www.siemens.com.sg/SPACe

SPACe 2013Siemens Process Automation Conference & Exhibition

10-11 June 2013 | Bangkok, Thailand

Participating Solution Partners Special Acknowledgement

Asian Pacific Research Taiwan

Official Media Partner

06 Welcome 24 Technology Infoshops14 User Advisory Board 34 Key Notes

06 – 07 Welcome MessageMr. David Ong Chairman, SPACe 2013 User Conference Siemens and User Process Automation User Advisory Board ASEAN-Pacific

08 – 09 Welcome MessageMr. Ashish Bhat Senior Vice President Siemens Industry Industrial Automation Cluster ASEAN

10 – 11 Welcome MessageDr. Markus Lade Head Siemens Industrial Automation Process Automation ASEAN-Pacific

14 – 19 Up CloseEnd-Users

20 – 21 Up CloseSolution Partners

22 – 23 Up CloseSiemens and User Process Automation Advisory Board

34 – 35 Technological Trends and Challenges for the process industriesMr. Axel Lorenz Vice President & Global Head Siemens Process Automation Industries Germany

36 – 37 Impact of New Environmental Policies on Process Industries in ASEANMs. Olivia Chen CEO Asian Pacific Research Taiwan

38 – 39 SPACe User Community Siemens and User Advisory Board in ASEAN-PacificMr. David Ong Managing Director Excel Marco Pte. Ltd.

24 Advanced Process Library25 COMOS26 Field News and Process Safety27 PCS 7 / Open OS28 Process Historian & Information Server

Table of Contents Unilever IndonesiaReference Story

28 Technology Infoshops

28 Integrated Energy Management29 Process Safety Standards & Risk

Management30 Process Analytical Technology (SIPAT)31 Optimized Packaging Line32 Plant Wide Automation33 Waste Heat Recovery

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75 Siemens 40 Market Launch 74 Location Maps

62 Reference Stories

84 Microfair: Participating Solution Partners

40 –41 SIMATIC PCS 7: Innovations 2013

42 – 43 The “new” CPU 410: One Process Controller for everything

62 – 65 Ocean Glass ThailandOcean’s Life Pleasurei

66 – 73 Unilever IndonesiaRefreshing Automation

84 DNR Process Solutions Pte. Ltd.

85 Excel Marco Pte. Ltd.

86 Rovisys

87 Rieckermann Mahinery and Industrial Equipment

88 Control Engineering Asia

74 Centara Grand Hotel CentralWorld

75 SPACe Conference Map

Ocean Glass ThailandReference Story

88 Media Partner

Table of Contents

44 Case Studies/References44 –47 Victorian Desalination Plant: The Victorian

Desalination Plant

48 – 49 PT Krakatau Steel: Overall Control Hierarchical Structure of Hot Strip Mill Plant

50– 51 HOLCIM: HPHI Process Control System Upgrade Project

52 – 53 Baxter: SIMATIC PCS 7 - Integration with MES

54 – 55 A*STAR (ICES): Process Analytical Technology in the Pharmaceutical Industry

56 – 57 TPI POLENE: PCS 7 in the Cement Process

58 Case Studies/References

58 –59 CPC: Implementation of Advanced Process Control in RDS Pilot Plant

60 – 60 Vietso Petro: PCS 7 Application for VietsoPetro Offshore Platform Projects

61– 61 Evyap: Totally Integrated Automation for Oleochemical Plant and Facilities

76 Conference Schedule

76 Conference Schedule

75 - 83 Siemens - Global Solutions for Process Automation

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The SPACe User Community “The networking community &

its activities establishes a strong bond between Siemens and the users. It also encourages 3-way communication among the participants: from Siemens to users and users to fellow users.”

David Ong

Chairman, SPACe 2013-2015 Siemens - User Process Automation Advisory Board

Welcome to SPACe - Siemens Process Automation Conference (& Exhibition)

When I was asked by Siemens to become a member of SPACe User Advisory Board, without hesitation, I told that I would be more than happy to do so. This is the second time we are having this much waited event again. We are all here again at least for one common reason, that is to get the most out of Siemens technology and partnership. Coming to Bangkok, some of us may have second agendas - like enjoying good food and great company. (I don’t know what you have in mind but this is what I meant! )

Siemens may have jumped onto the band wagon of Process Automation

success. Machines whether mechanical, electronics or digital are created by human talent. So it is still human creativity and partnership that are the ultimate drivers in technology. People working with people creating solutions that solve real world problems. Creating solutions that we have never been thought possible. Creating solutions that we never thought we needed before.

In fact we are all moving so fast that jumping onto the band wagon is already out moded long ago.

slightly later than a few other major players. However, in terms of technological advancement and market penetration, I believe it has been making splashes if not waves to the peril of its competition.

This event is about learning newer technology that Siemens has brought about through its R&D investement and to gather customers feedback. Some are product improvement and enhancment, others are more radical changes that requires a paradigm shift. Beyond technology, this event is also about the Partnership of Supplier-Integrator-User triparte triangle of

Launching into Space that knows no limit is our constant desire to explore the next frontiers. Let our odyssey begin into SPACe. Let’s use this event as our launching pad to meet people. And also to let people meet with you. Let the odyssey begin!

Thank you all and have a pleasant stay in Bangkok!

Welcome fellow Users

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Welcome to Thailand

The Asian Market is one of the world’s largest consumer of Industry automation technologies, and the Asia Pacific regions is a key contributor to this demand. The increasing demand and the need to replace aging equipment were listed as the top two reason for rising budgets while delayed servicing activities to preserve cash reserves and excessive capacity were listed as the primary reasons for declining budgets. Buyers in the food and beverage and chemical sectors were confident about their growth prospects driven by higher demands.

Therefore this timely event provides us an excellent opportunity to share ideas to support our fast growing markets.

Once again a warm welcome to our SPACe User conference 2013 & enjoy your stay in the land of smiles.

“One of our most important responsibility is to provide for the technology needs of our users. We can only accomplish this by listening to our users who are here now & by “listening” to those who are likely to be (Siemens) users in the future.”

Ashish Bhat

Sr. Vice President Siemens Industry Industrial Automation ASEAN

Siemens Industry Industrial Automation

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“Our goal is to strengthen our (Siemens) relationship with our users by establishing a single user community within Southeast Asia, Korea, Taiwan & Australia & use the 3 Learning Platforms of Engagement as the key to a three-way communication. “

Dr. Markus Lade

Head Siemens Industrial Automation Process Automations ASEAN-Pacific

The SPACe User Community

Welcome to SPACe

We are pleased to welcome you to the 2nd SPACe User Conference in Bangkok Thailand.

Siemens is very proud of its independent user group communities around the world, most of all, OUR SPACe ASEAN-Pacific Community.

Globally, Siemens has established user groups in UK, USA, China, India and of course SouthEast Asia and the Pacific Cluster.

Every good conversation starts with good listening.

Our user groups and Siemens understand the value of listening. This is the reason why we established the three (3) learning platforms of engagements.

Since the last user conference, we are pleased to inform you of the latest achievements to improve our user community.

Technology Topics, Case Studies and User References

In this years’ SPACe User Conference, we are pleased to offer you 17 case studies & project examples presented by our fellow user members.

We also organized 6 technology infoshops that is scheduled in two sessions to give you the opportunity to maximize your learning experience during the conference.

Siemens make sure that the members of the groups meet to network, share best practices, and learn about Siemens latest technologies and services, develop network among fellow users and learn from each others experiences.

In addition, we also invited market analyst - Asian Pacific Research to present their insights on “The Impact of New Environmental Policies on Process Industries in ASEAN”. This topic is one of the major drivers and rather one of the most important shaping the process industries in Asia.

From Siemens Headquarters, we will present the technological trends in the process industries which include PCS 7 version 8, COMOS Integrated Engineering, Totally Integrated Automation and Power concepts, and

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the new Siemens CPU 410 controller for the process industries.

Siemens and User Process Automation Advisory Board

We are excited to announce the formation of the new Siemens and User Process Automation Advisory Board in Cluster ASEAN-Pacific. The UAB is composed of 21 users and 6 Siemens from all over the Cluster. The members and their short profile are presented in the next succeeding pages of this book.

Networking Nights

Siemens Industry Thailand organized two (2) networking activities for the community. On Day 1, we will be dining on a stylish luxurious Chao Phraya cruise. This cruise will give you a view of the historical landmarks on a river cruise along the Chao Phraya River and experience the beautiful night sceneries with a relaxing atmosphere on our dinner cruise in the middle of Bangkok.

On Day 2, Siemens also organized a Farewell Dinner & Drink at the Hard Rock Cafe Bangkok—where good times are only as far away as your next electric sliding step.

We invite you to continue with your communities as we reach out to learn more about the way your work together, your expectations and aspirations for your groups. We look forward to providing lots of information about Siemens, too.

We are ready to engage with you, answer any questions you have and

meet with your representatives. Our team of Siemens experts in every region of the world will ensure that all your concerns are received and addressed!

Above all, we want our users to understand the value of networking, sharing best practices and learning about our products and services. So please continue to communicate with each other and with our global team of experienced Siemens experts.

This is an exciting time for all of us. We are thrilled to work with you and hope that you will continue to participate as an active member of our community.

Listen Up.

We want to hear from you. We look forward to learning more about you and engaging with you!

Please send mail to our e-mail: admarketing.sg@siemens.com with your questions and/or concerns.

If your community wants to host a teleconference or meet with a member of our User Advisory Board, please contact us or send mail to our user group mail. Our board members will monitor provides a response as quickly as possible!

Again, welcome to SPACe! Siemens look forward to seeing or hearing from you soon!

Enjoy the conference and have a pleasant learning experience.

“Our aim is to get closer to our customers. Only by understanding their industry requirements will help us built sustainable business and this is possible by establishing a user community. This years’ formation of the PA User Advisory Board & organization of a user event empowers our users to voice out their challenges - may it be with our (Siemens) products or market demands. This is our way of telling them that “We are here to listen and always ready to respond - & fast.” “

Mr. Axel Lorenz

Sr. Vice President Siemens I IA Process Automation Global

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Up Close with our User Advisory Board Members

User Advisory Board

Dr. Jeng-Fan Leu Ph.D. CPC TaiwanJeng-Fan Leu received his B.S. from the National Taiwan University in 1995, the M.S. from the Chung Cheng University, Taiwan in 1997 and the Ph.D. form the Cheng Kung University, Taiwan in 2002, all in Chemical Engineering. He has been employed by CPC Corporation, Taiwan, as a Chemical Engineer working for RDS Project at Refining & Manufacturing Research Institute since 2000. His research interests are in the area of RDS catalyst evaluation, heavy organics deposition and process control.

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Feng-Chang Wu CPC TaiwanFeng-Chang Wu received his B.S. in Electrical Engineering from the Ta Yeh University, Taiwan in 2002. He has been employed by CPC Corpo-ration, Taiwan, as a Technician at Refining & Manufacturing Research Institute since 2005. His major tasks are for RDS Project, including analysis of physical properties of RDS catalyst, distillation of heavy oil and system integration for pilot plant.

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Ronald Ruiz Jr. AMHERST Unilab PhilippinesRonald J Ruiz Jr. is a graduate of Master of Science in electronics engineering major in control systems from MIT (Mapua Institute of Technology) and with a Bachelor’s Degree in Mechatronics Engineering from Bulacan State University. He is currently the controls and instrumentation engineer of Unilab –Philippines largest and no. 1 pharmaceutical company providing engineering support to company’s manufacturing network for new and existing facilities/plants. Prior to joining Unilab, he worked with Siemens Philippines (2009-2011) and Emerson Philippines (2008-2009) as a control systems/ automation engineering professional.

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David Ong Excel Marco Pte. Ltd. SingaporeDavid Ong has over 20 years of professional experience and is widely recognized as an active professional in process automation safety industries. He is a CFSE (Certified Functional Safety Expert) and also a member of the advisory board of CFSE Governance Board. During the course of his career, he has executed many major projects in the Oil & Gas industry both onshore and offshore on Process Automation Safety & Control. Having involved with many major Oil companies such as ExxonMobil, Shell, Sinopec, PetroChina, Total, Unocal and so on, he is well versed with the corporate standards and practices of these companies. He has also helped to develop key product marketing specifications for safety PLC and SIS (Safety Instrumented Systems) in general. Over the years, he has maintained focused on Safety PLC related application and was involved in conducting training on Functional Safety Standards and Practices. His current principal work responsibilities include management, business development and marketing of a highly dynamic company and is the fast growth oil & gas industry.

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ChairmanSiemens - User

PA Advisory Board

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Up Close with our User Advisory Board Members

Rainer Schimpf BBraun MalaysiaRainer Schimpf is living for many years in Asia and has more than 20 years of experience in IT. His professional career brought him from a technical Engineer via software development towards SAP. After man-aging several years successful SAP roll-out projects with multi-na-tional teams in various countries in the Asia Pacific Region he is now the Head of Regional IT for Asia Pacific for BBraun Medical Industries, a privately owned German company dealing in manufacturing of Medical products with about 4.5 billion EUR annual revenue in 2010. At present Rainer is striving to transform the B.Braun production site in Penang into a world class highly automated factory. He has a pat-ent pending with the US Patent Office on “System and methods to prevent products from counterfeiting and surplus production also of tracking their way of distribution”.

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Wilhelm FK Schellenberger Soft Rock Technologies Sdn Bhd, MalaysiaWilhelm Schellenberger, a German professional Engineer for Automa-tion and Electronics, has more than 25 years of experience in leading positions in German and international companies as well as many years experience with automation projects in Europe, Africa, Asia and USA. The design, development and integration of machine and plant controls put him in a position to understand the interaction of mechanic, automation and IT as a holistic system. In his carreer as lead engineer and manager he founded several companies in Europe, USA and Asia and worked most of his time as independent entrepre-neur. He is also supporting B. Braun Medical Ind. Sdn Bhd in Penang, Malaysia as Automation and Technical IT Consultant. In 1996 Wil-helm Schellenberger was granted an US Patent and several national patents regarding Automated Cleaning and Drying of Silicon Wafers with HF and Ozone.

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Heinrich Bertl Andritz Automation, ChinaSpecialization:

Project Management (technical design responsible) �

Lead designer for PLC/SCADA/ETHERNET �

Working experience at Andritz AG: �

Water treatment plants (electric + process) �

Waste water plants (electric + process) �

Paper industries (electric) �

Cold rolling mills (electric) �

Sludge drying/ dewatering plants (electric) �

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Tok Lay Mui (Ms) Baxter BioScience Manufacturing SARL, Singapore Ms. Lay Mui is currently leading the IT and Automation function in Baxter BioScience Singapore. She had more than 15 years of experi-ence in leading the IT organization & operations. With her tracked record, she had expanded her portfolio to oversee the Process Auto-mation function for the organization. This is one of the key functions in BioScience Manufacturing Operation whereby the processes are automated & controlled through computerization. Lay Mui graduated from National University of Singapore with a Bachelor Degree in Infor-mation System.

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Up Close with our User Advisory Board Members

Ari Azhar PT. Krakatau Daya Listrik (Krakatau Steel Group) IndonesiaCurrently, Mr. Ari Azhar is the Electrical & Instrumentation Mainte-nance Superintendent of PT Krakatau Daya Listrik (Krakatau Steel Group) and aggressively involved in providing best maintenance & energy conservation practices. Ari Azhar has his bachelor degree in Electrical Engineering from Institut Teknologi Bandung (ITB) and has extensive experiences in many project activities especially related to Automation & Electrical System including Energy Conservation Pro-motion. In addition, he has experience in various local and foreign trainings and seminars as a trainee or as an active speaker.

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Arturo Lahip Air Products & Chemicals, Inc Singapore

Field/Design E&I Engineer with Bechtel Aust Pty Ltd, Petroleum �Development Projects – New Guinea , Stone & Webster, Water Injection & Power Projects – UAE , Kentz Corp, Modernization of Das Island Onshore/Offshore Control System - UAE , Kurihara Corp projects - Japan/Singapore.

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Bob Gill Control Engineering Asia SingaporeBob Gill is currently Editor-in-Chief at Contineo Media in Singapore, where he has group responsibility for the Control Engineering Asia, Asia Food Journal, and PharmaAsia, Logistics Insight Asia and Payload Asia, business-to-business trade titles, as well as being Editor of Control Engineering Asia.A qualified engineer with many years of industrial experience in automation, manufacturing and logistics, his past appointments include Editor of Asia Pacific technology magazines Industrial Automation Asia and Asia Pacific Metalworking Equipment News; Research Fellow, Automation Technology Division, SIMTech; Senior Manufacturing Engineer, GEC; and Flight Test Instrumentation Engineer, British Aerospace. In the UK, as a Senior Manufacturing Engineer at GEC, he was involved in implementing (1993) the country’s first factory fieldbus (WorldFIP) network, and from 1997 to 2002, he was a member of the SIMTech project team that developed the multi-million dollar warehouse logistics control system for Singapore Airlines’ first fully automated cargo terminal (T6). The project went on to receive the Institute of Engineers Singapore (IES) Prestigious Engineering Award in 2003. He holds a BSc (Hons) in Electronics and an MSc in Manufacturing Systems Engineering, from Cardiff University, UK, and an MBA from NTU, Singapore. He is a contributing author to the books Action Learning Cases In Organisational Behaviour (2004) and Many Ships, One Boat: Expat Tales and Tips (2011). He also previously lectured on the MSc Logistics course at the University of Central England, UK.

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More end-user membersAyi Hardiansyah, PT Clariant Chemicals Indonesia �

Elman Rudolf Pakpakan, Indocement Indonesia �

Mark Gerkema, PURAC Thailand �

Daniel Hong, Evonik Singapore �

Cinderella Basilio, Evonik Singapore �

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Up Close with our User Advisory Board Members

Low Ai Ming, VP Sales, Excel Marco Pte. Ltd.

VP of Sales for Excel Marco Pte Ltd. More than 18 years of experience providing automation control system, safety systems, critical control system and fire and gas system solution to various industries such as Petrochemical , Oil and Gas and Chemical industries.

Dinesh Sharma, Founder & CEO, DNR Process Solutions

The founder and CEO of DNR Process Solutions is Dinesh Sharma who has been in Industrial Automation business for more than 35 years. He graduated in Electrical Engineering with Hons, degree from well established University in India. He founded “DNR Process Solutions Pte Ltd” in the year 2002 and established successful operation with the vision to provide solutions connecting process manufacturing plants and business in real time using leading edge automation and Information technologies. To fill up the gap between plant automation and enterprise, DNR has developed several industry specific and asset management soft ware solutions. With several iconic projects executed successfully against stiff competition from International companies, DNR is on way to become true global enterprise to help customers to manage their plant assets with efficacy. Prior to establishing DNR During initial stage of his career, Dinesh Sharma was responsible for successful execution of Instrumentation and control system of several Power plant units in India, Malaysia and Indonesia.Dinesh Sharma has been president of Profibus association of SE Asia and he is Senior member of ISA. He is also the member of Rotary club of Singapore and has been the director on board of the club. Dinesh Sharma has received DBS-SICCI award as Entrepreneur of the year in year 2009 and one of the emerging Enterprise in 2011.

Bill Hurder, Managing Director of RoviSys Asia Company

Education: Bachelors of Science in Chemical Engineering, Minor of Mathematics – Ohio University Experience: Over 7 years experience in APAC region Implemented projects in LCD Manufacturing, Solar Manufacturing, BMS, Power Monitoring and Batch Chemical in Controls, SCADA and Data Historian

Brian Trapp, Rovisys Asia

Education: Bachelors of Science in Electrical Engineering Technology, Minor of Management Information Systems from Penn State Erie – The Behrend College (Erie, Pennsylvania, USA)

10 years of experience::Foundry Automation �Pharma Automation �Chemical Automation �Power and Energy Automation �Waste Water Automation �Interface, OPC, and Integration Expertise �Process Optimization and Advanced �Process Control. �

Tran Thanh Nguyên, NamTech JSC Vietnam

Managing Director , Nam Anh Technical Services and �Trading JSC (NamTech JSC)

Innovative Technology Development Corp (ITD Corp), �Business Development Director

Tan Tien Automation Technology Corp. (Tan Tien �Corp.), Managing Director

Tan Tien Automation Technology Ltd. (Tan Tien Ltd.), �Sales & Services Manager

Dong Nam Associates Ltd, HCMC Rep. Office �

More Solution Partner Members: Precision Controls Sdn. Bhd.

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Siemens-PA User Advisory Board ASEAN-Pacific 2013

Ronaldo Ruiz Amherst Unilab (Pharma)

Wilhelm Schellenberger Soft Rock Technologies (Pharma)

Heinrich Bertl Andritz (Water, Utilities)

Dr. Jeng Fan Leu CPC (Petrochem R&D)

Dr. Feng Chang Wu CPC (Petrochem R&D)

David Ong Chairman Excel Marco Americas, Asia & Middle East (FPSO,Oil&Gas)

Axel Lorenz Vice President Process Automation Global

Dr. Stefan Bamberger Head of Product Management Process Automation Global

Mr. Ashish Bhat Head of Industry Industrial Automation Systems ASEAN-Pacific

Dr. Markus Lade Head of Industry Industrial Automation Vertical Markets Process Automation ASEAN-Pacific

Abram Ziegeelar Head of Industry Automation Engineering ASEAN

Marie Caraan Market Management Siemens I IA VSS PA ASEAN-Pacific

Solution Partners

Name Company Industry

Dinesh Sharma DNR Process Solutions All

Bill Hurder Rovisys Pharma

Brian Trapp Rovisys Pharma

Mr. Tran Thanh Nguyen

NamTech Cement

Quek Kheh Long Precision Controls All

(Ms) Tok Lay Mui Baxter (Pharma)

Arturo Lahip Air Products (Chemicals)

Mark Gerkema Purac (Chemicals)

Elman Rudolf Pakpakan Indocement (Cement)

Bob Gill Control Engineering Asia (Industry Automation, Media)

Ari Azhar PT. Krakatau Daya Listrik (Krakatau Steel Group) (Steel)

Rainier Schmipf BBRaun (Pharma)

Ayi Hardiansyah PT Clariant (Chemicals)

Low Ai Ming Excel Marco (FPSO& Oil&Gas)

Cinderella Basilo Evonik (Chemicals)

Daniel Hong Evonik (Chemicals)

Siemens - User PA Advisory Board Members

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Thomas Haerteis

Business Development Consultant, Plant Lie Cycle Solutions ASEAN, AUS AS CIS Siemens Singapore

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Technology Infoshop

Advanced Process Library Industry Library

Abstract:

Since PCS 7 V7.1, the Advanced Process Library (APL) is the standard library. In addition, the Industry Library (IL) is completing the functional range.

Highlights:

News of APL V8.0 SP1

Presentation of new function blocks PidConS, OpAnSm

Priority Based Alarming„

Basics of the IL: Easy integration of package units and panels

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Technology Infoshop

COMOS

Abstract:

Increasing global competition as well as enormous cost and time pressures, demand solutions that help companies to enhance performance across the entire life cycle of a plant. With COMOS and SIMATIC PCS 7, Siemens ensures integrated engineering with central data management for plant engineers as well as operators.

Highlights:

Integrated Engineering: System Overview, Architecture and Scope for efficient consistent engineering

COMOS Automation Interface: Integration of Comos with PCS 7

Lee Wing Cheong

Technical ConsultantSiemens Singapore

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Lee Wing Cheong

Technical ConsultantSiemens Singapore

Xu Feng

Technical Consultant ASEANSiemens Singapore

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Technology Infoshop

Field News & Process Safety

Abstract:

Become familiar with our new PDM! Realize how intuitive all types of field bus systems can be configured with only one tool, PDM. You will get information about new developments in our field bus systems. Additionally we will inform you about new hardware products.

Highlights:

PROFINET: Integration in PCS 7

FF: expandable online

News: Maintenance Station

New hardware modules

Extension for the S7 mEC

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Technology Infoshop

PCS7 / Open OS

Abstract:

Experience PCS 7 OS as universal window for your process and learn more about the extension possibilities with PCS 7/OPEN OS.

Highlights:

Introduction of PCS 7/OPEN OS

Integration of 3rd party DCS and package units

PCS 7/OPEN OS tools

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Jessica Liao

Technical Consultant ASEANSiemens Singapore

Adnan Abdul Rahman

Business Development Manager ASEANSiemens Singapore

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Technology Infoshop

Process Historian & Infomation Server

Abstract:

The Process Historian is a long-term archiving system for OS tags and alarms. The Information Server is a flexible reporting system for historical data located on the Process Historian and OS stations. With this workshop you will get an overview of new functions released with PCS 7 V8.0 SP1.

Highlights:

Migration of CAS Data into the Process Historian

Redundant Process Historian

Time based Backups

Improved Excel Add-ins

OS archive data in combination with the Information Server

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Break-out Session

Integrated Energy Management

Abstract:

With the volatile cost of fuel today, effective energy management will takes high priority. Siemens provides answers to this challenge by offering the Integrated Energy Management portfolio. We provide sustainable and innovative yet competitive system to maximize the users return.

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Kenny Lim

Business Development Manager ASEANSiemens Singapore

Stanley Joseph

Business Development Manager ASEANSiemens Singapore

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Break-out Session

Process Safety Standards & Risk Management

Abstract:

For all types of business, the risk for potential operation accountability exists. The Process Safety Standards provides guidance for realistic assessment and gainful reduction of these risks - critical to protecting the safety of personnel (employees and the public), asset, business continuation (including exposure to legal and regulatory compliance) and reducing environmental damage. Risk tolerance and risk acceptance principles will be discussed with particular reference to Process Safety Standards and Safety Life Cycle concepts.

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Break-out Session

Process Analytical Technolgy (SIPAT)

Abstract:

PAT (Process Analytical Technology) is a system used in the pharmaceutical industry to design, analyze and controlling manufacturing processes and parameters based on timely measurements of Critical Quality Attributes (CQA), with the goal of achieving real-time-release (RTR). Doing so, final product quality can be achieved towards continuous manufacturing (CM) and improved plant equipment optimization, this will in turn, increase plant throughput and reduced production costs.

Highlights

FDA guidelines

Siemens solution : SIPAT and the 4 key advantages toward total quality management

Project Reference: A*STAR

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9 Rajesh Vasant Samarth

Application Engineering Manager & OPL Promoter ASEAN Siemens Thailand

Break-out Sessions

Optimized Packaging Line

Abstract:

Optimized Packaging Line (OPL) is a comprehensive standardization concept for the automation of packaging machines and –lines, which helps to save costs and efforts by using international standards

Highlights

The objectives of OPL

How do I optimize my filling-/ packaging line?

OPL - Standard line architecture

Modular approach of OPL

10 Choo Woon Fu

Director, Glass ASEANSiemens Singapore

Break-out Sessions

Plant Wide Automation/Waste Heat Recovery

Plant- wide Automation (PWA)

The advantage of PCS7 is that we can seamlessly combine process automation with factory automation as glass production is a hybrid process. The hot-end and utilities is more process control oriented (DCS), the batch house and cold-end are more FA oriented ( PLC). As PCS7 is a DCS-system based on PLC which is a ideal architecture to form a COMMON platform, it provides an optimum solution for the Glass Industry.

Waste Heat Recovery

The glass production process creates tremendous amounts of waste heat which is too valuable to simply released through a stack. It is possible to convert the waste heat into electricity by means of a boiler and a turbine-generator

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11 Axel Lorenz

Vice President & Global Head of Siemens Process Automation Industries , Germany

Key Note

Technological Trends and Challenges for the process industries

Abstract:

Siemens is the key driver for the technological trends in the process industries. These trends include products and solutions for the entire plant lifecycle from engineering, operation to maintenance. Discover how the process industry can benefit from Siemens innovations and gain competitive edge through higher plant productivity and lower total cost of ownership.

Applying the well-established concepts Totally Integrated Automation and Totally Integrated Power optimizes production processes and realize significant synergy potential. Siemens’ industry know-how is the basis for tailored, powerful and safe products, systems and solutions that ranges from laboratories up to large plants, from the

field level up to the control level, from the medium-voltage power grid supply up to the socket user outlet.

Our process control system SIMATIC PCS 7 with integral Plant Asset Management, Safety Matrix or Advanced Process Control fits exactly to continuous processes. It guarantees safe process control, simple modifications even with uninterrupted production, and thus for a maximum plant availability and process yield. Benefits throughout the entire life-cycle of your petrochemical plant – from the planning phase through operation, maintenance and modernization up to the next expansion.

In the future the concept of Digital Enterprise Platform will integrate all level across the entire plant life-cycle enabling seamless cooperation between all disciplines involved. Already today, the standard COMOS data platform provides plant design engineers, plant operating personnel, company management, and solution partners with a continuous flow of data that meet their specific needs across all project phases. This enables a globally integrated, comprehensive software solution concept. Consistent life cycle engineering with Siemens COMOS software enables you to assimilate planning and operating environments which results in more efficient workflows as well as higher productivity and quality.

This presentation will provide an insight into the challenges faced by the process industries and will use customer reference stories as application examples to demonstrate the benefits achieved to integrate the organization - no matter what your plant produces. Operational effectiveness, workforce excellence, globalization as well as energy and resource efficiency are the key to economic success in the continuous production processes.

Speakers Profile:

Mr. Axel Lorenz is currently the Vice President for Process Automation of Siemens’ Business

Unit “Industrial Automation Systems”, responsible for a business volume of 1 billion USD

and 1000 employees world-wide. In addition, he is also leading the Vertical Sub Segments

(VSS) for branch specific development of the Process Industries including Petrochemical.

Mr. Axel Lorenz has been with Siemens for more than 20 years, starting from engineering

and commissioning for Process Automation projects.

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12 Olivia Chen

CEOAsian Pacific ResearchTaiwan

Key Note

Impact of New Environmental Policies on Process Industries in ASEAN

Abstract:

The pursuit of ‘low carbon green growth’ policies in ASEAN countries is creating new business opportunities for technology-rich engineering service companies to

Develop the capacity of existing and emerging process industries to reduce the environmental impact of their

operations

Assist the growth of the environmental goods and service sector

Build up new skills in the work force

Part of the business challenge is how to develop cost-effective marketing strategies that can enable engineering service companies to match their technologies to these new opportunities in what is often a slow-moving, government-led process.

Speakers Profile:

Olivia Chen is the Chief Executive Officer of Asian Pacific Research Ltd.. She has led the

company’s expansion in industrial market research throughout the Asia Pacific region.

She has worked extensively on industrial marketing issues with Asian and western

government policy makers and with major international companies in a wide range of

process industries, including chemicals, display, environmental protection and

biotechnology. Prior to joining APR, Olivia worked with L’Oreal. Olivia obtained her

Master’s degree in Engineering Business Management from Warwick University, U.K.

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13 David Ong

Managing Director Excel Marco Pte. Ltd. Singapore

Key Note

Siemens & User Advisory Board ASEAN-Pacific

Abstract:

As social media has revolutionized how people are connected and ideas are exchanged in the digital age, does conference and face to face meeting still have relevancy?

It is ever more so important to stay engaged through direct interaction in person. Not telepresence, not media presence, not cyber presence but be present, in person, all mind and soul. Social media only complements, it does not replace nor displace.

Process Automation needs to incessantly keep up with newer technology and create paradigm shifts to reinvent itself. One of the best ways to achieve this, is through the meeting of

minds. Many like minded and some not so like minded thinkers, all in one timeline, in one Space such as:

To share old field proven ideas that worked faithfully

To introduce new technologies that beckon creative applications.

To identify technology and competency gaps with candid open minds.

To foster stronger relationship and celebrate achievements.

Space is borderless and so is “SPACe”. Only our own imagination can limit SPACe. So let’s imagine what we could achieve if we all launch our limitless imagination into the SPACe User Community.

Speakers Profile:

David Ong is currently the Managing Director of Excel Marco Pte. Ltd. He has over 20 years

of professional experience and is widely recognized as an active professional in process

automation safety industries. He is a CFSE (Certified Functional Safety Expert) and also a

member of the advisory board of CFSE Governance Board. During the course of his career,

he has executed many major projects in the Oil & Gas industry both onshore and offshore

on Process Automation Safety & Control. Having involved with many major Oil companies

such as ExxonMobil, Shell, Sinopec, PetroChina, Total, Unocal and so on, he is well versed

with the corporate standards and practices of these companies. He has also helped to

develop key product marketing specifications for safety PLC and SIS (Safety Instrumented

Systems) in general.

He has also been selected to lead the SPACe Siemens & PA User Advisory Board this year.

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14 Dr. Stefan Bamberger

Head of ProductManagementProcess AutomationGlobal

Market Launch

SIMATIC PCS 7: Innovations 2013

Abstract:

The Siemens Industry Automation Division has equipped the Simatic PCS 7 V8.0 of its process control system with a host of new functions. The new features range from improved data exchange, an easier engineering workflow and redundancy-related and fault-tolerant functions to new controllers and extended functionalities for the software tools.

Simatic PCS 7 V8: main new features

Integrated engineering: Better data exchange between the Comos plant management software and the PCS 7

engineering tools and an easier engineering workflow,

resulting in higher engineering quality and easier documentation of changes

Windows 7 support: Ability to use the latest PC technologies in process automation

Process Historian and Information Server: Better access to plant data for asset and performance management

Extensions in communication, availability, and scalability: More possibilities with Profibus and

Profinet communication; high-performance Simatic S7-400H controller with greater I/O quantity framework; setup of highly available, redundant ring structures; and system-redundant connection of I/O devices

Efficient software tools: More efficient integration and management of process devices and more efficient

application engineering through the use of libraries

Integration of automation and switchgear: Integration of medium-voltage switchgear into PCS 7 via Simatic

PCS 7 PowerControl

Speakers Profile:

Dr. Bamberger joined the reasearch and development department of Siemens Automation

Systems in Germany in 1998. In the following years he held different technical and

management positions within the development of the Process Control System SIMATIC PCS

7. In 2004 he took over the technical integration position of the MES department at Genoa,

Italy. There, he was responsible for standardizing concepts for integrated Process Control

and MES products and solutions. Since 2006, Dr. Bamberger is head of Product

Management Process Automation in Karlsruhe, Germany. He is responsible for the global

product portfolio strategy for Process Automation. Dr. Stefan Bamberger has a certificate

in Computer Science from the Technical University Karlsruhe and made his doctoral thesis

in Artificial Intelligence at the University of Würzburg.

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15 Jorey Guzman

Head of Siemens Process Automation Systems Support ASEAN

Market Launch

The “new” CPU 410: One process controller for everything

Abstract:

Siemens Industry Automation Division is adding an especially powerful, versatile, and rugged CPU for the process industry to its Simatic controller family. Simatic PCS 7 CPU410-5H is currently the fastest and most powerful controller on the market and covers all applications, application scopes, and performance range with a single

hardware and firmware platform. The CPU is supplied with the maximum configuration. According to the new dimensioning model, the user defines the performance required of the system using the expansion card to match the quantity framework along with the size and type of application.

Simatic PCS 7 CPU 410-5H gives users of the Simatic PCS 7 process control system a high-performance controller with a computing capacity suitable for the high demands of the process industry. The controller is designed for around-the-clock industrial use and also withstands tough temperature, vibration, shock, and EMC requirements. The additional coating of the PCBs and electronic components complying with ISA-S71.04 Severity Level G3 enhances reliability in the presence of condensation and possible sources of corrosion.

The CPU is supplied as a standard high-end version in terms of memory, CPU power, and communication interfaces. It also has a failsafe design by default and is equipped with all functions for safety-related applications. Users define the required application-specific performance themselves with the system expansion card (SE card). With the SE card, the performance can be adapted at any time without replacing the CPU, for example if it becomes necessary to load more process objects. This also simplifies spare part management and reduces the associated costs.

Highlights:

Powerful, versatile, and rugged CPU for the process industry

The fastest and most powerful controller on the market

Covers all applications, application scopes, and performance ranges

The desired quantity framework can be selected via a new license model

Speakers Profile:

Jose Rey Guzman has 13 years with Siemens handling systems support for both process

automation and factory automation

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16 Carlos Rodriguez

Degremont and Thiess Services Joint Venture, Australia

Case Studies/ Project References

The Victorian Desalination Plant

Abstract:

The $3.5 billion Victorian Desalination Project is one of the biggest infrastructure projects in Victoria’s history. It will deliver Australia’s largest desalination plant, securing a source of water for Melbourne and regional communities, independent of rainfall. Located in Wonthaggi, the project’s main components are:

Desalination plant – with an initial production capacity of up to 150 billion litres of water a year (411 million litres per day) and the capability to expand to 200 billion litres a year (548 million litres per day)

Seawater intake/outlet – underground seawater intake/outlet structures

17 Hung Chan

MESCADA Australia

Transfer pipeline – 84 km of underground pipeline to connect the plant to Melbourne’s existing water network

Power supply – 87 km of underground cable to connect the plant with the electricity grid

Fibre optic cable – underground cables to monitor performance of the pipeline and power line and provide capacity to improve communications services to local communities.

The initial production capacity means the desalination plant will be capable of supplying about a third of Melbourne’s annual water needs.

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Technology highlights:

The Victorian Desalination Plant uses reverse osmosis (membrane based) desalination technology to turn seawater into freshwater.

There are several steps to this process. Firstly, seawater is drawn in from an underground and undersea tunnel. Fine particles are then removed during an initial screening before the water passes through the reverse osmosis membrane. Once converted, the water from the desalination plant is treated to Australian drinking water standards and blended with current drinking water supplies.

The following text and accompanying diagram explains the process in more detail:

Seawater enters the desalination plant through a 1. specially designed intake system, including a tunnel approximately 1.2km long. Water enters at a low speed to avoid impacts on the marine environment. Even small fish

will be able to swim against the intake current and a protective grill will ensure larger marine life can’t swim into the structure.

Seawater passes through an initial screening to remove 2. fine particles including sand and sediment. Seawater is then filtered to remove finer particles.

The filtered seawater passes through two stages of 3. reverse osmosis, where it is pushed through more than 55,000 ultra-fine membranes under high pressure. Fresh water will pass through, leaving sea water concentrate behind.

Desalinated water is treated to meet Australian drinking 4. water standards and Victorian health requirements.

Drinking water may be stored in tanks before it is 5. distributed into the Melbourne and regional water networks where it may be blended with water from existing catchments.

Seawater concentrate will be safely returned to Bass Strait 6. though an underground and undersea tunnel approximately 1.5km long and discharge structures. The salt content and temperature will return to normal seawater salinity and temperature a short distance from the discharge nozzles, which act as diffusers. Ocean currents dilute the concentrate within seconds.

Speakers Profile:

Carlos Rodriguez is the ICT Manager for the DTSJV, which operates and maintains the

Victorian Desalination Project. He has more than 20 years of experience in Control Systems

and IT projects across Spain, South-America and Australia. Education background in

Science, IT and Business Management. During the last 12 years he has had project

management roles in major infrastructure projects (Electronic Tolling and Control Systems)

in Public-Private partnership initiatives.

HUNG is the co-founder of Mescada, a company that provides IT, MES, Engineer Life Cycle

and Control Systems project solutions. With education background in Computer and

Network Systems Engineering, Hung spent his earlier professional career in Services and

Solutions departments within Siemens Australia Industry division. During this time, he was

responsible for module services, technical support, field service, SAP roll out, Sarbane

Oxley as an auditor, project life cycle deliveries, ISA-S88, ISA-S95 and ISA-S99

implementations. 46 47

18 Samekta Hadi

PT. Krakatau Steel (Persero), Tbk, Indonesia

Case Studies/ Project References

PT Krakatau Steel : Overall Control Hierarchical Structure of Hot Strip Mill Plant

Abstract:

PT. Krakatau Steel’s Hot Strip Mill produces a 2.4 million tons per year of steel strip and coil with thickness 1.6-25 mm and width 800-2000 mm from 1600 mm width and 200 mm thickness steel slab really needs sophisticated and reliable automation technology.

The automation function includes thickness control, width control, profile control, temperature control, mechanical & microstructure control, tracking control and packaging control to ensure the final product meet the quality requirements.

For productivity, a reliable, free maintenance, user friendly, easy troubleshoot automation hardware had to be selected.

This presentation will review the understanding and experience working with hardware and software from PT. Krakatau Steel’s Hot Strip Mill’s basic and process automation system.

Technology Highlights:

PT. Krakatau Steel’s Hot Strip Mill review

Hierarchical Automation System at PT. Krakatau Steel Hot Strip Mill

Basic Automation System : hardware and software

Process Automation System : hardware and software

Speakers Profile:

Currently, Mr. Samekta Hadi holds the Computer Process Engineer position at Hot Strip Mill

of PT Krakatau Steel and aggressively involved in providing best maintenance &

automation practices. Samekta Hadi has his bachelor degree in Electrical Engineering from

Institut Teknologi Bandung (ITB) and has experiences in project activities especially related

to Automation System. In addition, he has experienced in local and foreign trainings and

seminars as a trainee or as an active speaker.

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19 Michael June Gumba

Holcim Cement, Philippines

Case Studies/ Project References

HPHI Process Control System Upgrade Project

Abstract:

Holcim Philippines Inc Plants is confronted with obsolescence of its automation systems, which have long been due for replacement. However, based on the Pareto diagram, equipment failures associated to automation system is the least to be seen, reason which could have probably deferred the plans for its replacement.

Alternatively, Holcim Head Office (Switzerland) has been campaigning for PCS standardization for all its group companies worldwide and Holcim Philippines was among the companies that were identified as due for PCS upgrading. As a result of the campaign, intensive assessments were done & roadmaps were presented which resulted to the approval to upgrade all the main automation systems. The major reason

for the upgrade is simply to ensure PCS reliability, maintainability and functionality in a long term view. As well as data availability for our Technical Information system. The PCS upgrade will also prepare us for high level control installations in the future which will optimize our mill operations.

Speakers Profile:

Chico joined Holcim Philippines in 2008 as an Automation/Instrumentation Project

Engineer in a rehabilitation project. He also held a wide variety of EIA assessment projects

for all Holcim Philippines assets.

Since 2010 he was assigned as one of the corporate automation engineers to perform the

PCS upgrade projects for all four plants. He has been part of the team who did the

conceptualization, design, construction and commissioning activities.

His strong commitment to due dates, high quality of work and pro-activity, positive and

polite attitude even under heavy work pressure, made out of him a key PCS project team

player and a reliable engineer with solid developmental potential. His exemplary

behaviour and performance was duly recognized by two Special Citation Awards given by

the SVP manufacturing.

Currently, Chico is leading and managing the PCS upgrade project of one of its plants.

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20 Zoon Keong Low

Baxter BioScience Manufacturing SARL Singapore

Case Studies/ Project References

SIMATIC PCS 7 - Integration with MES

Abstract:

This presentation will give a detail overview of how PCS7 is able to work seamlessly with XFP via SIT

An overview of ISA 95 and the integration between Process Control System and Manufacturing Execution

System.

SIT PM, interface between XFP and PCS7

The various methods on how information can be exchange at various level of PCS7.

A typical scenario of how data are exchanged

Speakers Profile:

Low Zoon Keong, is the team lead for Process Automation within the Information System &

Automation function at Baxter Bioscience Singapore. Zoon Keong is to assure the local

organization is able to manage systems under the group. E.g. Manufacturing Execution

System, Process Control System, Historian and Package Units. Zoon Keong is also

accountable for the success of any team related projects. Prior to joining Baxter, Zoon

Keong was with Rockwell Automation South East Asia, a leading company dedicated to

industrial automation. As a project engineer, Zoon Keong, assumed the role of project

manager, software lead or programmer for various projects. Zoon Keong has a Bachelor

Degree in Engineering (Electrical and Electronics Engineering)

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21 Dr. Chew Wee

Institute of Chemical & Engineering Sciences (ICES), A*STAR Singapore

Case Studies/ Project References

Process Analytical Technology in the Pharmaceutical industry

Abstract:

Since the turn of the 21st century the pharmaceutical industry is making bold revamps through various initiatives from the regulators (FDA, EMA) and professional societies (ICH, ASTM, ISPE). The ideology of Quality by Design (QbD) and its associated Process Analytical Technology (PAT) framework were strongly promoted alongside this paradigm shift. One important aspect in this QbD/ PAT endeavour is the management, analyses and modeling of information-rich multivariate data within stipulated regulatory requirements, such as FDA’s 21 CFR Part 11 Electronics Record. The Siemens SIPAT software proved to be efficacious in developing relevant informatics capabilities for QbD/ PAT applications. Such an implementation was delivered as an Integrated Platform technology at the Institute of Chemical and

Engineering Sciences (ICES) in Singapore. This integrated platform facilitates data handling of spectroscopic and scalar from process measurements, process control interfaces via legacy DCS, process simulation/ modeling, optimization and economic evaluations of QbD/PAT processes.

Speakers Profile:

Dr Chew Wee is currently leading Process Analytical Technology (PAT) and Quality by

Design (QbD) related endeavors at the Institute of Chemical and Engineering Sciences

(ICES) in Singapore. His research involves implementing Raman and FTIR spectroscopies

and microspectroscopic imaging techniques, and developing multivariate chemometrics

analyses to applications, which include process development, chemical reaction kinetics

and mechanistic studies, biological cells imaging and hyperspectral pattern recognition.

Wee published 18 international referred journal articles and 40 conference papers, and is

actively promoting PAT/QbD with the ISPE PAT community of practice and ASTM Committee

E55 for pharmaceutical manufacturing. He is an editorial board member of the Journal of

Spectroscopy.

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22 Dr. Puvarin Nilrangsee

TPI Polene Public Company LimitedThailand

Case Studies/ Project References

PCS 7 in the Cement Process

Abstract:

TPI Polene Public Company Limited was established in 1987. We are the one of the major manufacturers and distributors of cement products and mortar cement under the trade name “TPIPL”. The first cement plant operated since 1992. Much like human beings as they get older, the control systems trend to suffer from health problem. Devices start to malfunction or failure, finding replacement parts become increasingly difficult as the original vender stopped supporting the system. Without of reliable source of parts supply, a control system become easy grind to a halt. Along with this issue of obsolescence, the old control system is unlikely to be able to take advantage of productivity enhancing.

By 2005, the control system was installed 17 years ago. We were facing a lot of problems with our existing control system. It was becoming more and more difficult to find spare parts, and even when we could find it, the price was very high. Along with this situation our operations were starting to be affected through process downtime. TPI Polene started transformation a control system by select three vendors, invited to submit bids. Selection criteria including service and support capability, user friendliness, easy of programming, reliability, and cost are considered. Finally Siemens and its PCS 7 CEMAT process control system in the winner frame. After installation of Siemens PCS 7 in 2005, the control system performance illustrated through zero process breakdown due to control system problem and lower spare part cost than the old control system.

Speakers Profile:

Dr.Puvarin has over 15 years of professional experience in process automation and

instrument engineering in Cement industry. He is also specialization in Production &

Operation management, and Cost reduction & Productivity Improvement. During the

period of his career, he has executed many projects on process automation and instrument

engineering, including the project of PCS7 in the Cement Process.

Current main positions

TPI Polene Public Company Limited His current principal work responsibilities include �

management, process automation, Instrument Engineering, Cost reduction & Productivity

improvement, Human resource development, Quality assurance, and safety.

Graduate School of Commerce (GSC), Burapha University He is lecturer in MBA �

program for the course Business Statistics and Quantitative Analysis (84 hrs./year),

Production and Operation management (84 hrs./year), and Logistics Management (84 hrs./

year). He is Thesis and Dissertation advisor for MBA and Ph.D. programs.

Credentials

D.Eng. Doctor of Engineering and management, AIT. �

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Case Studies/ Project References

Implementation of Advanced Process Control in RDS Pilot Plant

23 Dr. Jeng-Fan Leu Ph.D.

CPC Corporation, Taiwan

Abstract:

“PLC or DCS?” This question is reviewed again for an upgrade of control system in residue desulfurization (RDS) Pilot Plant. From aspects of features, economics and users’ requirements, DCS is considered as the better solution for this project. Subsequently, PCS 7 has been commissioned in CPC RMRI since 2010, also as an essential foundation for implementation of Advanced Process Control (APC). Among various PCS 7 standard APC tools, we select Model Predictive Control (MPC) for reaction temperature control of RDS Pilot Plant.

Comparing with conventional method, MPC can significantly reduce manual interventions by 80% and lead to tenfold more control accuracy. Not only operator, engineer also

24 Mr. Feng-Chang Wu

CPC CorporationTaiwan

benefits by using MPC configuration tool of PCS 7 on reduction of engineering work, which would be usually tremendous for in-house controller design.

Speakers Profile:

Jeng-Fan Leu received the B.S. from the National Taiwan University in 1995, the M.S. from

the Chung Cheng University, Taiwan in 1997 and the Ph.D. form the Cheng Kung University,

Taiwan in 2002, all in Chemical Engineering. He has been employed by CPC Corporation,

Taiwan, as a Chemical Engineer worked for RDS Project at Refining & Manufacturing

Research Institute since 2000. His research interests are in the area of RDS catalyst

evaluation, heavy organics deposition and process control.

Mr. Feng-Chang Wu received the B.S. in Electrical Engineering from the Ta Yeh University,

Taiwan in 2002. He has been employed by CPC Corporation, Taiwan, as a Technician at

Refining & Manufacturing Research Institute since 2005. His major tasks are for RDS

Project, including analysis of physical properties of RDS catalyst, distillation of heavy oil

and system integration for pilot plant.

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25 Nguyen Duc Manh

Vietso PetroVietnam

Case Studies/ Project References

PCS7 Application for Vietsovpetro offshore Platform Projects

Abstract:

Introduction Vietsovpetro: As end-user and an engineering for Siemens Vietnam

PCS7 Application in practical status for Vietsovpetro’s O&G production offshore platforms

PCS7 pros and cons for engineering, integrating and programming in Vietsovpetro

26 Sham B. Thakur

Evyap Sabun Sdn BhdMalaysia

System Solution Provider: DNR Process Solutions Pte. Ltd. Singapore

Abstract:

Evyap Sabun Malaysia Sdn Bhd is setting up manufacturing plant at the Tanjung Langsat industrial estate in Pasir Gudang, Johor, covering 22.25ha of area with a production capacity of 1,000 tonnes daily (Phase 1)

The New facility comprises of following Plants Fractionation & Distillation ( 550 TPD and 300 TPD), Splitting ( 2000 and 2100), Glycerine water Pretreatment, Glycerine water Evapouration,Glycerine distillation & bleaching, Saponification, Utilities, Tank Farm and Loading / Unloading Facility supplied by different precess engineering companies like Sulzer, JJ-Lurgi, Mazzoni, etc.

The challenge was to intergate the instruments and controls for all plants, utilities, tank farm and loading / unloading facility into a totally integrated architecture complete with information management system with a dash board where the key porcess information is available plant wide locally as well at the HQ in Istanbul.

DNR Process Solutions took up the challenge by employing Simatic PCS-7 Distributed Control System, Profibus Communications, Tankfarm and Material Movements Management System (POIMS) to proivide a state of the art totally integrated autmation systemSpeakers Profile:

Mr. Shambahadur Thakur is the Senior Projects Manager of

Evyap Sabun Malaysia Sdn,

Totally Integrated Automation for Oleochemical Plant & Facilities

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Ocean’s Life Pleasure

Ocean Glass, Thailand � If you are fortunate enough to stay in one of the higher-end hotels next time you are in Bangkok then it is more than likely that the refreshing iced water, cold pint of

beer or even sparkling champagne will be served to you with a touch of the ocean. Ocean Glass, that is.

This Thai manufacturer has built up a reputation as a high quality provider of glassware – tumblers, cups, mugs, plates, ashtrays, etc – to the extent that it can now count customers (retail chains and service outlets) in over 50 countries around the world, including those in demanding markets such as Japan, Sweden and the USA. Notably, 70 percent of the output from its single production facility in Thailand is destined for export.

This factory, located in the Bangpoo Industrial Estate on the outskirts of the capital, commenced glassware production in 1982, three years after the company, Ocean Glass, was set up as an industrial diversification of Thailand’s Ocean Insurance Group. It now employs 1,200 people, has an annual production capacity of 140 million pieces of glassware, and is a publicly listed company on the country’s stock exchange.

“Everything is done here,” says Apichart Srichalerm, electrical maintenance engineer, Ocean Glass. Indeed, all of the company’s design and production activities take place at the Bangpoo facility. Glassware shapes and structures along with enhancements such as decals, frosting, gold rims are designed with

the aid of CAD software. And as for manufacturing, it goes literally all the way from sand to packaged product.

“It’s the typical glass manufacturing process,” explains Apichart “The raw materials comprise silica (sand), soda ash and dolomite stone. However, because our stress is on quality, we ensure that all impurities are removed from the sand such that what remains in 99.9 percent crystallized silica that is then blended with the other raw materials.

“The mixture is then sent to the furnace for melting in the intensely hot environment of 1,600 deg C. The now molten material is then conveyed to the forming machine, which produces the desired glassware shape. The final stage is packing of the finished glass items. We currently have three glass production plants at this facility,” he says.

As for automation, Ocean Glass had previously relied upon PLC based systems, and these came from a variety of vendors. “Having different brands of controllers resulted in frequent communication problems and consequent process downtime,” recalls Apichart Srichalerm. “So we decided to look for a new automation solution.”

So in 2006, Ocean Glass commenced the search for some new technology. In the final frame were solutions from two globally renowned automation suppliers. One of these was Siemens, which was proposing its PCS 7 process automation system, then in its version

Ocean Glass Bangpoo Glass Manufacturing Facility located in Bangkok, Thailand

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“Yes, I would use Siemens automation technology again.

We have built up significant knowledge on PCS 7 here at

Ocean Glass. Furthermore, it has proved to be a very

reliable system and helped us to assure the product

quality that makes us Thailand’s top glassware

manufacturer.”

6.0 stage. And it was Siemens that made it first past the finishing line following the evaluation process.

“Why Siemens? Well, we found that the PCS 7 system was more easily able to connect to our machines. And we were also aware that many glass factories around the world have adopted Siemens process automation technology,” Apichart. explained.

PCS 7 was implemented at two of the plants in 2006, and at the third in 2008. After an upgrade three years ago, all plants now run version 7.0 of PCS 7 and have the same hardware and network structure.

In terms of specifics, there are total of 9 417-2H redundant controllers; one OS (operator system) with redundant

server; one ES (engineering system); one web server; and 10 client stations.

Other system components include Profibus DP network for connecting the controllers out to ET 200M remote I/O stations that interface to instrumentation, some from Siemens, others from different vendors. And for raw materials recipe management, Simatic Batch software is used.

“In terms of what we need to monitor and control, it is temperature, pressure and material level in the furnace. And in the forming machines, we need to synchronize position and speed,” outlines Apichart.

The implementation was done by a systems integrator from Germany. Ocean Glass felt that this SI had the requisite knowledge of the intricacies

of the glass production process as well as of Siemens automation technology.

So what has been the impact of PCS 7 at Ocean Glass? Apichart , who was chiefly responsible for specifying and now managing the system, points to maintenance being a whole lot easier now than before.

“Previously, when we had a production problem it was very difficult to locate the cause. But now, through the extensive monitoring capability provided by PCS 7, we can locate and fix problems much more quickly,” he says. Process alarms and production activity reports that are available from the system have proved to be very welcome.

The electrical and maintenance engineer is also evidently enamored of

the web server functionality, which enables him to see the activity in all the three plants from virtually anywhere. “I can now see everything!” he exclaims.Speaking about his relationship with Siemens Thailand, Apichart reports that the Siemens country office is a source for spare parts as well as technical advice. More complicated issues to do with the implemented system require liaison with the SI in Germany.

“Yes, I would use Siemens automation technology again,” reveals Apichart. “We have built up significant knowledge on PCS 7 here at Ocean Glass. Furthermore, it has proved to be a very reliable system and helped us to assure the product quality that makes us Thailand’s top glassware manufacturer.”

Apichart Srichalerm

Electrical Maintenance Engineer, Ocean Glass

Apichart Srichalerm with Thanadee Sittialangkanon,

Siemens Thailand

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Workers at personal care factory

A high degree of batch flexibility and a virtualized systems infrastructure were two key automation system requirements when Unilever was looking to expand its skin care plant in Indonesia. Bob Gill reports.

Refreshing Automation

Unilever, Indonesia �

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The virtualization concept supported by Siemens PCS 7 enables easier and more effective management of the control-room operator stations along with a much more secure environment

The virtualization concept supported by It was imperative that the delivered process automation solution have solid batch functionality, including S88 compliance, said Adhi Winata (second from right), engineering manager for skin/deo

Partners in an intensive but successful project (l-r): Hendy Sutanto, project engineer at systems integrator Simentari; Achmad Fathoni, assistant ICAE manager, Unilever Indonesia; Muhammad Ali Jinnah, PCS 7 promoter, Siemens Indonesia.

01

03

Indonesia is now one of Asia Pacific’s most vibrant democracies and has maintained political stability and emerged as a confident middleincome country.

That is the view of the World Bank, which forecast that the most populous nation in Southeast Asia should hit 6.4 percent GDP growth this year.

Certainly, the country has come a long way since the dark days of the Asian Financial Crisis of the late 1990s and the frequent political changes and uncertainties for some years after. The current regime of President Yudhoyono is regularly praised by observers for its sound fiscal stewardship, which has in turn encouraged increased investment from both local and foreign entities.

While many global players may have turned an anticipatory gaze on the country only recently, given the potential of a 230 million plus population and rising income levels, the same cannot be said of Unilever, the giant food, household and personal care company.

That is because it has had a presence in Indonesia since 1933 and has grown (in the form of PT Unilever Indonesia) to encompass several manufacturing sites, an extensive distribution network, and extensive outreach to communities through respected corporate social responsibility programs.

At its FY2011 results announcement on May 29, 2012, the company

reported a near 20 percent increase in revenue to Rp 23.5 trillion (US$2.5 billion) and an operating income of Rp 5.5 trillion. “2011 turned out to be a great year for Unilever Indonesia. We saw a steady improvement in consumer confidence over the course of the year; and in particular resurgence of Indonesia’s rapidly growing middle class,” said president director Maurits Lalisang.

The Unilever Indonesia chief also revealed that the company is continuing to invest heavily: “In 2011 we invested some Rp 1.7 trillion to increase our production capacity and to improve our distribution capability. Our total investment from 2010 to end 2012 will have reached around €350 million.”

Increasing capacity

Travel some 30 km out of Jakarta to the Jababeka Industrial Estate in Cikarang and you can see some of that investment in the form of Unilever’s largest skin care factory – not only in Indonesia or Asia, but globally. Built at an initial investment cost of Rp 500 billion and stretching across 10 hectares of land area, the site is home to the production of familiar cream, lotion, handwash, shower foam and deodorant brands like Pond’s, Vaseline, Dove, Lux, Lifebuoy and Rexona.

Along with a healthy and rising domestic market for such products, the Skin Care factory is also a key element in Unilever’s global

02

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manufacturing strategy, with exports going to places as far as Brazil and Japan, as well to neighboring countries in Southeast Asia.

With the first production line (known as Zara 1) established in 2007, it soon became apparent that further capacity was needed to meet burgeoning

demand. Hence it was the end of 2011 that the saw the start of operation of a second production line, Zara 2.

“The heart of the manufacturing process is the mixer (of which there are several) where the constituent materials that form the “recipe” for a particular product are added and

Located in Cikarang, Indonesia, Unilever’s globally largest skin care factory produces familiar brands such as Pond’s, Vaseline, Dove, Lux, Lifebuoy and Rexona.

“We were pleased to see that the Siemens PCS 7 version 7.1 supported virtualization,” recalls Fathoni. “The advantages come particularly in easing of administration tasks, because the software resides in the client virtualization server and the actual physical client PCs are essentially plug and play. So we don’t need to maintain the operator stations one by one, and software updates can be made remotely, plus it’s much more solid environment in terms of security.”

Achmad Fathoni, Assistant ICAE Manager

Unilever Indonesia

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which we had to customize ourselves. So we were attracted by the promise of Simatic Batch integrated into PCS 7.”

In Zara 1, the batch handling was done via logic written in the PLC. Considerable time was needed to configure the system in terms of specific code for the production equipment.

“But with Simatic Batch it has been so much simpler and quicker. Instead of having to configure everything from scratch, there are templates for on/off valves, motors, dosing system, and other equipment. Instead of ladder logic, the batch recipes are written directly in the Simatic Batch software and then linked to the relevant equipment module in the PLC.

“Given our production demands of running one or two batches and then changing the recipe, and with all the different variants, all in all, the batch solution we have in Zara 2 is much more powerful, flexible, and easier to apply,” says Winata.

Going virtual

Aside from Simatic Batch, salient features of the implemented PC7 system include three in-cabinet S7-400 PLCs which connect down to the field via a Profibus DP network, which then connects directly to a Profibus DP compliant device (e.g. variable speed drive); to an ET 200M remote I/O station – for hard-wired field instruments; and to a DP/AS-i Link – for communication with around 1000

agitated,” explains Adhi Winata, engineering manager for skin/deo. “The formulation is then conveyed to storage tanks and then on to the filling lines.”

Winata adds that manufacturing in the Skin Care factory is characterized by high product variety – as there can be numerous color and size variants for each product, and frequent batch changeovers – to meet the required output in terms of product mix. “This is what creates the complexity in this plant,” he remarks.

Batch demands

Work on specifying the automation system for the new production line began in early 2011. “Unilever has a global policy of only contracting with the large automation vendors. However, from this list, the final selection is made locally,” explains Winata.

There were two vendors in the frame for Zara 2, and the selection criteria were based on the quality of the proposal and the likely benefits of the solution. In the end, it was Siemens Indonesia which won out with its offering of the PCS 7 (version 7.1) process control system with Simatic Batch add-on module.

“Our most important requirement was that the solution should provide for solid batch functionality, including S88 compliance,” relates Winata. In Zara 1, we went for a SCADA/PLC solution that proved to be not as flexible as we had hoped in terms of the batch system,

discrete on/off valves networked on an AS-i bus.

But it is at the above-PLC level where things get really unique and interesting. “Here at Unilever Indonesia we like to feel that we are adopting the very latest technology – and that is why we decided to go for a virtualization solution,” relates Achmad Fathoni, assistant ICAE manager.

An increasing trend in the IT world, virtualization decouples computer hardware from the operating system and applications, via a virtualization layer, to create what can be several “virtual machines” running on the same hardware. In client virtualization, many virtual clients run on a host server and the user accesses his authorized “desktop” over a network connection from his PC to the server.

“We were pleased to see that the Siemens PCS 7 version 7.1 supported virtualization,” recalls Fathoni. “The advantages come particularly in easing of administration tasks, because the software resides in the client virtualization server and the actual physical client PCs are essentially plug and play. So we don’t need to maintain the operator stations one by one, and software updates can be made remotely, plus it’s much more solid environment in terms of security.”

Performance review

“We did not want a vendor that just sold us equipment,” says Winata. “But one that could give us good advice,

discuss the feasibility of various solution options, and share its experience of industry best practices.”

According to Siemens Indonesia PCS 7 promoter Muhammad Ali Jinnah, as well as providing a high level of local consultation and support, Siemens Indonesia was able to call on additional regional resources such as Simatic Batch expertise from Siemens Singapore. And the project was implemented with the added capabilities and expertise of Indonesian systems integrator Simentari.

The performance of the automation system in Zara 2 is firmly in line with expectations, according to Adhi Winata. In particular, the key requirement on batch flexibility has been met, and the system has been robust since going live in November 2011.

“It is especially pleasing to see that we have been able to successfully showcase our capabilities in implementing leading edge technology like virtualization – we are the first Unilever plant worldwide to implement the concept.

“And this was a highly important project for us, given that we are the largest Unilever skin plant globally and considering the amount of investment that has gone into the facility in just a few short years. In fact, our CEO from HQ in London came and personally toured Zara 2. So it is very satisfying to show what we can do here in Indonesia,” concludes Winata.

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MapsCentara Grand at CentralWorld

Centara Grand at CentralWorld, one of the largest in Asia Pacific and featuring 505 luxurious rooms and suites, is located within the central business district. The hotel features 9 executive floors including one floor of World Executive Club, 9 restaurants and bars including Fifty Five (an unforgetable outdoor roof top venue with impressive views across the city skyline) and 5 star-hotel facilities.

Infoshops and Conference location

74 75

siemens.com/processautomation

Global Solutions for Process Automation

Answers for industry.

Conference Schedule

76 77

Partnership you trust

With our evergrowing and changing world, process industries continually face new challenges, be it merging

markets, environmental protection or financial dependencies. Despite these global challenges, the goals on

the operational level of the plant, remain the same: long-term safe operations combined with high efficiency

to maximize your return on investment.

Your Success Factor: Siemens

Competitive pressure is rising, and you must react. You need answers to your most pressing questions:

How do I start up faster and more efficiently?

How do I minimize my energy and material costs?

How do I maximize throughput and improve quality?

How do I reduce unplanned shutdowns and prolong the time between shutdowns?

How do I capture the knowledge of retiring staff?

How do I significantly reduce my maintenance cost?

And how do I switch over to new equipment?

Siemens has the right answers: Effective solutions backed by long industry expertise and first-class products, carefully designed down to the last detail while always keeping an eye on the big picture – your success.

“Business is based on trust,” said Carl Friedrich von Siemens, the son of the founder.(...) It’s especially in difficult times that trusted, reliable partners prove their value.

Peter Löscher, CEO Siemens AG

We provide not just the technology but also the know-how and expertise you need to maximize the profitabi ity of your business

We maximize the return on equipment investments and continuous life cycle support

We search for new ways to extend the ife of your systems and maximize the value of installed equipment

We offer modular Siemens solutions – free to select any combination of products and professional services you need

We commit to ensure the long-term value of your plant with lifetime services

We do more than improve the performance of isolated areas in your plant. We deliver measurable performance improvements across your entire operation, including all of its processes and assets

78 79

Results you trust – Cost Efficiency & More

Real results and facts make the decision to work with us easier. With the right partner by your side,

you can meet tomorrow‘s demands today and ensure your lasting success: Cost efficiency all down the line.

Less is more: Less cost, more efficiency

There is great potential for savings in operations. t starts with the use of off-the-shelf solutions and innovative technologies and continues with project responsibi ity: Having a single point of contact means fewer interfaces, and thus lower costs, from engineering to installation. Offsite engineering and fabrication and optimized engi-neering design deliver additional savings.

On all levels: Keeping an eye on your advantages

As a leading process automation provider, it goes without saying that we implement savings for our customers on all levels.

Our objectives are:

Minimize coordination of multiple vendors

Minimize project management resources

Reduction of interfaces to be coordinated

Receiving a single point of contact for automation matters with clear responsibilities

Plant start-up within schedule and budget

Utilization of the MAV‘s experience, expertise and skilled resources in order to design a state-of-the-art system

Smooth integration of 3rd party equipment

Delivery of a safe, operational, maintainable and reliable automation platform

Implementation of a ife cycle strategy

Project assistance by Siemens: We have defined a clear structure of project phases, process steps and quality gates

Proofpoint Chemical Industry – Leading DCS System SIMATIC PCS 7

Siemens is a leading process automation vendor, and you can expect to receive first-class products and sys-tems. E.g. we provide the most performant automa-tion controllers on the market. This is what you need for success.

SIMATIC PCS 7 for the chemical industry is just one example. This leading process control system is easy to implement in any chemical plant.

ts open, modular system architecture and many other advantages impress engineers.

You save engineering and installation costs due to the use of digital bus systems and integrated devices.

Operational benefits for Managing Directors:

Siemens contributes significantly to “operational excellence“ and you can maximize throughput, availability and product quality, and at the same time minimize operating and maintenance costs, energy and raw material consumption, off-spec products, emissions and safety risks.

Cost-saving potentials in Integrated Automation, Electrical and Power Management

100%

80%

Examples of cost-saving

potentialsReduced spare parts and training

Reduced installation due to less wiring and type-tested products

Trusted performance, on-time delivery – Single source supply

Type-tested solutions using Industrial IT enabled products, proven interfaces, InTools generated db

Speed up process of enquiry, bidding and standardization

Early standardization, reduced cost to bid and reduced bid price

Expediting inspection

Commissioning, start-up, training

Installation

FEED, Bid phase

Engineering costs

Procurement

Project opening Quality planProcess Know-how Templates, Documents & Checklists

Organization Sub- contractorsWell-known Partners

Functional specificationTool-based Document Management

Hardware DesignStandardized HW Typicals (Cabinets, Termination Solutions)

Software DesignStandardized SW Typicals (Control Modules, HMI)

Purchasing & ManufacturingProcurement Successes

Implemen- tationTool-based SW Generation

Factory acceptanceTool-based Testing

DeliveryCoordinated Delivery

InstallationOn-site

Commis- sioningManagement of changes

Site acceptanceHandover to Service

Project closing

Operation Support Training

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Solutions you trust – Tailored to Your Needs

We‘re where you need us: On site, around the world

We listen to your needs to understand the specific situa - tion you are in. Our worldwide presence ensures that you can talk to a local Siemens partner near you. In order to prepare the best solution for you we have created a worldwide pool of industry experts. Countries are inked together within our global engineering community, which allows our specia ists a competent exchange of knowl- edge, while our standardized project execution methodol-ogy ensures the delivery of our solution in time and with the highest qua ity.

Comprehensive support: A broad portfolio for plant-wide automation

Our comprehensive portfolio covers everything from auto-mation and drive technology, production control, and system integration with industry software to efficient, precise service. In every case, you‘re sure to benefit from the perfect combination of productivity and automation.

A reliable partnership has many aspects: Being there when you‘re needed. Helping out even in the toughest

situations. Reacting flexibly to provide what‘s expected in any situation. Siemens has all the qualities that

make for a successful partnership. And the results speak for themselves: Dependable solutions that are tailored

precisely to customer requirements.

Flexible cooperation: Exactly what you need

Our cooperation with you is as flexible as your require-ments demand. Whether you‘re an end customer, OEM, EPC or system integrator, we offer exactly the scope of support you want. We can assume responsibility for every-thing from individual software components to complete projects.

Solution Portfolio for Industries – Plant-wide Automation

Consulting and Project Services IT Security and Services Building Security and Fire Protection Integrated Safety Instrumentation and Analytics Energy Supply, Distribution and Management

Integrated Automation Control Components Plant Engineering Software Motors and Drives Asset Management

Made for you: Industry-specific solutions

Whether for chemicals, oil and gas, glass and solar, life sciences, pulp and paper, food and beverage, metals and mining, cement, or water and wastewater – we offer solutions tailored to your industry. That‘s because our experts have many years of experience with the processes and procedures in your industry.

Siemens hardware and software

Experienced Siemens specialists

Siemens hardware and software

Siemens hardware and software

OEM EPC SI

OEM EPC SI

Siemens

Siemens & OEM / EPC / SI

OEM / EPC / SI

Global Network of Experts: Tuned to YOUR Requirements

System Responsibility Project Execution

Siemens project management

Siemens project management

Project Responsibility

Americas

190 Siemens project managers

120 Solution Partner companies

Overview of Project Execution Man Power and Locations in Process Automation

Europe and Africa

350 Siemens project managers

540 Solution Partner companies

Asia

240 Siemens project managers

255 Solution Partner companies

OEM EPC SI

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LegacyMigration

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ChemicalsGlassMetalsLife sciences

Food and beverageBuilding AutomationPower and energyOil & Gas

Industries Served

Our Team’s Competences

then Rieckermann Thailand has been known as a major sup-plier of machinery and industrial plants. For more than 60 years, Rieckermann Thailand has grown to become an increasingly versatile company offering highly sophisticated engineering so-lutions, tailor-made to suit each of our customer’s requirements.

Successful Solution Partnership

PCS7 in Thailand, Rieckermann has maintained its lead as the number one authorized distributor of SIEMENS Automation & Drives. We are proud to be the winner of “The Best Overall Performance” award by Siemens Limited Thailand,

2010 - 2011 Award 2011 - 2012 Award

Rieckermann (Thailand) Co.,Ltd.

438 / 3-8 Moo 5, Srinakarin Road, Samrongnua, Muang Samutprakarn, Samutprakarn 10270, ThailandPhone: +66 (0) 2 383 4333Fax: +66 (0) 2 383 4144-5E-mail: bangkok@rieckermann.comWebsite: www.rieckermann.com

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Siemens Solution Partner Siemens Solution Partner

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