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  • 1. Chemical Industry Migration for global standards Pharmaceutical Industry Automation safeguards insulin quality Lifecycle Management A Plan for Life The Magazine for the Process Industry Volume 17, Number 2, 2012 news process

2. 2 process news | 2-2012 C o n t e n t s p r o c e s s n e w s | 2 - 2 0 1 2 p Cover Lifecycle Management 4 A Plan for Life Lifecycle Management 8 The Next Step Integrated Engineering p Industry Chemical Industry 10 Smooth Standards Klber Lubrication, Germany Pharmaceutical Industry 12 Quality of Life, Quality of Product Julphar, United Arab Emirates 16 Clear Benets Curti Costruzioni Mecchaniche, Italy 18 Targeting the Supply Chain Alcon Cus S.A., Spain 20 Quality Medicine ICES, Singapore p Technology Process Control Technology 22 Innovative Operating Concept BASF, Germany 24 Partners for Global Solution Expertise Siemens Solution Partners 26 Eliminating Vulnerabilities with Updates and Patches Industrial Security Energy Management 28 Energy Efciency as a Business Process Spenner Zement, Germany 30 Web Exclusive 31 Dialogue BASF benets from a user-friendly and efcient operating concept for plant control systems that helps operators react fast and appropriately to changing process conditions Page 22 The new AVM machine series of Curti Costruzioni Mecchaniche can pack vials and ampoules fast and efciently using a perfectly aligned automation and drive solution Page 16 Using Simatic technology, Klber Lubrication implemented a standardized automation system covering the requirements of various batch processes and production plants Page 10 Klber SiemensAG BASF-SE/Hans-JuergenDoelger 3. process news | 2-2012 3 Guiding you through change Axel Lorenz Vice President Process Automation Industrial Automation Division Siemens AG Our theme for the Achema 2012 is: Guiding you through change Your trusted partner for lifecycle innovation. Every three years, experts and engineers from process technology, engineering, and process industry companies visit the worlds leading event for the process industry. The Achema has always been a trendsetting technology summit for chemical engineering, environmental protection, and biotechnology, and we are proud that we can make a contribution to innovation through our expertise and technology. This year, we will showcase a complete lifecycle management portfolio to reduce the total cost of ownership. The exhibits show how the process industry can benet from our products, systems, solutions, and services in research and development, process development, plant design, production, and maintenance as well as optimization and modernization. In this issue of process news, we have included a special edition with some of our technology innovations, such as the latest version of our Comos and Sipat software. Several case studies illustrate how our process industry partners and customers can benet from our solutions and services throughout their system and plant lifecycle. For example, read an interview with Dr. Birk from BASF on how lifecycle management can improve plant performance. Innovative products and solutions, process know-how combined with lifecycle services make Siemens a trusted partner for a sustainable business in dynamic times. We work with the worlds leading chemical and pharmaceutical companies to make sure that they get the most out of their plant and activities and we will continue to develop and improve our offerings to that aim. Enjoy the read! E d i t o r i a l 4. 4 process news | 2-2012 C o v e r L i f e c y c l e M a n a g e m e n t Photo:BASFSE 5. process news | 2-2012 5 p Lifecycle Management A Plan for Life From his ofce window, Joachim Birk can see several BASF SE. He is director of the Center of Excellence for Automation Technology at BASF in Ludwigshafen and leads a team that has been the driving force in the development of new concepts for process control system lifecycle management. The Center of Excellence focuses on the contribution of automation to efcient, reliable plant operation when developing and deploying process con- trol systems. Birk ex- plains: BASF SE, with its numerous plants and systems in different sizes and phases of life, is an ideal eld of application for new concepts in pro- cess control engineer- ing. Together with our partners, we are constantly evaluating novel concepts, as automation technol- ogy is a critical component in the safety, productiv- ity, and availability of plants. We need to ensure this contribution with continuous system care. Innovation as a challenge For Birk, one of the central tasks of lifecycle man- agement is coordinating the different lifecycles of plants and automation systems: On average, we expect a process plant to have a life of 30 years in operation, even longer in the case of some plants here in Ludwigshafen. In comparison, lifecycles in Ten years ago, the Center of Excellence for Automation Technology of BASF SE in Ludwigshafen, Germany, started to develop concepts for effective and efcient lifecycle management of process control systems. In this context, the general technical framework for plant operation and system maintenance is one critical aspect. However, equally important is communicating benets to users and management. automation technology are about 10 to 15 years for hardware and just 5 years for software components. We have to match and align these cycles, always keeping in mind that we can only implement new features or components when production operations permit this. In some cases, we can migrate systems during operation, but typically we need a plant shut- down to perform them efciently. The top priority is not affecting plant operation in any negative way innovations must pay off in daily pro- duction. We expect suppliers to respect these cycles with their products. This means that we need to develop a common understanding for those phases in which we can carry out upgrades. Solutions for life The intensive work of the last 10 years has already paid off for Birk: In our bids, we have succeeded in getting our suppliers to offer not only a price for the initial investment but also for the lifecycle costs, for example, for 15 years. This makes the maintenance of automation technology a plannable and above all a calculable component of the system lifecycle. We can assess how much a system will cost us in the course of these 15 years; this is a major step for- Maintenance of automation technology must become a plannable and above all a calculable part of the system lifecycle. 6. 6 process news | 2-2012 ward, and we were also one of the trendsetters in the industry with this approach. Another aspect is standardization of automation technology. BASF actively promotes this both in terms of the compatibility of different systems and within the system software. For example, BASF uses standardized software modules for engineer- ing Simatic PCS 7 process control systems. These modules represent typical control system tasks that are frequently needed. BASF has developed this tool kit together with Siemens, one of its preferred suppliers for process control systems. We use the tool kit worldwide in all the new BASF plants. Instead of having an individually programmed stand-alone system, we can work with a control system that is largely composed of standard com- ponents and uses customized functions only where expressly needed. An additional benefit of this approach is that it helps us migrate systems more efciently. We have good documentation and can easily access all required information. This de- nitely reduces the project complexity that you have with current control systems signicantly, explains Birk. Our teams save time during engineering, and the tool kit makes many tasks simpler, plus we can reap additional benets over the system lifecycle. However, Birk says that it is essential to evaluate standardization in terms of the contribution it makes to efficient lifecycle management: It is important to nd the right balance between stan- dardization and customization, keeping the system simple and efficient. And we need to talk fre- quently with the project teams on-site to make sure the people who have to work with the systems at the construction site or in the plant share our approach. Open exchange and common objectives Sharing and exchanging information are important for Birk, also to establish a good working relation- ship with suppliers and partners. Siemens is not just someone who we have been working with for a long time, building a lot of trust. Both companies share common objectives, so we can openly discuss and evaluate ideas and concepts in the area of process control engineering, Birk explains. For example, we can assess together which innovations for instance, in the area of operating concepts, IT secu- rity, or remote maintenance should be introduced where and when. We also carry out beta tests together and match development activities to requirements. This dialogue is also important for us as it helps us put our own concepts to the test and remain open for new ideas. I think that our job is not so much to predict the future but to actively shape it and Siemens is a partner that is already well posi- tioned for this. Particularly the last point developing joint ideas and speaking with each other is an integral part of the corporate culture at BASF. Consequently, we have many young and well-qualied employees, whom we train intensively, says Birk. We actively promote the exchange between specialists not only within our BASF community for automation technology but also with our partners. Fostering knowledge in our teams is an important aspect when you talk about lifecycle management. On a more technological level, Birk sees more untapped potential in the area of standards: We collaborate actively in committees such as NAMUR (Standards Committee for Measurement and Control in the Chemical Industry) to improve and promote exi