process news - Siemens 01, 2008 · The Magazine for the Process Industry process ... Volume 13, No....

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Renewable energy: a growth market with a prosperous future

Green Gold

The Magazine for the Process Industry

processVol. 13, No. x, 2008

newsThe Magazine for the Process Industry

processVolume 13, No. 2, 2008

news

2 process news | 2-2008

C o n t e n t s p r o c e s s n e w s | 2 - 2 0 0 8

p Focus

Renewable Energy 4 Green Fuel

Choren Industries, Germany

8 A Greener FutureWorld Energy Alternatives, USA

12 Optimized Effi ciencyBiogas

p Technology

Energy Management 14 Effi cient Use

Performance optimization

Process Control 18 A Diva of the Seas

Meyer Werft, Germany

MES 22 Savoring Success

R. J. Reynolds Tobacco Company, USA

Process Analytics 26 Good Design from the Start

Services

p Industry

Pharmaceutical Industry 20 A Signifi cant Contribution

Responsible Care

Cement 24 Cementing Savings

Lafarge Group, Malaysia

Oil and Gas 28 Premier Performance

IBW Engineering, Switzerland

30 In Brief

31 Dialogue

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Choren Industries in Freiberg in Germany reaps the benefi ts of Totally Integrated Automation in its Beta plant for synthetic biofuels

Page 4

A special version of Simatic PCS 7for seagoing vessels controls the technology on board the new AIDAdiva cruise liner

Page 18

After upgrading the motor drive and control system in one of its plants, Lafarge Group benefi ts from cost savings and better performance

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process news | 2-2008 3

E d i t o r i a l

Dear Readers:

In the US as in other parts of the world, the subject of energy has been dominating the headlines. Even before the price of crude oil passed the $100 per barrel milestone on January 2 of this year, the stage had been set for major changes in global energy policy. With fossil fuels becoming increasingly valuable commodities, consumers and government offi cials call for alternative sources of energy and fuel. “Green fuels,” such as bioethanol or synthetic biofuels, can contribute to a more sustainable energy mix that also reduces greenhouse gas emissions.I am happy to report that Siemens is leading the way in support-ing the production of alternative fuels – not only in the US, where over 50 percent of corn ethanol plants in operation today are controlled by a Siemens DCS, but also in other regions of the world. For Choren in Germany, we supplied a comprehensive automation, instrumentation, and power distribution package for the world’s fi rst industry-scale production of synthetic biofuels – see pages 4 to 7. We are also helping leading manufacturers of biodiesel, as shown in the story on World Energy on pages 8 to 11.In addition to the biofuels market, we are helping customers in many industries minimize their energy consumption. By leverag-ing Simatic PCS 7 and Totally Integrated Automation, our custom-ers are able to gain the data necessary to reduce or shed non-process-critical loads or successfully recover waste heat from their process for use in cogeneration.I hope you fi nd the articles valuable.

David Hankins

Vice President Chemical / Pharmaceutical Center of CompetenceSiemens Energy & Automation


Choren ensures that the fuel has a consistently high quality by frequent and comprehensive tests

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Choren Industries, Germany

Green Fuelp

Choren Industries had its origins in the Frei-berg Fuel Institute, which began performing research on the energetic refi nement of or-

ganic raw materials and their gasifi cation in the 1970s. After the founding of Umwelt- und Energie-technik Freiberg GmbH in 1990, the company was ini-tially concerned with topics such as drying in steam-fl uidized bed processes, power plant optimization studies, and other energy conversion processes. From 1994 on, it has focused its activities on the develop-ment of technology for producing synthetic bio-fuels.

From Alpha and Beta to Sigma

The so-called Alpha plant, a pilot plant for fuel gas and syngas from renewable hydrocarbon sources, was put into operation in 1998. The fi rst liquid products were synthesized from wood on a laboratory scale as early as 2001, and then for the fi rst time in continu-ous operation in 2003. The successor to this pilot sys-tem is the Beta plant, the world’s fi rst commercial-scale plant for the synthesis of BtL (biomass-to-liquid) fuel. It is expected to begin operation in spring 2008 and have an annual capacity of 18 million liters of BtL fuel. In addition to the actual process units for the generation of the syngas and the Fischer-Tropsch syn-thesis, the plant’s premises also accommodate all re-lated utilities and auxiliary processes such as biomass handling, storage, and preprocessing as well as sys-tems for process gas conditioning. Choren Industries has now taken another step following the Beta plant and is planning to build the fi rst large industrial plant in Germany, the so-called Sigma 1 plant with an an-nual production capacity of 200,000 tons (250 million liters).

Multistage process

The biomass used in the Beta plant is wood chips that are delivered to the plant and unloaded into under-ground silos. Impurities such as metal objects and stones are removed, and wet wood is dried using sur-plus process heat. Then the wood chips are trans-ferred to high silos for intermediate storage.

The heart of Choren Industries is the Carbo-V ® pro-cess, which is protected by international patents. Us-ing this multistage gasifi cation process, it is possible to convert solid biomass and other feed materials con-taining carbon into highly pure, tar-free, low-meth-ane syngas that is resynthesized using what is known as Fischer-Tropsch synthesis – a catalytic process for liquefying gas – to form a synthetic biofuel.

During the fi rst stage, the low-temperature gasifi -cation process, the biomass is continually carbonized through partial oxidation with air or oxygen at tem-peratures between 400 and 500 degrees Celsius and broken down into a gas containing tar (volatile parts) and solid carbon (char).

During the second process stage, high-temperature gasifi cation, the gas containing tar is post-oxidized hypostoichiometrically using air and/or oxygen in a combustion chamber operating above the melting point of the fuel’s ash to turn it into a hot gasifi cation medium.

During the third process stage, the endothermic en-trained bed gasifi cation, the char is ground down into pulverized fuel and is blown into the hot gasifi cation medium. The pulverized fuel and the gasifi cation me-dium react endothermically in the gasifi cation reac-tor and are converted into a raw synthesis gas. Once this has been treated in the appropriate manner, it can be used as a combustible gas for generating elec-

Choren Industries in Freiberg in Germany reaps

the benefi ts of Totally Integrated Automation in

its Beta plant for synthetic biofuels.


Good experience with Siemens technology

Siemens gas analyzers had already been operating suc-cess fully in the fi rst two CarboCompact and Carbo-V ® pilot plants and had proven their worth during the de-manding trial runs and experiments conducted in these plants. This positive experience and the excel-lent technical consulting also favored the decision to use Siemens technology in the fi rst commercial plant for BtL production. “There is always a certain risk in opting for a new supplier. We have been in close co-operation with Siemens for a long time and are famil-iar with the systems, not only the gas analyzers. We had been using a Simatic S7-400 in the Alpha plant since 1997, also with positive results,” explains Olaf Schulze, technical manager at Choren Industries. “We wanted to exploit this acquired knowledge, so this was also one reason why we used Simatic technology for the gradual expansion of the Beta plant – starting in 2003 with the fi rst expansion stage, the gasifi cation plant, and later also in other process units.”

Choren especially benefi ts from the broad Siemens portfolio in a complex project such as the Beta plant, as Schulze explains: “We always fi nd a solution with Siemens, both for the process control technology and for the process analytics – even for very specifi c re-quirements. The systems are well aligned with each other, thanks to Totally Integrated Automation, so ev-erything fi ts together. This also applies to the linking of the monitoring and measuring systems with the process control system. Moreover, Siemens technol-ogy is well established in the market, so there are many knowledgeable programmers for these systems. In addition, Siemens supports us directly with the programming. And, thanks to the company’s wealth

The new Beta plant in Freiberg – the photo shows the plant in October

2007 – is expectedto deliver the fi rst

synthetic biofuel in August 2008

tricity, steam, and heat or as a syngas for pro-ducing BtL fuels.

A multistage purifi cation and conditioning process then pretreats the gas so that it can be introduced into the synthesis process: quench-ing, mechanical dedusting, multistage wet scrubbing, carbon monoxide conversion, and

purifi cation. In the subsequent Fischer-Tropsch syn-thesis the reactive components of the syngas, carbon monoxide and hydrogen, interact with a catalyst to form hydrocarbons.

In order to maximize the fuel output, the waxes formed during the synthesis process are further pro-cessed using hydrocracking techniques, a standard process that is used in the petrochemical sector to re-

cycle waste substances at refi neries, and then sepa-rated by distillation into a diesel and a light hydrocar-bon (naphtha) fraction.

Gaseous by-products and remaining gas from the synthesis are used in the power station for generating steam and electricity. Additional facilities include an oxygen supply unit and a wastewater treatment plant, and a tank farm with transfer units for transferring the fi nished products to tank trucks.

»We are very satisfi ed with the process

control technology and will be using it for

our future projects.«Olaf Schulze, Technical Manager, Choren



info

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www.choren.de www.siemens.com/processanalyticswww.siemens.com/[email protected]

of experience in the fi eld of gas analytics, Siemens is able to supply a solution to fi t the task exactly. The consulting has a sound basis and is oriented to our requirements and not to selling as many or as expen-sive devices as possible, as you frequently fi nd else-where.”

Comprehensive control for the entire process

Siemens process analyzers are implemented through-out the process. Areas relevant to safety are moni-tored by the fast, low-maintenance devices of the Ultramat 23 series, while several Ultramat 6 and Calomat 6 devices are used for complex control and monitoring tasks related to the gas production and conditioning processes. Maxum II process gas chro-matographs are used in the resynthesis of the syngas into liquid hydrocarbons. All process parameters are transferred to the Simatic PCS 7 system, where they are available to the plant operator.

In addition to the process analyzers and the process control system, Siemens also supplied systems for the low-voltage distribution as well as four transformers. The engineering for the process control system was provided by the Siemens Automation Solution Part-ner Actemium.

Right on schedule

At the beginning of this year, the plant was fi ne-tuned so that it will be in operation by spring. Schulze is confi dent that the fi rst fuel can be delivered as planned in August 2008. So far everything is going almost perfectly according to plan, and Schulze is

pleased with the delivered technology: “We are very satisfi ed with the process control technology and will be using it for our future projects.” This applies par-ticularly to the planned Sigma plant, which will be one of Choren Industries’ next challenges. “Although we are only in the scouting phase at the moment, I can see no reason why we should not use Siemens tech-nology again,” Schulze says, adding: “Never change a winning team.” p

S i e m e n s t e c h n o l o g y i n t h e B e t a p l a n t

2 analyzer shelters with Ultramat, Oxymat, and Calomat devices for continuous gas analysis and 2 Maxum process gas chromatographs, including sample preparation and electrical equipmentProcess control technology with the Simatic PCS 7 process control system, with more than 3,000 I/O devices; hardware and software engineering by Solution Partner Actemium, including support for the compilation of specifi cations as well as commissioning supportLow-voltage switching system with 32 Sivacon 8PV panels as well as 3 Sivacon 8PT panels with compensation and 2000/4000 A bus barsMedium-voltage 6 kV type 8DH10 switching system4 cast-resin 3 to 5 MVA transformers

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T a n k u p t h e s u n : S u n D i e s e l ®

Synthetic biofuels, also known as BtL (biomass-to-liquid) fuels, are largely carbon dioxide (CO2)

neutral and therefore play a major role in protecting environment and climate. Together with Daimler AG and Volkswagen AG, Choren markets one of its range of BtL fuels using the name SunDiesel®. SunDiesel® features a number of positive properties:

It is renewable and largely CO2 neutral because the volume of CO

2 released in the manufacture

and combustion is only that which was drawn from the atmosphere previously by the plants.It has a high cetane number and therefore provides much better ignition performance than conventional diesel fuel.It has no aromatics or sulfur and signifi cantly reduces pollutants from exhaust emissions (by 30 to 50 percent compared to fossil fuels).It can be used without any adjustment to existing infrastructure or engine systems.It is produced from nonfood biomass consisting of agricultural waste products, scrap wood,and low-quality forest wood (branches, treetops).It has a very high yield per acre in comparison with other biofuels.It has a high energy density of approximately 40 megajoules per liter.It is suitable for long-distance transport and storage and can be produced and consumed locally.

The SunDiesel® brand is a registered trademark of Volkswagen AG in the European Union and other countries and is used under license to the brand owner, Volkswagen AG.

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World Energy Alternatives, USA

A Greener Future

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The Simatic PCS 7 process control

system helps World Energy maintain

its leading position in the biodiesel

industry.

During the fi rst week of January 2008, the price of oil skyrocketed over $100 per barrel and affected the world’s economic markets.

As a result of continuing high oil prices, alternative fuel sources are becoming increasingly attractive, not only from an environmental perspective but also from an economic perspective.

The situation has created an urgent need for Amer-ica to fi nd practical alternatives to its dependency on fossil-based fuels. One of the rising fuel alternatives in the industry is biodiesel, produced from oils de-rived from plant and animal feedstocks such as soy-bean oil and animal fat, which are extremely abun-dant in areas of America. Recycled cooking oils and “yellow” grease feedstocks can be used in biodiesel production as well.

Feedstock fl exibility

At the forefront of this rapidly emerging industry is World Energy Alternatives. This company operates a biodiesel production facility located in Lakeland, Florida.

World Energy’s biodiesel facility has the capability to produce biodiesel from several types of feedstock and utilizes specifi c processes for refi ned oils with both higher and lower content of free fatty acids (FFAs). The majority of the company’s current output is from refi ned oil feedstock such as soybean oil.

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Of all the factors considered in the biodiesel process (e.g., time, labor, chemicals, and feedstock), almost 80 percent of the total cost of production is deter-mined by the type of feedstock selected.

The Lakeland facility operates in a continuous batch mode, which means it processes the feedstock in batches, and each batch is immediately followed by the next throughout the production day. All pre- and post-batch processing takes place in a continu-ous fashion. The facility manufactures approximately 18 million gallons per year of biodiesel fuel using this hybrid process.

Migrating the operator level

The original process control system used two differ-ent systems for the interactive graphic screens of the biodiesel and glycerin portions of the operation. This system had aged over the years, and fi nally the com-puter for the biodiesel screen graphics went down.

All the interface graphics for the biodiesel operation were lost. Fortunately, this resulted in only a short outage, as some screens that had previously been de-veloped for the biodiesel process were retrieved from

another system and used temporarily to get the oper-ation running again.

Siemens suggested migrating to the operating sys-tem of the Simatic PCS 7 process control system and converting all existing HMI screens over to the PCS 7 operator interface as well. Siemens engineers devel-oped six replacement screens for the biodiesel pro-cess and two for the glycerin refi ning process off-site, working with frequent input from World Energy. The controller confi guration codes from the original HMI station, which are stored in the controller and backed up by battery, provided the starting point for the World Energy/Siemens team to upgrade the sys-tem. New graphics were created (to minimize change for the operators) while incorporating the powerful new features of the PCS 7 operating system, such as zoom and pan capability, HMI alarming, a built-in historian, and tool tips.

The Database Automation Tool performed dynamic linking of the HMI symbols to the control strategy,

enabling the new graphics to be created in a shorter period than the originals. The open architecture of the Simatic PCS 7 platform made commissioning an easy task. The workingteam relationship between Siemens and World Energy resulted in a smooth transi-tion. The system was fully commissioned just a little more than three months after the order was signed.

“The migration was near- ly seamless,” states Lucas Altic, engineering pro ject manager and in-house con-trols specialist for World Energy. “It took one week-end to completely install and troubleshoot the new system. Siemens developed most of the initial graphics and converted the existing code in-house before per-forming the tie-in on-site. Migrating to PCS 7 required little more than a few code tweaks, which improved the system performance.

“When I went back to modify a few of the graph-ics to fi t the Lakeland fa-

cility’s specifi c operational needs, I found the graph-ics-building process simple and intuitive,” said Altic. “It is a far cry from the limited functionality of older products. The database automation tool seamlessly

W o r l d E n e r g y

Founded in 1998, World Energy Alter-natives is a premier supplier of bio-diesel, biodiesel blends, and biofuels.World Energy has become the largest multi-feedstock biodiesel producer in America, with the largest, most comprehensive biodiesel distribution network.The Lakeland facility is the company’s only owned production facility; how-ever, the business model includes plans to expand the company’s produc-tion interests into various parts of the world. The Lakeland facility’s feedstock adaptability is among the best in the industry.


infocontact

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Siem

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At World Energy, the process control system including all HMI screens was migrated over to Simatic PCS 7

and automatically adds controller faceplates to the screens and links them back to the appropriate tags with almost shameful ease.”

Fit for a greener future

The new architecture includes an engineering work-station as well as a single workstation for additional integrations. The engineering station operates as a client and contains the existing toolset, allowing World Energy to update, troubleshoot, and maintain the legacy hardware confi guration from the same station that is used to view the process. The single station includes a 512-tag SQL historian for the archiving of process variables, alarms, and events.

As the demand for biodiesel continues to grow, new advancements will enable the company to pro-duce more gallons at the same facility. Additionally, with each new piece of equipment, the process be-comes more effective and more economical.

“To implement a new change with the older sys-tems, it meant hours spent in development, and shut-ting down the facility for days,” states Altic. “With the new PCS 7 architecture, engineering time is mini-mal. If a new system goes in, it takes less than an hour to code the controllers and link them to the

HMI. That translates directly into greater produc-tivity.”

World Energy is currently launching a multimil-lion-dollar capital expansion program. With the new technology from Siemens it now has the fl exibility to implement complex control applications with mini-mal in-house development time. The program will further allow World Energy to shift its focus from control engineering to plant engineering. With each new advancement, more biodiesel will be produced from the same-sized facility.

“Whatever future role biodiesel might have, World Energy stands poised and ready to help fulfi ll those needs,” says Altic. “With a platform like PCS 7, Siemens enables current and future facilities to easily expand their production needs as the demand for biodiesel and alternative fuels continues to grow.” p


A lthough the production of biogas is a growth market that has gained in importance world-wide in recent years, hardly any of the biogas

plants have yet been equipped with measuring and automation technology. However, in a biological pro-cess such as the production of biogas, plant operators can benefi t enormously from optimum control of the environmental conditions for the microbes. Using process instrumentation and automation technology effectively minimizes the risk of production losses. At the same time, biogas production can be optimized through higher process visibility. If important pro-cess parameters such as pH values, temperatures, or nutrient compositions can be kept in the optimum

range, process stability and plant availability are con-siderably increased. Operators of biogas plants pur-sue multiple targets: maximizing energy output to achieve higher revenues, reducing feed amounts to cut down on expenses, using different feedstocks to exploit market opportunities, and minimizing oper-ating risks to increase operational reliability and plant availability.

Instrumentation and automation suited for any task

In order to monitor and control all the processes in a biogas plant, Siemens offers a wide range of process

Biogas

Optimized Effi ciency

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Biogas plants benefi t from targeted

process control with modern process

instrumentation and automation

systems.

E q u i p m e n t f o r b i o g a s p l a n t s

Ultrasonic or radar devices for continuous level monitoringSitrans F fl ow-measuring instruments for dosing tasks, monitoring of liquid and gas volume fl ows, and calculating fl ow and material balancesCustody-transfer-approved Sitrans FUE950 energy calculator for energy fl owmetering after the combined heat and power unitSitrans T transducers for monitoring the temperature in the fermenter or after the combined heat and power station for optimum plant operation Sitrans P pressure transducers for monitoring actual pressures in all plant sections as well as for detecting pressure fl uctuations and possible faults in the fermenter, circulation pump lines, or intermediate gas buffer

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instrumentation solutions and process control tech-nology – for any required size and degree of automa-tion. The analytical parameters that are optimal for the fermentation process (pH value, redox value, dry substance, etc.) are monitored by devices perfectly tailored to the specifi c task. The monitoring of the pa-rameters can be seamlessly integrated into the con-trol system. Thanks to the broad experience of Hach Lange GmbH, of Düsseldorf, Germany, in wastewater analytics, the company’s analytical instruments are also used successfully in biogas plants.

In addition to the Simatic WinCC HMI system with its numerous programming, software, and database interfaces, the compact Simatic PCS 7 Box process control system is perfectly suited to the needs of bio-gas plants. With this system, biogas plant operators can benefi t from the performance of a large control system. The slightly higher initial investment re-quired for a full-scale control system typically will amortize itself through reduced engineering and commissioning costs alone.

Comprehensive monitoring

The option of retrofi tting biogas plants that have already been in operation for several years can be a

Process instrumentation from Siemens also offers the right solution for special tasks in the fi eld of regenerative energies. One example is the measurement of the ethanol content in bioethanol.To determine the actual quantity of alcohol produced by a bioethanol plant, the exact ethanol content of the product fl ow must be measured reliably. However, the product fl ow always contains a certain amount of residue water in addition to ethanol. The Sitrans FC mass fl owmeter uses the Coriolis principle for monitoring fl ow and can measure both the weight and the density of the product stream containing alcohol and water by using a special function for fraction fl ow measurement. This function requires a minimum of fi ve different densities for ethanol within the expected tempera-

ture range in order to perform a polynomial calculation that is stored as a software function in the device before it is deliv-ered to the site of application. Built-in temperature sensors in the Sitrans FC enable accurate temperature compensation, so it is possible to reach an accuracy of 0.1 percent deviation for ethanol when measuring density and mass with the Massfl ow MASS 2100 DI3 series.The benefi t for the customer: instead of three different devices for measuring temperature, density, and fl ow, only one device must be installed. This offers considerable cost savings, as typically a density-measuring instrument in this accuracy range alone costs several times more than the Sitrans FC. Installation and engineering effort are also signifi cantly re-duced, as only a single device must be integrated in the pipe.

S i t r a n s F C i n b i o e t h a n o l p l a n t s

viable choice if a detailed analysis of the specifi c plant situation yields appropriate results. With the right in-strumentation and automation, the utilization rate of biogas plants, which is on average only 70 percent in Germany at the moment, can be increased consider-ably, to more than 95 percent. This increase enables plants that have a combined heat and power plant with an electrical power output of 500 kilowatts to provide a continuous power supply for approximately 4,000 people; thus, biogas plants can be used for basic load energy supply. This concept is already being used successfully in the biogas plants of EnerCess GmbH in Bad Oeynhausen. The installed instrumen-tation controls the feeding process of the biogas plants with various feedstocks. In addition, the oper-ator can use the information provided by the systems to optimize plant operation. p

infocontact

www.siemens.com/[email protected]


Performance optimization

Effi cient Usep

The year 2007 made headlines as the most ex-pensive year for energy ever. And experts agree that energy prices will keep rising. The German

Institute for Economic Research (DIW) even expects a price of US $220 to $250 per barrel for crude oil over the long term. Electricity prices will continue to rise too. Such high prices have a particularly hard impact on energy-intensive industries such as the chemical industry. Therefore, this sector is looking for ways to use energy as effi ciently as possible.

Lowering primary energy consumption also has a positive effect on the carbon dioxide balance. The con-tinuous optimization and modernization measures typically also increase plant availability, and products can be adapted more easily to current market de-mands.

Energy management offers a systematic and sus-tainable solution that helps companies measure, ana-lyze, and improve their utilization of energy. The keys to achieving this are effi cient systems and technolo-gies, energy management systems, and energy ser-vices.

Reducing power consumption with innovative technology

There is an enormous savings potential in the use of energy-effi cient motors or drive systems but also in the optimum interaction of processes, especially in the intelligent coupling of exothermic and endother-mic processes.

A comprehensive concept for energy management

can help avoid unnecessary costs and emissions in the

chemical industry.

T e c h n o l o g y E n e r g y M a n a g e m e n t

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With frequency converters, process units can always be operated in the optimum range

Another area for savings in plants with high levels of energy consumption is implementing energy-effi -cient motors (Eff1–Eff2) that feature up to 42 percent less power loss. Since the total costs of a motor are made up of about 2 percent procurement price and about 98 percent energy costs over the life cycle, there is a considerable potential for savings here, depend-ing on the application and the operating hours.

Saving energy with frequency converters

In many companies motors run only in partial-load mode and therefore operate with high energy losses. By equipping process units such as pumps, fans, and compressors with variable-speed drives, these units can be operated in the optimum operation range. This can result in energy savings of up to 50 percent in comparison with conventional methods such as throttling, as less energy needs to be used to obtain the same output power when using variable-speed drives with frequency converters.

The higher initial investment for a converter must be taken into account in the analysis of the life-cycle costs. These investments are often amortized after

T e c h n o l o g y E n e r g y M a n a g e m e n t

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M a d e - t o - m e a s u r e e n e r g y c o n s u l t i n g

Individual services and specifi c solutions from Siemens process engineers enable plant owners to achieve extremely effi cient energy management with short amortization times. Siemens supports its customers with a special consulting service that helps eliminate energy drains and track down areas of potential savings. To determine areas of potential energy savings and effective cost-reduction measures, a total solution for all units is required –a solution that especially includes the technical processes in addition to the electrical and building technology. The project begins with intensive talks with the customer, in which the multidisciplinary Siemens team obtains a fi rst impression of the location and the production processes it houses from plans, consumption and machine data, energy cost accounts, delivery contracts, and other information. The next step is an inventory of the actual state and a detailed analysis of the individual consumers. This results in an energy study created in coopera-tion with the customer that provides a full energy balance of the facilities.Based on these results, the Siemens engineers roughly estimate potential savings and suggest initial measures. Based on their long years of experience in the construction of chemical plants,

they may be able to recommend minor conversions at an early stage, through which considerable savings can be achieved. The initial suggestions are refi ned and verifi ed with computer-aided calculation methods. Further measures can then be identifi ed – for example, the preliminary design of an additional heat ex-changer or buffer container. The consultants rely on their wide experience, which also includes cost estimates for the additional hardware that might need to be installed.At the end of the evaluation, Siemens presents its results to the customer, documents them, puts the possible savings potential in fi gures, and recommends a catalog of actions that can be implemented by the plant owner. After a positive investment decision, Siemens remains a competent partner for the cus-tomer, from the complete conversion planning to the com-missioning of chemical process plants as well as solutions for building technology or energy-saving motors.

a short time. The strategy should be to analyze all drives early to be able to respond to possible fl uctua-tions in requirements and changes in the plant.

Advanced solutions for process control

Advanced Process Control (APC) can also contribute to higher energy effi ciency. Normally, continuous processes have a fi xed throughput that is set once. APC optimizes the processes by entering appropriate data to achieve control aims such as lower energy con-sumption or better quality. Model Predictive Control (MPC) provides process control that achieves the de-sired output at the required quality level with the op-timum use of primary energy.

Savings potential through transparency

The key to effective energy management is to make all the available information from the process transpar-ent. Through vertical integration with the process control system as well as the operation control sys-tem, the energy and material fl ows can be balanced and costs clearly assigned and settled. With integrated

asset management, for example, the error profi le of a pump drive unit can be made visible. Pump damage is typically indicated by an increase in power con-sumption. The early detection of changes in the pump characteristics enables preemptive maintenance.

Services increase cost-effectiveness

Customized energy-saving consulting concepts such as energy consulting (see sidebar) are available to help reduce the energy budget of individual compa-nies. First the savings possibilities are identifi ed, analyzed, and evaluated, and then a total concept is developed that defi nes measures for optimizing energy consumption. p

infocontact

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


The air-conditioning systems of the AIDAdiva – including the wellness area – are integrated into the process control system as well

Meyer Werft, Germany

A Diva of the Seas

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The AIDAdiva, delivered by the Meyer Werft shipyard in Papenburg in Germany on April 16, 2007, is the fi rst of four next-generation

cruise liners ordered by AIDA Cruises. The cruise liner is 252 meters long and 32 meters in beam and accommodates 1,025 cabins, 11 bars, and a 2,300-square-meter wellness area. The main attraction, however, is the 3,000-sqare-meter “Theatrium.” En-closed in glass and located in the middle of the ship, this versatile entertainment space extends over three decks and across the entire width of the ship. Four large diesel engines generate 36,000 kilowatts that propel the new ship at a speed of more than 21 knots.

Siemens is delivering the complete systems for power generation, electrical propulsion, and auto-mation for all ships in the new AIDA line. One of the technical highlights is the diesel-electric main pro-pulsion systems that feature extremely low levels of noise and vibration. The diesel-electric propulsion systems will also be exceptionally eco-friendly in that harmful exhaust emissions from the engines, when running at their rated load, will be drastically reduced. With this propulsion system, based on the Siship Drive MV system, the AIDAdiva fulfi lls the lat-est classifi cation notations. This innovative propul-sion concept will ensure an availability of 50 percent propulsion power even when one watertight section is fl ooded.

All systems at a glance

All technical systems onboard the AIDAdiva are mon-itored by 25 operating stations located in a central control room. Approximately 360 operator screens enable excellent system visibility, so operators are always well informed of all process states.

At the heart of the monitoring and control technol-ogy is the Siship PAX integrated solution for large and small passenger ships. It handles the drive sys-tem, power supply, power distribution, and automa-

A special version of Simatic PCS 7 for seagoing

vessels controls the technology on board the new

AIDAdiva cruise liner.

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


infocontact


About 350,000 spectators along the banks of the Elbe River watched the christening of the new

AIDAdiva cruise liner at the Port of Hamburg

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tion, including all monitoring, alarm, and inspection functions on board the ship. The Siship IMAC auto-mation system is based on the Simatic PCS 7 process control system. Through Siship IMAC, PCS 7 is im-plemented on seagoing vessels – a fi rst in the history of PCS 7. The processes on the ship are controlled through several distributed units connected with each other by local networks. This intelligent solu-tion not only reduces wiring expenses but also pro-vides a much higher degree of fail-safety. The safety-management system, the air-conditioning control, the machinery automation, and the emergency shut-down system are also integrated into the control sys-tem.

The system data is provided through approxi-mately 13,000 measuring points giving detailed information for all the processes on board. High availability is achieved through integrated power management, which automatically adapts the power supply to the current requirements on board. The smooth interaction of all control system components was tested in simulations prior to installation, so the Siemens team was able to concentrate on the details during sea trials and meet the tight deadline speci-fi ed by Meyer Werft.

Successful maiden voyage

The system concept of the AIDAdiva will also be im-plemented in the other fi ve ships of the new line that will be built in the next few years. The new AIDAdiva has successfully completed its maiden voyage to Ma-jorca, and the second ship, the AIDAbella, is already under construction and scheduled for delivery in spring 2009. p

C o m p r e h e n s i v e s o l u t i o n

The Siship PAX product series integrates drive, energy supply, and process control systems into a comprehensive solution for passenger ships. The details of the solution on the new AIDAdiva:

Diesel-electric main propulsion systems with an output of 2 x 12.5 MWSiship Drive MV drive systemFour synchronous generators with a total power of 48 MVA for the energy supplyPower management system for automatic synchronization of power supply and current consumptionSiship IMAC ship automation system based on Simatic PCS 7Integrated emergency shutdown (ESD) systemDistributed process control with links via local networks25 operating stations, including four with dual screens and one 50-inch plasma screen13,000 I/O devices throughout the ship

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The pharmaceutical and life science industry is a highly innovative industry segment that makes an essential contribution to the health

and well-being of people all over the world. Its prod-ucts infl uence human lives like no other industry’s products do, which is perhaps why the industry is fre-quently the target of criticism: the numerous suc-cesses in fi ghting and curing previously incurable diseases often draw less public attention than the rare failures or accidents.

This suspicion of the pharmaceutical industry is partly due to the complex processes involved both in research and development and in the production of active pharmaceutical ingredients. These processes can be diffi cult to understand from an outside per-spective. At the same time, the development and pro-duction of medicines and active pharmaceutical in-gredients is costly – in terms of energy, resources, and money. In addition, these processes often involve the handling of highly pathogenic substances, so the protection of both staff and the environment is a cen-tral aspect.

Responsible Care

A Signifi cant Contribution

p

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

Customers in the pharmaceutical industry

benefi t from a wide range of pharma-

specifi c solutions from Siemens that

effectively support the pharmaceutical

industry in operating safely, profi tably,

and with due care for future generations.

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With the Responsible Care initiative, the pharmaceutical industry wants to demonstrate how its health, safety, and environmental performance has improved over the years, and to develop policies for further improvement

Consequently, following the approaches outlined in the Responsible Care program that was originally initiated by the chemical industry, the pharmaceuti-cal industry strives to continuously improve its health, safety, and environmental performance, and to communicate with stakeholders about the indus-try’s products and processes.

Health and safety

The pharmaceutical industry’s fi rst responsibility relates to ensuring the safety of its products. For this reason the industry is subject to very strict regula-tions. Regulatory agencies make stringent demands on the documentation and safety of production of ac-tive pharmaceutical ingredients and drugs, so that only effective products with uncompromised quality will reach patients.

Another aspect of safety is that no dangerous sub-stances from production or laboratories can be re-leased into the surrounding environment or pose a health risk to staff. Finally, safety must also be an in-herent aspect of the actual production or manufactur-ing process – for example, when highly fl ammable substances must be handled.

In all these areas, Siemens supports its customers in the pharmaceutical industry with solutions and services for validating the production processes, the building infrastructure, and the information technol-ogy infrastructure; ensuring a consistently high prod-uct quality; safely handling dangerous or pathogenic substances; and guaranteeing safe plant operation under Ex conditions.

Protecting the environment

Environmental protection in the pharmaceutical in-dustry obviously means reducing waste and emis-sions as well as ensuring a consistently high product quality. Every off-spec product must be disposed of as hazardous waste, so the fi rst and most effective measure for reducing waste is to make sure that the process delivers on-spec products. Biotech processes in particular pose a certain challenge in this respect, as they can be diffi cult to control in a way that reliably delivers the desired output. Moreover, production and manufacturing processes typically leave biologi-cal and chemical waste products as solid waste, off-gas, or wastewater streams that must also be elimi-nated and disposed of safely.

Siemens has developed innovative solutions that contribute to avoiding waste and providing safe dis-posal of waste that cannot be avoided – while increas-ing the effi ciency and reproducibility of the produc-tion process.

Sustainable use of resources

Responsible care for present and future generations also includes the sustainable use of resources. The two main targets in this area are water and energy.

In the pharmaceutical industry, heating, air-condi-tioning, and ventilation (HVAC) technology, especially for the laboratories and clean rooms of the produc-tion environment, ranks among the top energy con-sumers. With intelligent solutions, Siemens helps its customers ensure the safety of employees, maintain the controlled ambient conditions that are crucial to product quality, and at the same time reduce the en-ergy consumption of the HVAC technology systems.

Water consumption can also be considerably re-duced with intelligent conditioning technology – for example, if the water supply does not run in circula-tion because smart systems provide treated water on an as-needed basis.

Innovation for safety and effi ciency

In the next few issues of process news, we will be pre-senting individual aspects of Responsible Care and demonstrating how the pharmaceutical industry is making a signifi cant contribution to sustainable de-velopment with systems and solutions from Siemens. The series will begin with energy effi ciency. HVAC solutions from Siemens can make a difference for pharmaceutical companies that want to reduce their energy costs and carbon dioxide emissions without compromising safety and product quality. p

Health and Safety

Environment Protection

Use of Resources

Responsible Care

Waste Emissions to Air

Emissions to Water

Energy Consumption

Water Consumption


R. J. Reynolds Tobacco Company, USA

Savoring Successp

When R. J. Reynolds merged with the Brown & Williamson Tobacco Corporation in 2004, the subsidiary of Reynolds Ameri-

can Inc. grew overnight into the second largest to-bacco company in the United States, manufacturing about one in three cigarettes sold in the country. The company, based in Winston-Salem, North Carolina, employs about 5,800 people. It accounts for approxi-mately 30 percent of US cigarette sales, including 5 of the 10 best-selling US cigarette brands: Camel, Kool, Winston, Pall Mall, and Doral.

Managing change

The merger meant that the “new” R. J. Reynolds To-bacco Company was faced with managing the com-plex specifi cations of a diverse product portfolio. In the past, product specifi cations had been managed in internally developed and supported applications.

America’s second largest tobacco company

gets top results with Simatic IT.

These legacy applications needed to be replaced due to expansion limitations and obsolescence issues.

That was not all. A new product specifi cation man-agement solution was needed that would interface with R. J. Reynolds’ new enterprise resource planning (ERP) implementation as well as other legacy sys-tems. A more up-to-date specifi cation management solution was required that would provide more ver-satility and greatly reduce the complexity of the pro-cesses required to manage and maintain product specifi cations from conception to fi nished product.

R. J. Reynolds decided to implement SAP as its new ERP system and chose to deploy Simatic IT Interspec as its product specifi cation management solution.

Effi cient specifi cation management

The company undertook a rigorous schedule for the implemention of SAP with Simatic IT Interspec and

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

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Simatic IT Data Integration Service (DIS). Simatic IT Interspec was deployed as an enterprise solution and the sole source for all product specifi cations. Tight integration with SAP was vital to the success of this project, and R. J. Reynolds utilized the Simatic IT framework with DIS and Production Modeler (PM) to manage this interaction with SAP. The tight integra-tion allows for the detailed material and production bill data to move seamlessly between SAP and Interspec in near real time. Simatic IT Interspec as a product spec-ifi cation management solu-tion supports the creation and maintenance of the def-initions of all specifi cations used in the manufacturing process.

R. J. Reynolds says that Simatic IT Interspec pro-vides a very fl exible ap-proval process in which all relevant parties can quickly collaborate on any required changes to exist-ing products. Product changes can be communicated and approved quickly, as it is easy to determine who still needs to take action for fi nal specifi cation ap-proval.

Simatic IT Interspec also helps speed new products to market by streamlining review processes and elim-inating manual data entry into multiple disparate systems. And it fully supports key functional ele-ments such as planned packaging rotations, global updates, change versioning, and multiple versions of bills of materials.

A rich solution for managing complexity

Simatic IT Interspec is now managing all R. J. Reynolds’ product specifi cations and is fully integrated, and the company says it is providing tremendous results. Specifi cation changes are being implemented in re-cord time, and time to market for new products is be-ing impacted in a very positive way. And the company

is very happy. “Interspec provided us a functionally rich solution for managing the complexity of our product specifi cations and provided the necessary integration required of our ERP system,” says Jerry Romans Jr., R. J. Reynolds’ senior director of manu-facturing business solutions. p

K e y c h a l l e n g e s

Replacement of legacy solutions for product specifi cation managementEnterprise moving to SAPSAP being deployed in parallel with tight timelineIntegration of brands

The solution:Simatic IT InterspecSimatic IT MIS Bundle:• Simatic IT Data Integration Service• Simatic IT Production Modeler• Simatic IT Historian• Simatic IT Report Manager• Simatic IT Client Application

Key benefi ts:Faster time to market for new products and product changesTight integration with SAPFlexible specifi cation approval processQuick collaboration between all departmentsSingle source (Interspec) for all product specifi cationsStreamlined specifi cation review process

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» Siemens provided experienced and competent

technical support during the entire life cycle of this

project. We could not have done it without them. «June Reece, R. J. Reynolds’ senior manager, product standards


I n d u s t r y C e m e n t

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The new three-phase AC motor could be easily mounted on the existing foundation

Lafarge Group, Malaysia

Cementing Savingsp

Typically for equipment in cement works, the components and systems in the Lafarge cement plant on the island of Langkawi in Malaysia had

begun to suffer from the adverse environmental con-ditions. Consequently, there was a risk of failure. As unplanned production stoppages result in enormous costs – due not only to production losses but also to increased costs for emergency repair visits and rushed replacement parts – Lafarge decided to modernize its rotary kiln’s main drive and control system.

Using the technology of today and tomorrow

When the plant was built in 1995, its kiln was given DC (direct current) power because at that time AC (alternating current) could not provide the enor-

Siemens helped Lafarge Group upgrade the motor

drive and control system in one of its plants. The result

was cost savings and better performance.

mous starting torque of 250 percent needed by the kiln’s main drives, and the plant operators were more accustomed to DC.

To upgrade, Siemens suggested that the plant up-date the control system and switch to AC power. Tech-nological advances now permit AC to meet the kiln’s power needs. And a state-of-the-art three-phase AC drive system needs less maintenance and uses less energy. Siemens also suggested that the plant be given a control system that could be upgraded easily in the future. For the drive tasks, the project team therefore selected the Sinamics S120 converter sys-tem, which can be confi gured within a wide power range. For the control and communication functions, the team chose a Simatic S7-300 controller, a modu-lar PLC (programmable logic controller). The S7-300

K e y i s s u e s a t L a f a r g e

The plant needed to upgrade its aging control system and motor drives because they kept breaking down, causing expensive production losses and costly repairs.A key strategy in a successful upgrade was switching from DC to three-phase AC power, because it uses less energy, is more reliable, and is easier to maintain.For the sake of fl exibility and easy upgrading, the Sinamics S120CM converter and Simatic S7-300 PLC were chosen for the project. These can provide drive solutions for any application in the cement plant and are easy to use and upgrade.The upgrade needed to be implemented during a 20-day scheduled shutdown. The Siemens offi ces in Germany and Malaysia worked together to plan ahead for it, and they made the upgrade a success.

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The Lafarge cement plant on the island of Langkawi in Malaysia

Lafa

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was set up to exchange data from the converter sys-tem via Profi bus DP and to process all signals and communication from the process and transmit them to the existing control system. The S7-300 can be easily upgraded later if necessary.

The new drive system would give the plant a user-friendly control interface tailored to its exact needs. The system would also provide easy troubleshooting, reliable operation, reduced repair costs, and fast re-pair and part replacement.

Need to upgrade quickly

Siemens had 20 days to make the upgrade, during one of the plant’s scheduled shutdowns. To prepare in advance, Siemens Ltd. Malaysia and Siemens Ger-many collaborated to identify the existing interfaces, determine the required hardware (converter, motor, and PLC), create the PLC software, and build a fi tting frame for mounting the new motor onto the existing foundation.

During the 20-day shutdown, Siemens needed to erect new converter cabinets and install the PLC; dis-assemble the DC motor; install the new AC motor; lay control cable and connect it to the motor; commission the rectifi er, motor, and control unit; and then imple-ment a 24-hour idle run test.

Performing the upgrade

While preparing to perform the upgrade, Siemens determined that the secondary winding of the exist-ing power transformer could continue to be used in the new drive system. Necessary adjustments to off-load voltage were made via the transformer taps.

But the compensation system of the old drive was no longer needed, thanks to the much-improved power factor of the new Sinamics S120 converter.

Selection of the new motor was based on the tech-nical ratings of the old one. Because the shaft height of the new motor (500 mm) is less than that of the old one (630 mm), it was easy to mount the new motor onto the old foundation using a fi tting frame. Due to the different shaft diameter, a new coupling half was provided for the three-phase motor.

When production restarted, Siemens power-tested the new three-phase AC drive system and it worked perfectly, much to the customer’s satisfaction.

Results of the implementation

With the new system, plant personnel will be able to easily change or adjust the control logic as needed without any special training, thanks to the S7-300 PLC. If the control system needs to be upgraded fur-ther, plant personnel can easily add these connec-tions without much effort.

All applications in the cement plant are assured of receiving the drive solutions they need, because of the range of power that can be provided by the S120.

The customer now has a powerful, state-of-the-art main kiln drive, setting new standards in terms of reliability, maintenance, availability of replacement parts, and available service know-how. This example demonstrates that in the cement industry, it is worth-while to check the electrical systems periodically to fi nd modern and more effi cient solutions. The new system is already prepared for easy connection to a modernized distributed control system. p


FEED for Process Analytics offers adapted service

modules addressing the entire plant

life cycle

Services

Good Design from the Start

p

When building, extending, or modernizing a process plant, the return on investment (ROI) is always critical – and this trans-

lates into a clear profi le of technical specifi cations for production: highly effi cient production of con-sistent-quality products at maximum reliability and availability. Because the design phase offers a unique opportunity to evaluate different options for a plant, play out several scenarios, and align the correspond-ing target parameters to fi nd an appropriate solu-tion, this is exactly where front-end engineering and design (FEED) comes in and opens up considerable potential for savings. A study by the Construction In-dustry Institute of the University of Texas in Austin

confi rms this: in comparison to projects without FEED, the costs with FEED can be reduced by up to 20 percent and time requirements reduced by up to 39 percent.

Focus on process analysis

These benefi ts also apply in the fi eld of process ana-lytics. However, the challenge for many companies here is that they typically do not have the necessary know-how in-house. Even established consultants of-ten have different areas of expertise: they concen-trate above all on process technology and mechanical engineering and are rarely familiar with the latest

Front-end engineering and design services help pave the

way for effi cient and reliable processes and a high return on

investment – right from the start.

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

Plant operator/EPC

4. Invitation

to tender

1. Process analytics

requirements

Process

analytics

supplier

2. Assessment of

the situation

3. Studies, concepts, alternative

comparisons, specifi cation and

documentation of process analytics

FEED for Process Analytics,

performed by interdisciplinary teams of experts

Module 1

Project Review

Module 2

Engineering

Concept

Module 3

Alternative

Review

Module 4

Design &

Engineering

Bundled service modules, fl exible in size and content

Studies and concepts Realization

5. Offer


infocontact


At a very early stage, FEED for Process Analytics can pave the way for substantial cost savings over the entire project life cycle

L o c a l a n a l y t i c s e x p e r t i s e

When designing and implementing a solution for process analytics, the local conditions and requirements are a crucial aspect. Consequently, Siemens supports its customers with special regional solution and competence centers for process analytics. The tasks of the centers range from developing customized solutions to develop-ing applications, and also include systems inte-gration, training, and repairs. The employees are familiar with the local requirements and can also use a globally accessible knowledge database for process analytics. Following the existing sites in Karlsruhe, Germany; Houston, Texas, USA; and Singapore, the fi rst solution and competence center has now been opened in China. Located in the Songjiang Export Processing Zone in Shang-hai, it is in the direct vicinity of the decision makers and investment sites of the Chinese chemical and petrochemical industry.

developments in the fi eld of process analytics. For this reason it makes sense to outsource the analysis package separately to specialists.

Essential know-how

Siemens has ample experience in analyzer technolo-gies, applications, and the creation of complete ana-lytics solutions for many industries. In order to pro-vide its customers with optimum support, the com-pany offers not only numerous after-sales services but also presales consulting services: FEED for Pro-cess Analytics.

The fi rst step is to analyze and evaluate the cus-tomer requirements. What is to be achieved? What is the aim of the investment? Siemens provides the ex-pertise for this even before the invitation to tender. A consultant engineer on-site at the customer’s facility views the project, defi nes the aim with the customer, and helps with the planning – from creating compar-isons to producing detailed documents for invita-tions to tender based on the identifi ed concepts. In the case of upgrades or expansions, the experts study the existing plant, examine the condition of the ex-isting analytics system, and determine an optimum strategy for modernization, replacement, or expan-sion – in the form of manufacturer-independent neu-tral consulting, of course.

Perfect match

The result is not simply proven off-the-shelf solu-tions but comprehensive and integrated concepts based on the latest analysis and automation technol-ogy. The solutions are specifi cally adapted to be a perfect match for the requirements of the customer and are developed in close cooperation with all the partners involved in the project and evolve within the scope of an effi cient engineering and planning process with maximum time and cost savings. p

F E E D f o r P r o c e s s A n a l y t i c s

The FEED for Process Analytics package com-prises four clearly defi ned service modules addressing all aspects relating to the planning, implementation, and evaluation of an analytics solution:

Project ReviewEngineering ConceptAlternative ReviewDesign & Engineering

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Impact factor Costs

OperationExecutionFront end

The new controller racks were integrated into the existing cabinets

IBW Engineering, Switzerland

Premier Performance

p

IBW Engineering replaced the relay controls

for gas turbine generator stations at a crude

oil-loading terminal in Nigeria with a powerful

solution based on the Simatic PCS 7 process

control system.

The large pumps in the Nigerian Qua Iboe ter-minal load crude oil onto oceangoing vessels. Gas turbine generator sets produce the elec -

tric power to drive the pumps. The generators also feed an “island network” providing a maximum of 25 megawatts of active power to the terminal, which houses 800 employees in the offi ces and workshops.

The two gas turbine generators were monitored and controlled by older relay controls installed in 1970 that were increasingly prone to faults. The plant operator therefore decided to implement a new solu-tion.

Switzerland-based IBW Engineering was able to secure the contract for installing a modern control system, including new electrohydraulic actuators and sensors. One decisive factor in favor of IBW was the extensive technical knowledge of gas turbines that the founder of IBW Engineering, Christian Weiss, had acquired while working for various companies on power station projects.

Modern systems ensure greater safety

The technology used in the Qua Iboe terminal – relay technology and mechanical hydraulic modules for controlling and monitoring the gas turbines – has been used in all areas of industry. However, it cur-rently poses a problem, as there are fewer and fewer workers who are familiar with it.

Handling turbines is more complex than handling many other industrial products. According to Weiss, “If something goes wrong during food processing,

I B W E n g i n e e r i n g

Founded in 1995 and based in Bühler, Switzerland, IBW Engi-neering GmbH produces process control systems for the food-processing and power-generating industries. In the latter fi eld, the company has developed and is successfully using its PCS 7-based TurboLogics for generator stations driven by gas turbines. Other control system projects – primarily in the food industry – round out its portfolio.

www.ibw-engineering.ch

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specialists also used this tool. The hardware with the two operator stations was installed for this, and all situations were simulated.

Weiss still uses the simulation for the analysis of faults, although that has been necessary only once. “Thanks to the complex yet simple system I was able to insert, compile, and load the prepared modifi ca-

tions on the computer by telephone in cooperation with the local expert in no time,” he says – a perfor-mance that was also greatly appreciated by the cus-tomer, as was confi rmed in a feedback e-mail from the terminal operator. p

The operators are very content with the new Simatic PCS 7 process control system

the customer will perhaps lose a batch. But damage to a turbine can quickly cost millions.”

To address this challenge, IBW developed a stan-dard application with program modules for turbines called TurboLogics, a robust and integrated control system to optimize the operation of gas turbine gen-erators. The company used the Simatic PCS 7 process control system as a basis for the development. “The tools of this product meet our high demands,” Weiss explains. “We needed a robust system with reliable hardware and extensive software. PCS 7 allowed us to develop a consistent, tailor-made system with self-written functions (controllers) and image compo-nents (operator stations). We are able to develop the control components together with the graphical in-terface so that they fi t both the plant and the docu-mentation standards.”

Initially, the customer was not completely con-vinced of the benefi ts of this technology. However, the fi rst installation of PCS 7 quickly won the cus-tomer over, as Weiss confi rms: “The process control system clearly handles and integrates the organiza-tion of messages and trends. It supports the effi cient creation of function plans with CFC and helps keep a clear grip on operations.”

Tested with simulation

IBW used the PLCSIM simulation tool to test every step. This tool simulates the controller and therefore enables test runs through all operating states. The factory acceptance test carried out by the customer’s

»We needed a robust system

with reliable hardware

and extensive software.«

Christian Weiss, founder of IBW Engineering GmbH



Electrifi cation package for a new pulp line for Asia Pacifi c

New Drive for Paper

Asia Pacifi c Resources International Hold-ing Ltd. (APRIL), Singapore, contracted Siemens to supply the complete process electrifi cation package for a pulp line. The new production line will have a capacity of one million metric tons per year. It is to be built in the Rizhao facility in China and is scheduled to start operating at the begin-ning of 2009.

For the new pulp line, Siemens is sup-plying 18 medium-voltage motors with the associated 6.9 kilovolt switchgear, 1,100 low-voltage motors, 1,900 motor starters in 270 switchgear panels, and 250 Sinamics frequency converters as well as multiple-motor drive systems also sup-plied via Sinamics inverters for the pulp drying machines PD2 and PD3, each with 31 drives. In addition to being responsible for engineering all the systems as well as for installation and commissioning, Siemens will also support the customer during the start-up phase.

With the new pulp line, APRIL will boost its production capacity in Rizhao, where a smaller pulp line for around 300,000 met-ric tons per year and a board machine with an annual capacity of 170,000 metric tons are operating. p

www.siemens.com/sinamics

At the Platin location in Drogheda, which is around 50 kilometers north of Dublin, the largest cement producer in Ireland, Irish Cement Limited, is building a new kiln line and is modernizing existing installations

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National Corn-to-Ethanol Research Center partners with Siemens

Fuel for Growth

The National Corn-to-Ethanol Research Center (NCERC) and Siemens recently announced a partner-ship to speed the development of alternative fuel technology. The 10-year agreement between the cen-ter and Siemens represents hundreds of thousands of dollars in equipment, software, and on-site simula-tion training.

The Simatic PCS 7 distributed control system and instrumentation from Siemens are now being used by the NCERC to help validate near-term technologies that are enhancing the economics and sustainability of renewable fuel production.

“Our clients come to this facility for best-in-class, cutting-edge technology,” says John Caupert, director of the NCERC. “They are looking for the newest and most effi cient ways to convert grain-based feedstock to ethanol. Through our partnership with Siemens, the center will maintain that level of technology.” p

www.sea.siemens.com/biofuels

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Siemens will equip the Platin cement factory of Irish Cement Limited in Drogheda, which is around 50 kilome-ters north of Dublin, with an automa-tion system worth around two million euros. The project includes complete automation of a new kiln line (Kiln 3).

The work involved in equipping line 3 is scheduled for completion in sum-mer 2008. Line 2 is to follow around seven months later. One of the reasons the contract was awarded to Siemens was the capability of Siemens to carry out the project within the short time frame that the customer specifi ed. For the new kiln line 3, Siemens is plan-

ning and delivering all the automation equipment. On the existing kiln line 2, the Simatic S5 controllers will be re-placed with Simatic S7 controllers and the software will be uniformly up-graded to the current version of the Simatic PCS 7 process control system. Modernization of line 2 will mostly be carried out without any interruption of operations. After completion of the project, the two lines will be equipped with the version 7 of the Simatic PCS 7 process control system. p

www.siemens.com/cement

Simatic PCS 7 system for cement factory near Dublin

Success at Irish Cement

I n B r i e f


onlineOn the Internet at

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

PublisherSiemens Aktiengesellschaft,Gleiwitzer Str. 555, 90475 Nuremberg, Germanywww.siemens.com/automation

Drive Technologies DivisionCEO Klaus Helmrich

Industry Automation DivisionCEO Anton S. Huber

Responsible for ContentPeter Miodek

Responsible for Technical ContentCornelia Dürrfeld

ConceptChristian Leifels

EditorCornelia Dürrfeld, Siemens AG, A&D CC P MC Siemensallee 84, 76187 Karlsruhe, GermanyTel.: +49 (0) 7 21 5 95-25 91Fax: +49 (0) 7 21 5 95-63 [email protected]

Editorial CommitteeAlexandre Bouriant, Cristina Cerrato Accomazzo, Sigrun Ebert-Heffels, Petra Geiss, Michael Gilluck, Birgit Gottsauner, Walter Huber, Bernd Langhans, Ivonne Luthardt, Rüdiger Selig, Todd Stauffer, Roland Wieser, Eugene Yeo

Publishing HousePublicis KommunikationsAgentur GmbH, GWACorporate Publishing Medien 1 P.O. Box 3240, 91050 Erlangen, GermanyTel.: +49 (0) 91 31 91 92-5 01Fax: +49 (0) 91 31 91 92-5 [email protected]

Editor in chief: Kerstin PuruckerLayout: Jürgen StreitenbergerCopy editing: Irmgard Wagner

DTP: der Döss für Kommunikation, NurembergPrinting: Hofmann-Infocom, Nuremberg

process news is published quarterly.

Cover photo: daj

Circulation: 32.000Job number: 10687

© 2008 by Siemens Aktiengesellschaft Munich and Berlin, Germany.

All rights reserved by the publisher. This edition was printed on environmentally friendly chlorine-free paper.

ISSN 1430-2292 (Print)

The following products are registered trademarks of Siemens AG:CALOMAT, MASSFLO, MICROMASTER, OXYMAT, PCS 7, S7-300, S7-400, SIMATIC, SIMATIC IT, SINAMICS, SITRANS, SIVACON, TOTALLY INTEGRATED AUTOMATION, WinCC

If trademarks, trade names, technical solutions, or similar are not listed above, this does not imply that they are not registered.

The information provided in this magazine contains merely general descriptions or characteristics of performance, which in the case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteris-tics shall exist only if expressly agreed in the terms of contract.

IWI: TPOG Order No.: E20001-M6208-B100-X-7600Printed in Germany

process news 2-2008

events2008 Siemens Automation Summit

Inside Knowledge

Following the successful 2007 Automation Summit in Florida, the 2008 Siemens Automation Summit – A Users Conference – will be held in Chicago, Illinois, from July 23 to 25.

Attendees will have the opportunity to de-velop and share strate-gies for successful life-cycle management of their systems and learn how to increase produc-tion effi ciency, optimize plants, and improve process control.

Moreover, the sum-mit provides a platform for discussions of in-dustry best practices, targeted training and strategy sessions, and in-depth presentations by technology and manufac-turing experts. Specifi c formats include product tips and tricks, workshops, user application stories, and discussions of product road maps, with plenty of time for providing input into the future direction of Siemens products.

For more information and to register, please visit www2.sea.siemens.com/summit

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

www.siemens.com/processautomation

Co

rbis

D i a l o g u e

Answers for industry.

Our innovations combine virtual product planning with state-of-the-art factory automation for more flexibility in production. This also allows individual customer wishes to be realized cost efficiently. You are also welcome to visit us in hall 9 booth A72.

Here is the short cut.

There are many ways to increase the productivity of your company.

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