgrading to meet current and future demandsThe first aseptic production lines were commis-sioned in 1990 and 1991 when the plant was built by Bestfoods. In 2002/2003, Bestfoods changed 40 percent of its existing equipment to increase produc-tion capacity and to receive aseptic products made by a contract manufacturer. After that, it was no

longer possible to extend the existing automation system. Moreover, the automation system and components were also approaching the end of their service life. With this situation, several critical issues were identifi ed; a state-of-the-art and future-proof control solution was needed.

For the upgrading of the control system, Bestfoods decided to work with A.2.I. Automation et Informa-tique Industrielle from Saulcy-sur-Meurthe, France. In Duppigheim, A.2.I. had been involved in the plant and automation projects from the commissioning, so the company was a logical choice for the migration project, says Annie Le Borgne, who is responsible for investments and projects at Bestfoods plants (asep-tic and dehydrated) in Duppigheim. “The A.2.I. team is very flexible and reliable, and they are familiar with our processes and our automation systems. I very much appreciate their expertise.”

A key requirement for the migration was minimum plant shutdown times. Moreover, the project had a very tight budget and the company wanted to imple-ment the new system in several stages over three years. “When A.2.I. presented an automation con-cept based on Simatic PCS 7 that had been designed

for a similar project,” says Annie Le Borgne, “I found this approach very impres-sive, and after extensive discussion with my col-leagues, we decided to follow the suggestion from A.2.I.”

In the next three years, the control level of the existing control system was gradually replaced by six Simatic PCS 7 automa-

tion systems. In order to minimize the required plant shutdown times, A.2.I. maintained the installed I/O components of the legacy control system, says Joël Viry, director of A.2.I. “That way,” he explains, “we were able to retain all the wiring at the process level so that no loop check was required.” During the

Bestfoods France Industries’ aseptic plant recently migrated a

process control system to Simatic PCS 7. For this project, the

systems integrator A.2.I. implemented a benchmark solution that

contributes to improved overall operational performance.

» When A.2.I. presented an

automation concept based

on Simatic PCS 7 I found this

approach very impressive.«Annie Le Borgne, Responsible for Investments and Projects at Bestfoods in Duppigheim

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transition phase when both PCS 7 control systems and legacy systems were working in parallel, A.2.I. developed a custom-built communication solution for the two systems based on the legacy system’s protocol. As this was the fi rst PCS 7 installation in the Duppigheim plant, the automation engineers of the Bestfoods aseptic plant received training courses from Siemens, and the maintenance and operation staff was trained on the test system at the A.2.I. facilities.

Operational benefi tsWith the migration project completed, the project team of Bestfoods in Duppigheim is very satisfi ed with both the collaboration with A.2.I. and the performance of the new process control system. PCS 7 fully meets the expectations of Bestfoods: it provides improved production and process visibility and supports rapid analysis and resolution of pro-

duction problems. The operators benefi t from effec-tive support in plant operation and from powerful tools for visualization and data archiving. PCS 7 enables improved tracking of production data. The automation staff at the Bestfoods aseptic plant can easily implement modifi cations in the automation

system, and the system also provides suffi cient capacities for future plant expansions. There is only one issue with the new system, says Bestfoods aseptic plant project engineer Yannick Tacail with a smile: “The system works so reliably that we have virtually no failures. In fact, we do have some com-plaints from our maintenance staff, which has

practically no opportunity to get familiar with the new sys-tem because there is simply nothing to fi x.” Bestfoods plans to exchange the legacy I/O components and migrate to a fi eldbus solution with Simatic ET 200 devices and Profi bus DP in the next few years. The company also has plans for another PCS 7 project: the automation of a new pasteuri-zation unit, also designed and implemented by A.2.I. p

A . 2 . I . A u t o m a t i o n e t I n f o r m a t i q u e I n d u s t r i e l l e

A.2.I. Automation et Informatique Industrielle provides comprehensive services and solutions for industrial automation. The company focuses on automation solutions for food processing and can look back on more than 20 years of experience.

Address:

12, rue des prés Pécate88580 Saulcy-sur-MeurtheFrance

Tel.: + 33 (0) 329 55 30 31Fax: +33 (0) 329 56 66 06

www.a2i.eu

» We were able to retain all

the wiring at the process

level so that no loop

check was required.«Joël Viry, Director of A.2.I.

A.2

.I.

» The system works so

reliably that we have

virtually no failures.«Yannick Tacail, Bestfoods Aseptic Plant Project Engineer

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infocontact

www.siemens.com/[email protected]@a2i.eu

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R u b r i k U n t e r r u b r i k

Tetra Pak, Sweden p

Freshness Quality Assurance

Tetra PlantMaster is a customizable automation solution that enables plant offi cials to see processes that are not always visible to the

naked eye. The goal in developing Tetra PlantMaster was to increase effi ciency internally, to move from standard to customized solutions as effi ciently as possible, to exploit reusability to minimize engineer-ing hours, and at the same time to assure quality.

The integration of Simatic PCS 7 into Tetra Pak’s

Tetra PlantMaster ensures the production of high-quality

products for the food and beverage industries.

Tetra PlantMaster has several standard features to customize entire lines and facilities in the dairy, beverage, cheese, ice cream, and prepared food sectors. The solution automates all process functions that are essential for production, from the milk tank to process equipment such as separators, homoge-nizers, blenders, and pasteurizers, as well as fi lling machines and in-house distribution equipment.

Tetra PlantMaster is a platform that is used to customize entire processing lines and plants in the dairy, juice, and processed food industry



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An integrated platformTetra Pak has chosen the Simatic PCS 7 process control system as one of the standard automation platforms for Tetra PlantMaster. “With Tetra Plant-Master and Simatic PCS 7, we offer an effi cient, stable, and attractive automation platform for the food and beverage industry,” says Anders Fridh, development manager for the Tetra PlantMaster platform at Tetra Pak. The software platform is based on Simatic PCS 7, but uses Tetra Pak’s own architecture and standard interfaces for all process-ing modules from Tetra Pak Processing Systems. “We get the Tetra Pak look and feel and can standardize all our deliveries, but we can also easily customize the platform,” explains Richard Svensson, program development manager at Tetra Pak and project manager for the Simatic PCS 7 project.

Ensuring effi ciency and qualityThe Tetra PlantMaster integration ensures trace-ability, reporting ability, safety, and productivity attributes that are extremely important within the food and beverage industry. For example, Tetra PlantMaster makes standard productivity analysis available for performance review and optimization.

“Simatic PCS 7 fi ts well in our Tetra PlantMaster solu-tions because it takes fewer engineering hours to do projects. Productivity can be improved by 20 per-cent when compared with comparable SCADA solutions,” states Dan Nilsson, Tetra Pak’s head of systems for the development project.

Tetra PlantMaster PCS 7 was developed in coopera-tion between Tetra Pak headquarters in Lund, Swe-den, and the Tetra Pak market company in Spain. The Siemens support centers for the soft drink industry in Mann heim, Germany, and the dairy industry in Linz, Austria, of the Competence Center Food & Beverage were used as advisory groups. The fi rst customer projects with this standardized plat-form were completed in 2009 by Tetra Pak in Spain, among them one of the largest juice plants in Europe at Zumavesa. The platform has so far been introduced in southern and central Europe. p

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» With Tetra PlantMaster and Simatic PCS 7,

we offer an effi cient, stable, and attractive

automation platform for the food and

beverage industry.«Anders Fridh, Development Manager for the Tetra PlantMaster Platform at Tetra Pak


Rosen Eiskrem, Germany p

Cream of the Crop

Rosen Eiskrem, Europe’s largest private ice cream producer,

has thoroughly modernized its process control and

connected it with goods management in the ERP system.

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Rosen Eiskrem GmbH has been developing and producing ice cream for the European con-sumer food market for more than 40 years.

With four factories in Germany and an annual capac-ity of 230 million liters, the traditional company is Europe’s largest private ice cream producer and can make any product the market wants within a short time on 31 production lines.

The existing process control and control system of the ice cream mixing plant at the company’s Nurem-berg site were to be replaced after 15 years in opera-tion. There were other goals connected with this upgrade: quality improvement, a reduction in man-ual work, an increase in fl exibility and process effi -ciency, absolute production transparency, batch processing on several levels, and long-term archiving. In addition, the new solution was to be commissioned quickly.

Modernization with SiemensAfter an extensive comparison of available solutions, Rosen Eiskrem chose a combination of standard products from Siemens: Simatic IT Production Suite, Simatic PCS 7, Simatic Batch, and a special manufac-turing execution system (MES) library for the food and beverage industry. Rosen Eiskrem can handle complete orders in the new MES. Customer orders are created in the enterprise resource planning (ERP) system and transferred to the MES, which generates the appropriate batches. The batches are created fully automatically in Simatic Batch. The operating personnel merely start the orders in the MES and monitor the execution. The Simatic PCS 7 process control system controls and visualizes the entire weighing and mixing process. The status of the batches and information about consumed material and fi nished products are archived in the MES during runtime and can be traced continuously.

A considerable improvement in quality was achieved by the introduction of a radio scanner solution that makes sure that additives can be added manually only at specifi c recipe times and checks the manual interventions for plausibility. This largely rules out the faulty feeding of additives. The MES reports all order and consumption information to the ERP system automatically. This communication prevents double entries and input errors and allows the automatic creation of reports and evaluations of production and quality.

Proven benefi tsThe system was successfully commissioned in Janu-ary 2009, and Rosen Eiskrem now produces up to 450 tons of ice cream mix based on approximately

400 recipes every day. All the production and mate-rial data are archived and are available clearly and consistently at the push of a button. The new system reduces manual work, improves the quality and effectiveness of production, and is also an important step in the direction of a paperless environment. Flexible and user-friendly Web interfaces allow company-wide MES access via the intranet.

Redundant server systems make the solution highly available. The system can also be extended easily without impairing existing confi gurations. This secures the investment for the future. Georg Hassil, CEO of the Central Supplies Department at Rosen Eiskrem, sums up: “We are very pleased with the entire Siemens system and the company’s service throughout the project. Our main goals were all achieved, and we would not hesitate to give this contract to Siemens again.” p

» We are very pleased with the entire

Siemens system and the company’s

service throughout the project.« Georg Hassil, CEO of the Central Supplies Department at Rosen Eiskrem

P r o j e c t f a c t s

Challenge:

To replace the old process control and control system and integrate the new solution at the ERP level

Solution:

Simatic IT Production Suite 3

Simatic PCS 7 3

Simatic Batch 3

MES food and beverage 3library

Results:

Improved quality and process 3control

Improved data quality and data 3transparency

Production know-how available in 3the MES at any time

Less manual work (paperless 3production)

Lower production costs 3


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Ingenio El Viejo S. A., Costa Rica p

Sweet Solution

The sugar mill Ingenio El Viejo S. A. in the province of Guanacaste, Costa Rica, produces 50,000 tons of sugar products annually in

crude, white, and special varieties, including molas-ses, using an evaporation process.

A new approach to level monitoringReliable level measurement of the syrup in the evaporation part of the process is critical. The level of the syrup determines duration and stabilization in this stage of the process. All evaporators must have the correct setting to work together. The product inside is constantly boiling, and the density varies according to the evaporation stage. Sugar mills typically use pressure transmitters with remote seals for level measurement through static pressure monitoring. Although the measurements are reliable in principle, this method of installation has high maintenance requirements. Operators at Ingenio El Viejo were either fi xing or substituting pressure transmitters on a regular basis. An alternative solu-tion was needed to provide safe and reliable level readings that could also withstand the chemical cleaning events in the tank.

The instrumentation staff at Ingenio selected the Sitrans LR250 as the solution to their challenge at the plant. A noncontacting Sitrans LR250 radar transmitter was installed on one of the evaporation tanks. The device provided accurate level readings in a matter of minutes. The Sitrans LR250’s benefi cial

The Sitrans LR250 radar transmitter enables a Costa Rican sugar

producer to conduct reliable level measurements of its evaporator

tanks, thus producing a better-quality product for its customers.

features for this application include its simple and robust device design, faster implementation, and special internal programming to enable effi cient processes.

Signifi cantly reduced operation costsBesides offering a reliable level measurement solu-tion, the Sitrans LR250 has substantially reduced the maintenance requirements for the level instruments at El Viejo. The Sitrans LR250 can stay in place during the chemical cleaning process. This means signifi cant cost savings for El Viejo in labor time, equipment repairs, and replacement. Since the fi rst installation, an additional four Sitrans LR250 trans-mitters have been installed on other tanks. “With the installation of Sitrans LR250 radar transmitters from Siemens in our evaporators, we have been able to work through the entire harvest season without calibrating or adjusting the transmitters, and we are happy that we don’t have to replace them or fi x any parts. Since they are not affected by the changes in density, our maintenance is quite low. Very soon we will run tests in the other stages of our process where we believe this equipment will have no prob-lem,” says Juan Carlos Matarrita, engineer and head of automation at the El Viejo plant. p

R u b r i k U n t e r r u b r i kC o v e r F o o d a n d B e v e r a g e

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Kinmen Kaoliang Liquor Inc., Taiwan p

Level Accuracy

Founded in 1952, Kinmen Kaoliang Liquor Inc. (KKL) is Taiwan’s largest brewery, with 700 employees. Although the company was a

government-owned monopoly for many years, it has since been privatized and has committed itself to actively recruiting new talent from all areas, esca-lating its adoption of advanced technology, and developing new products.

A need to upgradeAwarded the Certifi cate for Outstanding Alcohol by the Ministry of Finance in 2007, the brewery has been producing excellent product in recent years. Quality and reliability are two key values in the company’s operation. So when KKL was looking for a state-of-the-art solution to replace the existing differential pressure-type level measuring system on the liquor storage tanks, the company wanted a system that could reliably monitor the level in an explosion-hazardous area. The system needed to allow remote control and remote display of the measured values. Additionally, the solution needed to be available at a competitive cost.

For this task, Siemens suggested installing Sitrans LR250 level transmitters on top of the tanks, com-bined with Sitrans RD100 remote digital displays on the sides of the tanks. Although the competition offered a lower price, the accuracy it offered was also lower. Convinced by the Siemens solution, KKL ordered 80 LR250/RD100 combinations.

Taiwan’s largest brewer turned to a Siemens solution to meet the

challenge of accurately measuring vaporous liquid in its storage tanks.

A satisfactory result

KKL now enjoys accurate online measurement with the possibility of using data for process control and optimization. Measurement costs have also been reduced, as fewer human resources are needed to gather data. KKL especially appreciates the infrared handheld programmer for local operation, and the support from headquarters and Siemens partner Nohken Technology Co. Ltd. p

S i t r a n s L R 2 5 0 h i g h l i g h t s

The Sitrans LR250 is a 2-wire, 25 GHz pulse radar level 3transmitter for continuous monitoring of liquids and slurries in storage and process vessels, including those with high temperatures and high pressure, to a range of 20 m

The Sitrans LR250’s unique design allows safe and simple 3programming using the Intrinsically Safe handheld programmer without having to open the instrument’s lid

Key applications: liquid bulk storage tanks, process 3vessels with agitators, vaporous liquids, high temperatures, low-dielectric media

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T e c h n o l o g y P r o c e s s C o n t r o l

Simulation p

Up and Running – Faster

The setup and operation of process plants also includes the installation and operation of process control systems that control all the

specifi ed technological processes. A visualization system forms the interface to the plant operator. Plant owners expect their process control systems to provide reliable handling of the work assignments with optimum utilization of raw materials and energy.

For this reason, process developers must employ extensive and effi cient test scenarios to make sure that their specifi c defi nitions have been imple-mented correctly before commissioning. The deliv-ery and commissioning of a process control system is therefore preceded by an extensive FAT (factory

The time required to test control system software can be reduced

by 30 percent with a simulation of the application programs.

The simulation also reveals optimization potential.

acceptance test). In the past, these tests were car-ried out completely at the control system cabinet, where the individual signals were trimmed by signal transmitters and the behavior of the user program tested. Such test scenarios often lasted many weeks.

FAT: simulation on the PCSimulating the functions with the Simit software tool allows this time to be considerably reduced, as is confi rmed by the experience of BST Buck System-technik GmbH, a Siemens Solution Partner from Brunsbüttel, Germany. BST has been handling pro-cess technology projects with Simatic PCS 7 for many years and added simulation applications to its service profi le in 2007. In recent years, many proj-ects have been tested based on Simit prior to com-

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infocontact

www.siemens.com/[email protected]@siemens.com


Delivery of a PCS 7 process control system 3to China, with installation and commissioning on-site

22 control cabinets with I/O systems, 3equipped on both sides

4 PCS 7 417-4H/FH automation systems 3(3xDCS, 1xESD)

1 redundant Profi bus with ET 200M, 3ET 200M F, and ET 200iSP modules for connecting 2,000 I/O signals

Separate I/O and software FAT: I/O FAT at 3the control cabinet, and software FAT in the offi ce with Simit

Reduction in commissioning time by at 3least 4 weeks

While the control system was installed in China, the BST engineers carried out the software FAT in a PCS 7 test environment in Germany

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B S T B u c k S y s t e m t e c h n i k G m b H

As a certifi ed Simatic PCS 7 and Safety Specialist Partner and strategic industry partner for the chemical industry, BST Buck Systemtechnik implements tailor-made PCS 7 Batch and Safety projects, primarily in the chemical industry and in power station environments.

Key activities are the modernization of existing automation systems and the engineering of new automation solutions all over the world.

Address: BST Buck Systemtechnik GmbHEmil-von-Behring-Straße 14D-25541 Brunsbüttel, Germany

Internet: www.bst-sys.com

missioning, and the BST engineers have opened up an innovative fi eld of business with the implementa-tion of several operator training systems that enable the quality of the control systems to be further improved.

BST recently received the contract to deliver a Simatic PCS 7 process control system to China and perform the commissioning. The BST engineers agreed on a two-part FAT with the client’s process engineers: the I/O test was to be carried out at the control system cabinet, and the test of the user program in a simulation environment at BST. The cabinet was tested, shipped to China, and installed in three weeks. In the meantime, the BST engineers carried out the software FAT in a PCS 7 test environ-ment in Germany. The data could be easily loaded into the simulation system from the PCS 7 user program with an appropriate hardware confi guration by a specially developed BST conversion program so that changed scenarios were soon available. In this way, the process specifi cations could be preset very easily with Simit and the expected reaction of the user program to the plant situation to be tested could be checked. This also produced new knowl-edge for the process technology, which fl owed immediately into the user program.

Commissioning in record timeWhen commissioning began in China, production was able to start almost immediately after the loop checks with all the connected process devices. Only the fi ne-tuning remained, along with the implemen-tation of a few special requests from the customer’s operators. The intensive software FAT therefore saved at least four weeks, and the productive opera-tion of the plant was able to start earlier as a result.

After BST’s positive experience with this fi rst soft-ware FAT using Simit, the BST team used the simula-tion in many subsequent projects to create the user program to rigorously test implemented subfunc-tions immediately and in a realistic environment. “In another project, we were able to reduce the two weeks planned for the FAT of a complex safety step sequence to just four days with Simit,” explains Olaf Schwarze, project manager at BST Buck System-technik. p


British American Tobacco, Poland p

Supply Chain Security

The illicit trade in cigarettes – for example, product counterfeiting and illegal imports – results in annual losses in tax receipts on the

order of billions. Effective countering of the illicit tobacco trade is also required from the perspective of the World Health Organization. Industry and government organizations are working on stemming the fl ow. An important aid here is seamless tracking and tracing (T&T) using optical codes. British Ameri-can Tobacco (BAT) in Poland is one of the first tobacco companies to install a comprehensive T&T

system. The company is active in 180 markets with 300 brands, including the four familiar names of Dunhill, Kent, Lucky Strike, and Pall Mall. The pro-duction site in Poland is one of the largest in the world and is simultaneously BAT’s most important export hub.

Direct T&TCartons and shipping cases must be designated with unique serial numbers for the purposes of T&T. This information is printed on the relevant label as human-

With an industrial identifi cation solution using Simatic MV440

code, reading systems, British American Tobacco ensures more

security in its supply chain.

T e c h n o l o g y I n d u s t r i a l I d e n t i f i c a t i o n


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readable text and as machine-readable code. A T&T system (line controller) installed on the production line captures the data and makes them available to the factory and enterprise levels. A system of this type is directly integrated in the production process and must therefore fulfi ll stringent demands for speed, reliability, and reading accuracy.

To ensure that these requirements could be met, Siemens was tasked with implementing the T&T system at the line level. The key functions are read-ing and processing the serial numbers printed on carton labels in the form of data matrix codes. Later in the process, the cartons are packed in “master cases,” which are in turn uniquely identifi ed by serial numbers. The T&T system links the different serial numbers of the cartons and master cases hierarchi-

cally and then sends this data record to the super-visory IT system (site controller). It was extremely important to BAT that the implemented solution would also function reliably during manual inter-vention in the process.

Reliable code reading with Simatic MV440For reading the data matrix codes printed on the carton labels, BAT decided in favor of the Simatic MV440 code-reading system. Thanks to its compact design and the option of reliably capturing codes even at the closest possible distances, the device can be mounted in the available machinery even in the most restricted installation situations – an important advantage for BAT. The integrated and space-saving lighting unit for the Simatic MV440 also makes

installation easier. Another important feature is continuous checking of the print quality on the label, performed automatically by the code-reading system at every read. This allows, for example, preventive measures such as cleaning of the camera lens to remove production dust, increasing the reliability of the code-reading system to a high degree. Finally, the multicode-reading system offers the option of reading the existing European Article Number (EAN) bar code together with the 2D serial code.

After the code has been read, the serialization data for all the cigarette cartons in a master case are transferred to the line controller via the integrated Profi net interface on the Simatic MV440. This line

controller was also designed by Siemens and con-tains, in addition to a Simatic Microbox PC, an unin-terruptible power supply. This ensures that no infor-mation is lost in the event of a power failure.

Holistic approach ensures fast rolloutIn addition to the technical features of the Simatic products used, a decisive factor for BAT was the comprehensive solution competence of Siemens. The components of the line controller were fully installed in the control cabinet at the Siemens fac-tory, and the entire system was tested to make the rollout as easy as possible. The software was also specially tailored to BAT’s requirements and installed in advance. “This allowed us to commission the tracking and tracing solution without significant production stops,” says Bernd Rabenstein, who was responsible for the development and commissioning of the line controller at BAT. Siemens formed an interdisciplinary team for the project that was able to relieve the customer of many coordination pro-cesses such as interfaces to the site level. “This holistic approach was very helpful to us in achieving a fast rollout,” says Michael Imminger, head of the tracking and tracing project and production sequencing at BAT. p

» The holistic approach was

very helpful to us in

achieving a fast rollout.«Michael Imminger, Head of the Tracking and Tracing Project and Production Sequencing at British American Tobacco

» This allowed us to commission

the tracking and tracing

solution without signifi cant

production stops.«Bernd Rabenstein, Responsible for Development and Commissioning of the Line Controller at BAT

The Simatic MV440 device can be easily set up for multicode reading

The Simatic MV440 code-reading system reliably reads and verifi es 1D/2D codes


T e c h n o l o g y P r o c e s s A n a l y t i c s

Analyzer Device Integration p

Analytics IntegratedThe OPC Foundation has published a new specifi cation that will enable

complex analyzers such as the Maxum II process gas chromatograph to be

easily connected to the master control technology.

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The aim of this specifi cation, which was writ-ten and published mainly on the initiative of the pharmaceutical industry, is to create a

uniform and effi cient interface for connecting com-plex analysis systems – covering as many measuring processes and systems as possible – to the control technology.

Simple, transparent accessThe advantage for the user is that he or she can now read all the information, such as a complete chromatogram of a Maxum II process gas chromato-graph, out of the analysis system and transfer it to a host computer. Previously available interfaces such as OPC DA (Data Acquisition) did not allow this.

Application in the pharmaceutical industryWhen evaluating analysis data with multivariate data analysis – for Process Analytical Technology (PAT) solutions in the pharmaceutical industry, for exam-ple – this information visibility is required to deter-mine control parameters and variables that are critical to quality and to develop suitable control strategies. With the new interface, PAT tools such as the Sipat software can evaluate complete spectra or chromatograms based on chemometric models and therefore contribute to a significant increase in product quality and the optimization of the produc-tion process. p

Analyzerinterface

OPC informationmodel

All requiredservices

OPC-ADI

OPC UA basic services

DA A&E HDA CMDs

The OPC-ADI interface is based on the OPC-UA specifi cation

W o r k i n g G r o u p A D I

On the initiative of several pharmaceutical compa-nies, the OPC Foundation initiated the Working Group ADI (Analyzer Device Integration) at the beginning of 2008. The working group is composed of representatives of pharmaceutical companies (i.e., users of analytical technology) and analyzer suppliers.

Its task was to specify an interface that would allow manufacturers to integrate complex analyzers such as spectrometers or chromatographs into the higher-level system technology more easily and with higher performance than ever before.

This problem was solved by an international team of manufacturers and users. As the leading pro-ducer of process gas chromatographs in this inter-national team, Siemens was responsible for the “Chromatography” chapter in the specifi cation for the new interface.

In November 2009, the OPC Foundation published the document as version RC 1.00.43 on the OPC Foundation Web site. It is available free to all OPC Foundation member companies.


T e c h n o l o g y P r o c e s s I n s t r u m e n t a t i o n

infocontact

www.siemens.com/fl [email protected]

Flow Metering p

Even Flow Operation

The combined leak detection and high- performance fl owmeter was needed for a terminal that received jet fuel from a barge

and when transported the fuel by pipeline 2 miles to a storage facility. From there the fuel was trans-ported by another pipeline approximately 5 miles to an air force base for usage. This terminal required leak detection measurement on all pipelines to the air base and from the dock. Since it had no metering or communication capabilities available, a complete system was needed, with requirements including simple operation, an easy user interface, and visual accountability – at low cost to the terminal owners.

Noncontacting solutionThe terminal owners chose a complete leak detec-tion system based on Sitrans FUH1010 nonintrusive ultrasonic fl owmeters, radio communications, and an industrial-quality transmitter to operate the leak detection software. Since the leak detection system was performing so well, when the requirement arose for a new meter to support billing to the air base,

Combining data from a leak detection system and a high-performance inline

ultrasonic fl owmeter based on Sitrans technology enables a northern U.S.

pipeline company to improve its management capabilities.

the terminal owners requested the Sitrans FUT1010 inline ultrasonic flowmeter. This device, which is based on a similar technology as the nonintrusive ultrasonic fl owmeters, could be tied into its new leak detection system.

Integrated functionalitiesThe combined technology was able to offer a com-patible solution wherein information could be easily exchanged between the Sitrans systems. This allowed functionalities such as diagnostic and data logging gathered by the leak detection system to be used for the billing system, which reduced equipment costs while enhancing the overall management capabili-ties of the complete system. p


Linde AG, Germany p

Safe and Economical

Whether supplying liquid hydrogen for the semiconductor industry, pure oxygen for refi neries and steelworks, or liquid nitro-

gen for cryogenic processes, requirement-based gas delivery is indispensable for almost all industries. Linde Gas, a division of Linde, produces technical, medical, food, and special gases for numerous industries in its gas production center in Leuna, which is the largest in Europe. Linde Gas decided to completely modernize the aged plant control tech-nology to be able to ensure the promised supply in the future.

Migration within a narrow time frameThe demands were high: the conversion had to be completed within as short a shutdown period as possible and the connected refi nery supplied with gas again immediately afterward. Linde was looking for a control system with integrated safety technol-ogy and wanted to be able to retain the installed sensors and actuators to a large degree. In addition to the LZA 7 and LZA 8 air separation plants, another air separation plant just a few kilometers away in Buna was to be operated and monitored by a central control room in Leuna. For this purpose, the existing control room had to be modernized completely. Linde also wanted to bring a hydrogen fi lling plant up to the state of the art. With Simatic PCS 7, Linde found a process control system that met all these requirements. Linde had also already had positive experiences with the Siemens process control sys-tem in LZA 8 and the air separator in Buna. Linde therefore contracted Siemens and the certifi ed Siemens Solution Partner Finze & Wagner EMSR Ingenieurgesellschaft mbH to perform the modern-ization.

Linde Gas in Leuna benefi ts from a modern, future-safe control system

with Simatic PCS 7 and from an extraordinarily short changeover time.

Competent team for a tailor-made solutionThe engineers of Finze & Wagner supported Linde in the development of the migration strategy for the control and safety technology and the automation systems as well as in the implementation. The exist-ing fail-safe programmable logic controllers (PLCs) and emergency stop relays were replaced by highly available Simatic S7-400 controllers, and the I/O devices were replaced by distributed I/O modules. Profi bus is used as a fi eld bus; Industrial Ethernet is used as a terminal bus. The system bus, which extends over 11 buildings, was completely restruc-tured. The sensors and actuators, which represent an enormous asset with a scope of approximately

I n d u s t r y C h e m i c a l I n d u s t r y


Modernization of the controller level with 3Simatic S7-400

Profi bus fi eldbus system 3

Industrial Ethernet-based terminal bus 3

New plant system bus networks 11 buildings 3

I/O level and the corresponding large 3investment was retained (approx. 8,000 measuring points)

Compliance with new HAZOP (hazard and 3operability) study necessitated replacing some temperature, pressure, and fi lling-level sensors by fail-safe SIL (Safety Integrity Level) 1- or SIL 2-capable devices


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8,000 measuring points, were largely retained. The implementation of a new HAZOP (hazard and opera-bility) study required the replacement of some temperature, pressure, and fi lling level sensors by fail-safe SIL (Safety Integrity Level) 1- or SIL 2-capa-ble devices. Nine of the total 11 automation systems in highly available versions are now in operation in the various plant sections. Thanks to the Siemens technology, complex bus links could be omitted. LZA Buna is connected to the terminal bus by a directional radio link. Both the two systems in Leuna and LZA Buna can be operated from any operator station. The process data are visualized on a total of eight clients. After the modernization of the control room, separate server rooms and modern large-screen technology with camera switching for access control have made work signifi cantly easier for the maintenance personnel.

Because the legacy and the new control system differed too greatly in terms of basic principles and philosophy, a 1:1 migration was not recommended. The application software with more than 10,000 I/Os was for the most part implemented functionally. For some application areas, the data of the legacy system were imported into Simatic PCS 7 with a software tool developed by Finze & Wagner. Stan-dardized typicals were used for specific controls such as the valve controls. The legacy logic could be replaced by standard blocks from the Linde library. This simplifi es troubleshooting, allows easy confi gu-ration, and saves costs in later updates. The image data of the legacy system were created by special grid layouts in the new system. All control elements are displayed on the operator stations in the accus-tomed array.

Leuna is not only one of the largest production sites of Linde Gas worldwide but also an important logistics and supply center

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Milestone factory acceptance testBecause the conversion time could not exceed 20 days, special attention was paid to the factory accep-tance test (FAT). In a fi rst internal FAT, the complete I/O level was tested, and then all the individual control functions and related functions of the plant were simulated and tested by means of a simulation tool. The subsequent FAT with Linde already enabled concrete process optimizations. These intensive preparations ensured that the plant ran 100 percent error-free after the conversion. What’s more, only 17 instead of the planned 20 days were required. This allowed the plant owners to bring the cold operation forward three days and considerably reduced the downtime as a result.

Another key factor in the successful completion of the project was the excellent and competent cooper-ation of the owner in Leuna and the energy depart-ment of Linde Gas in Pullach in all detail and concept matters during the planning, FAT, and commission-ing. “The good project coordination and the technol-ogy of the Simatic PCS 7 process control system convinced us,” says Hans-Jochen Schneeloch, head of electrical services at Linde Gas. “The migration standardized the system environment and increases the effi ciency, availability, and safety of the plant. We also benefi t from low maintenance costs thanks to uniform spare parts storage and the use of stan-dardized components.” p


I n d u s t r y C h e m i c a l I n d u s t r y

An athanor was a real innovation in the age of the alchemists. This furnace enabled the generated heat to be regulated for the fi rst

time and processes such as distillation or sublima-tion to be controlled accurately. When a group of entrepreneurs began producing hydrogen peroxide, acetic acid, and acetates in the Argentine province of Buenos Aires in 1938, they called their company Atanor in reference to the pioneering technology from the early days of chemistry.

Atanor has since become one of the world’s leading producers of agricultural chemicals and owns plants in Argentina and Brazil. The latest site is the chlorine alkali plant Cloro-Soda II in Río Tercero in the Argen-tine province of Córdoba. Here, base chemicals for pesticides and herbicides are manufactured by means of an electrolysis process. Soon, Atanor will also be operating in China.

Maximum reliability in operationAs far as the automation of the new process plant was concerned, Atanor had clear ideas from the very start. It was to be an open system based on recog-nized industrystandards and smooth interactions with the field devices of different manufacturers. A redundant client server structure in connection with standard monitoring software was to ensure maximum process safety up to Safety Integrity Level (SIL) 3. A scalable system that could grow easily with further expansion of production was also demanded.

Atanor, Argentina p

Paramount Availability

Atanor relies on PCS 7 and a scalable,

highly available architecture for the

building of a new production plant for

pesticides and herbicides.

S i m a t i c P C S 7 a t A t a n o r

Open system based on standard 3technologies and components

Scalable client server structure 3

Easy expansion of the plant possible at 3any time

Redundant Simatic PCS 7 confi guration 3with standard automation and Safety Integrated technology

Process safety according to SIL 3 3

Confi guration of the safety functions with 3Simatic Safety Matrix

Supply security in the power distribution 3by TIA/TIP integration

Intelligent diagnostic possibilities of OEM 3devices

Communication on the monitoring and 3control level via Industrial Ethernet and TCP/IP

Communication on the fi eldbus level via 3Profi bus, HART, and AS-Interface as well as conventional (wire) and optical (fi ber optic) cables

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Simatic PCS 7 met these requirements exactly. Atanor chose a system with a redundant server confi guration for the implementation. Although the plant could be controlled with only one automation system, in the event of a failure, a second Safety Integrated system with AS 417-FH was connected. It was added exclusively for the safety functions to the AS 417-H automation system that handles the standard applications. In addition, the system con-sists of three operator stations and an engineering and observation station, which enables program-ming down to the device level and monitoring of the plant.

An Industrial Ethernet with 100/10 Mb is used as a system bus; the fi eld level is linked via an optical bus. The majority of the fi eld instruments communi-cate via Profi bus PA. However, some devices linked directly via Profi bus DP were connected as well. The remaining devices (HART and 4-20 mA) were addressed by the also-redundant Simatic ET 200M peripheral stations.

Simple engineering on all levelsThe safety-relevant functions were confi gured by means of the Simatic Safety Matrix. This engineering tool enables automatic complex CFC safety programs to be generated and allows a much more reliable and faster confi guration of the safety logic. At the process level, the Simatic PDM process device man-ager enables central and time-saving confi guration,

parameterization, commissioning, diagnostics, and maintenance of process instruments and power drives directly from the control room.

In addition to the automation, Siemens also made a contribution to higher productivity and availability of the plant in terms of power distribution. For example, it provided a Micromaster frequency invert-ers and Sirius switchgear as well as circuit breakers, starter transformers with vacuum contactors, low-voltage inverters, soft starters, measuring devices, and intelligent motor contactors.

Successful implementation and new challengesThe implementation of the control system was completed smoothly and successfully due to the good, close cooperation between all the people involved at Atanor and Siemens. A continuation of this collaboration is already planned: next year, two other electrolysis cells are to be added to the chemi-cal plant and integrated into the existing Simatic PCS 7. p

The new control center at Atanor in Río Tercero

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The new 6 kV switchgear with a total of 20 rows of type 8KB20


SABMiller, United Kingdom

Accredited Supplier

Orica Ltd., Australia

Success Down Under

Siemens has been awarded a contract by Australia’s largest chemical company, Orica Ltd. (ORI), to equip its new ammonium nitrate plant in Bontang, Indonesia, being constructed by PT Kaltim Nitrate Indonesia (KNI). The contract involves implementa-tion of the entire integrated control and safety system solution based on Simatic PCS 7.

The plant, which already represents an investment of over US$ 200 million on the part of KNI, will produce up to 300,000 tons of ammonium nitrate per annum when fully operational in 2011. Siemens successfully met the client’s stringent performance specifi cation as well as its critical control and safety requirement profi le for this major contract using the Siemens PCS 7 process control system, thanks in large part to the close integration of control and safety aspects. Another deciding factor in the contract being awarded to Siemens was the company’s presence both in Australia, where Orica is based, and in Indonesia, the site of the new plant. For the client, this presence ensures optimum project management and local support.

www.siemens.com/chemicals

After an exhaustive process to accredit original equipment suppliers based on SABMiller’s GLT.CP.015 Standard for the Assessment of Equipment Suppliers Quality Management System, Siemens has become the fi rst supplier to be accredited.

Maurice Egan, group head: manufacturing, in SABMiller’s Group Technical division, says that through the accreditation, both companies are aligned with related policies, proce-dures, and work practices that impact on the quality of people, resources, and deliverables.

“When we buy plant, and equipment, the optimization of total cost of ownership is key to us and, in achieving this objective, the collaboration with Siemens and, indeed, any other accredited supplier, should benefi t SABMiller,” says Egan.

Siemens, which has a long-standing relationship with SAB-Miller, has about a 70 percent share of automation systems, more than 40 percent of power distribution equipment, and about the same percentage of process control equipment in the group’s breweries around the world.

www.siemens.com/beverages

Olaf Plante, Siemens corporate account manager for SABMiller (left) and Maurice Egan, group head: manufacturing, in SABMiller’s Group Technical division (right), proudly present the accreditation certifi cate for Siemens

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process news 3-2010PublisherSiemens Aktiengesellschaft,Gleiwitzer Str. 555, 90475 Nuremberg, Germanywww.siemens.com/automation

Drive Technologies DivisionCEO Klaus Helmrich

Industry Automation DivisionCEO Anton S. Huber

Editorial responsible in Accordance with the German Press LawArno Hoier

Responsible for Technical ContentCornelia Dürrfeld

ConceptChristian Leifels

EditorCornelia Dürrfeld, Siemens AG, I IA AS SM MP 7 Siemensallee 84, 76187 Karlsruhe, GermanyTel.: +49 (0) 7 21 5 95-25 91Fax: +49 (0) 7 21 5 95-63 [email protected]

Editorial CommitteeElisabeth Desmet, Sigrun Ebert-Heffels, Ute Forstner, Petra Geis, Michael Gilluck, Walter Huber, Rüdiger Selig, Roland Wieser

Publishing HousePublicis Publishing,Part of Publicis Pro Postfach 32 40, 91050 Erlangen, GermanyTel.: +49 (0) 91 31 91 92-5 01Fax: +49 (0) 91 31 91 92-5 [email protected]

Editor in chief: Kerstin PuruckerLayout: Stefanie Eger, Jürgen StreitenbergerCopy editing: Irmgard WagnerDTP: Mario Willms

Printing: Wünsch, Neumarkt, Germany

process news is published quarterly

Cover photo: Unser Bier

Circulation: 32,000Job number: 002800 28107© 2010 by Siemens Aktiengesellschaft Munich and Berlin

All rights reserved by the publisher. This edition was printed

on environmentally friendly chlorine-free paper.

ISSN 1430-2284 (Print)

The following products are registered trademarks of

Siemens AG:

SCADA, SIMATIC, SIMATIC PCS 7, SIMATIC IT, SIMATIC S7-400,

SINAMICS G150, SITRAIN, SITRANS, WinCC

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.

IWI: TPOG

Order number: E20001-M6310-B100-X-7600

Printed in Germany

onlinewww.siemens.com/processnews

Here you can download the current issue and past issues of process news as PDF fi les, or search directly for articles about specifi c topics, technologies, and systems in the Reference Center.

eventsBrau Beviale 2010

Create Sustainable Value

With the right technologies and solutions, the food and beverage industry is able to benefi t from sustainable and profi table operations that have a minimal impact on the environment. Plus, advanced automation and drive concepts can help reduce costs, improve produc-tivity, and ensure high production quality. At Brau Beviale 2010, Siemens presents the latest innovations in process automation for breweries from the Braumat product line and process automation with Simatic PCS 7 for the soft drink industry. The manufacturing execu-tion system Simatic IT offers perfectly aligned and powerful modules for manufacturing management, quality control, tracking and tracing. With Optimized Packaging Line, plant operators benefi t from greater effi ciency in their fi lling and packaging processes. The fair presentations also showcase comprehensive and integrated solutions comprising controller/HMI, motion control, drives/motors for the beverage industry, and process instrumentation, as well as solutions for energy management, water and wastewater management, and lifecycle management.

Visit us at Brau Beviale 2010 in Nuremberg:November 10 – 12, 2010, Hall 7, Booth 310.We look forward to seeing you there!

www.siemens.com/food-beverage

infoDo you want to know more about the systems and solutions for the process industry from Siemens Automation and Drives? Simply visit our information portal on the Internet at:

www.siemens.com/processautomation

Answers for industry.

How can I drive risk and cost out of my biofuels project?

With comprehensive solutions and proven technology, you will decrease risk and cost in your biofuels plant.

The renewables market is challenging. First-generation biofuels customers are working to manage costs and increase efficiency. Second-generation customers are looking for flexible, scalable and cost-effective solutions to take them through the lab, pilot, demonstration and commercial scale. With more than 400 biofuels projects and a proven commitment to innovation, Siemens has the experience to remove risk and cost from your projects. Our solutions are targeting performance and cost optimization over the entire life cycle. www.siemens.com/biofuels

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