RP93 EN Screen · 2009-11-24 · a few years ago, the Gold Coast City Council (GCCC) in Queensland, Australia, realized that if it didn’t tackle ... Queens land’s capital, population

Volume 14, Number 3, 2009

The Magazine for the Process Industry

Australia: Simatic technology helps protect resources on the driest settled continent

Water Future

The Magazine for the Process Industry

Volume 14, Number 3, 2009

newsprocess

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Pimpama Coomera is assured of a secure water supply thanks to a distribution and treatment solution using Simatic PCS 7

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The City of Luxembourg upgraded one of its water treatment plants with Siemens automation and instrumentation systems

Page 20

Elan Software implemented an MES solution for paperless manufac-turing for Baxter Healthcare in Ireland

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p r o c e s s n e w s | 3 - 2 0 0 9

2 process news | 3-2009

Cover

Australia 4 A Golden Future

Gold Coast City Council, Australia

8 Thirst for KnowledgeWater Corporation, Australia

10 Underwater PrecisionSydney Water, Australia

12 Cream of the CropBulla Dairy Foods, Australia

14 Time-to-Market BenchmarkIDT, Australia

16 Passing the Acid TestHenkel Adhesives, Sealants and Surface Treatments, Australia

18 A Safer ProcessTasmanian Electro Metallurgical Company, Australia

19 Living with Simatic PCS 7Qenos, Australia

Industry

Water Treatment 20 Small Plant with Huge Impact

City of Luxembourg, Luxembourg

Pharmaceutical Industry 22 Precision Filling

GlaxoSmithKline, Italy

Technology

Manufacturing Execution Systems 24 Paperless Manufacturing

Baxter Healthcare, Ireland

Process Control 26 Performance Tools

Simatic PCS 7 APC portfolio

Process Analytics 27 Tested Measurement

In situ measurement technology for engine test benches

Process Instrumentation 28 Water Assets

Flow measurement

29 In brief 31 Dialogue

process news | 3-2009 3

E d i t o r i a l

Dear Readers:

There is no question that the global challenge of environmental sustainability is among the most pressing issues that we are currently facing. In Australia, the sustainable and secure supply of water and energy has been identified as one of the most critical areas to address for our future.

In collaboration with our global Pictures of the Future research experts, our team of local researchers has examined the unique conditions facing Australia in the areas of water and energy and determined – from a technology perspective – what we believe to be the solutions for a sustainable and environmentally responsible supply mix for Australia in 2020 and beyond.

Throughout the world, Siemens innovations are already contributing to solving our environmental challenges. For example, Siemens Memcor membranes have long dominated the water reuse industry and are one of Australia’s great technology success stories. Now this extensive knowledge and experience in low-pressure membrane filtration technology are being used to provide energy-efficient and chemical-free filtration for seawater desalination.

Another case in point is the installation of Simatic PCS 7 in the Pimpama wastewater treatment plant, which has enabled the Gold Coast City Council to significantly reduce the use of drinking water for nonpotable applications, as well as keeping chemical usage to a minimum.

Siemens is committed to long-term collaboration with our customers and remains an active and responsible corporate citizen. With our innovative, technology-based solutions we will support our customers in achieving their environmental targets, and continue to make a marked contribution in securing a sustainable environment for future generations.

Yours,

Albert Goller

Managing Director and Chairman

Siemens Australia and New Zealand


C o v e r A u s t r a l i a

P i m p a m a W a t e r f u t u r e M a s t e r P l a n

Providing sustainable solutions for the urban water cycle, including

– Rainwater – Stormwater – Drinking water – Wastewater – Recycled water

Homes and businesses now built with two water supply networks:

– Drinking water network – Class A+ recycled water network

New wastewater and recycled water treatment plant

– Water goes through multiple process steps – Automation solution: Simatic PCS 7 system

with AS 417H CPU, networking via Profibus


When in the grip of the worst drought in liv-ing memory and with reservoir levels at their lowest ever, yet faced with a growing

population and increasing demand for water, it would be fair for water authorities to simply focus on main-taining supply. However, faced with this very scenario a few years ago, the Gold Coast City Council (GCCC) in Queensland, Australia, realized that if it didn’t tackle the problem in a proactive and environmentally re-sponsible manner, today’s problem would be a much bigger headache in years to come.

GCCC’s forward-thinking, socially and environmen-tally responsible decision resulted in the award-win-ning Pimpama Coomera Waterfuture Master Plan, which is now in the final stages of implementation. Pimpama Coomera is seen as the next major growth corridor in the rapidly expanding Gold Coast region. Located almost 50 kilometers south of Brisbane, Queens land’s capital, population growth is expected to rise from 15,000 to 150,000 by 2056. In fact, the en-tire Gold Coast is likely to experience a massive pop-ulation growth, from 500,000 to 1.2 million, in that same period. This means that both domestic and in-dustrial water consumption will increase exponen-tially, and with drought now a common occurrence in Australia, this is a major challenge.

The Pimpama Coomera Waterfuture Master Plan is a blueprint for sustainable water use in the area. It was devised to provide an integrated and sustainable solution for all elements of the urban water cycle, in-cluding rainwater, stormwater, drinking water, waste-water, and recycled water, and to introduce new water sources for appropriate uses.

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Gold Coast City Council, Australia

A Golden FuturePimpama Coomera is assured of a secure

water supply into the future thanks to an

innovative distribution and treatment

solution controlled by Simatic PCS 7.


All new homes and businesses are built with a separate water supply network for Class A+ recycled water

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Building for the future

Since 2005, all new homes and businesses in the Pim-pama Coomera area have been constructed with two separate water supply networks connecting them to both drinking water and Class A+ recycled water net-works. Class A+ water is highly treated with multiple process steps so that it meets Queensland’s tough en-vironmental and health guidelines; it is the highest class of recycled water in Queensland.

In addition, a new wastewater and recycled water treatment plant was built at Pimpama. This plant was designed to deliver Class A+ recycled water for spe-cific nondrinking purposes, such as toilet flushing, to dual-reticulated homes and businesses in the area.

Providing sustainable control for a sustainable plan

To provide this important facility within the tight time-scales required, GCCC selected United Group Ltd. – Infrastructure (UGL) to join the public water authority, Gold Coast Water, in the Watercycle Alli-ance to build the plant. UGL is one of the largest in-tegrated engineering, construction, industrial main-tenance, and facilities management businesses in Australia, offering a range of water-related services to meet clients’ needs. With its combined experience in design, construction, and operation of many water and wastewater treatment plants around Australia, this team was clearly the ideal choice for such an im-portant and complex project.

GCCC also selected the Simatic PCS 7 process auto-mation system early in the process. The council had already used Simatic PCS 7 when it built its Coomba-bah and Merrimac wastewater treatment plants, and the results had been very positive. It was the high standard of automation Simatic PCS 7 provides, plus the system’s user-friendliness and operator satisfac-tion, that made it the preferred option for the Pim-pama project. UGL’s highly experienced in-house in-tegration group was also keen to use the system, and the members tackled their first Simatic PCS 7 project with verve and determination.

As UGL’s Karen Eaton explains, the owners of water and wastewater plants need simple, intuitive opera-tor interfaces, which the Siemens system readily pro-vides. “It is essential in the water industry to be able to react rapidly and economically to new demands. With our extensive systems integration capabilities, UGL is able to develop advanced systems, such as Simatic PCS 7, rapidly and efficiently to meet complex customer-specific requirements. This is especially rel-evant in fast-tracked Watercycle Alliance project envi-ronments,” says Eaton.

The Profibus fieldbus system was used extensively in order to achieve the highest levels of operational efficiency from the plant for instrumentation, drives, and motor control. Combined with the power of Simatic PCS 7, the enhanced levels of diagnostics give exceptional levels of performance data and provide the basis for an effective maintenance philosophy for the plant. Profibus provides the speed, reliability, and flexibility to manage such data requirements, as well as the surety of a technology that is widely used and the ability to combine control, instrument, and elec-trical infrastructures under one simple communica-tions structure.

The Pimpama Wastewater Treatment Plant was de-signed to achieve very high levels of operational effi-ciency and reliability. As such, a decision was made to implement high levels of protection through redun-dancy at critical points in the system. Plant servers, plant communications, and the high-availability main controller with a powerful PCS 7 417H CPU were used in redundant configurations. The redundant control-ler units of the PCS 7 automation system were installed


infocontact

www.siemens.com/[email protected]

» The integration of all major control

elements, allowing ongoing

flexibility for system development,

was a key requirement in selecting

Simatic PCS 7 as our preferred

system. « L. Wells, electrical and control systems coordinator, Gold Coast Water

The treatment plant helps recycle water by providing treated water for nondrinking purposes

in different physical locations to further improve avail-ability. Connected to each other by fiber- optic synchro-nization cables, the PCS 7 processors provide high-speed, high-availability setup, thus facilitating the process of configuration changes and device additions while the plant is running.

When developing the application, UGL’s engineers also paid particular attention to the plant operator’s needs. Simatic PCS 7 provides a range of user-friendly tools to ensure easy navigation between plant areas and ready access to plant diagnostic information. The use of the sequential function chart visualization tool also provides an efficient means of tracing plant se-quences. In addition, the Smart Alarm Hiding function ensures that alarm deluges do not overwhelm plant operators.

Reaping the rewards

Through implementation of Simatic PCS 7 and Profibus, UGL’s systems integration team was able to meet the plant’s stringent demands. GCCC’s innovative ap-proach to the sustainability of its water supplies is al-ready starting to reap rich rewards, which will be magnified many times over in coming years as the Pimpama Coomera area develops. By providing a sus-tainable solution for all elements of the urban water cycle, GCCC is playing an active role in environmen-tal and social management. Now the residents of the Pimpama Coomera district can be assured of a sus-tainable water future.

A critical unit for ensuring water supply safety: the new treatment plant that provides highly treated Class A+ water


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

Facing the worst drought in decades in 2005, Western Australia’s water company, Water Cor-poration, needed to take positive steps to allevi-

ate the immediate lack of water and to ensure a secure supply for the future. After weighing all the options, desalination was seen as the logical solution.

The project team opted for a seawater reverse os-mosis plant, as such plants are more efficient, use less power, and are more compact than traditional thermal desalination plants. The contract for a 45-gi-galiter-per-annum plant at Kwinana Beach went to a joint venture between Degrémont SA of France and Multiplex Engineering Pty. Because Water Corpora-tion wanted to keep the power consumption of this

energy-intensive process to a minimum, innovative energy recovery was required.

The project was conducted in two stages: design and construction, and operation and maintenance. Build schedules were tight, with fewer than 18 months to deliver Phase 1, and there were strict requirements to maximize operational effectiveness. It was vital that the control and electrical systems were highly re-liable, capable of managing the complexities of the process effectively, and able to provide the depth of information needed to make all aspects of the plant transparent. Simatic PCS 7 and Profibus have an ex-tensive track record in desalination, so it followed that these technologies were chosen for this project.

Water Corporation, Australia

Thirst for KnowledgeIn a prestigious project that won a Zenith Award in 2008, one of the largest reverse

osmosis desalination plants in the Southern Hemisphere benefits from detailed

process information provided by Simatic PCS 7 and Profibus. The plant is also very

eco-friendly, as it is powered by renewable wind energy.

T h e a u t o m a t i o n p r o j e c t

Simatic PCS 7 PCS 7 Web server 300 Profibus PA instruments Sinamics G150 drives Simocode motor starters


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The Simatic PCS 7 environment provides detailed diagnostic data access to all key components for efficient plant operation

Easy diagnostics

Profibus brings together electrical and instrument communications in a single bus system, which is very important to a plant with more than 300 Profibus PA instruments, multiple Sinamics G150 drives, and an array of intelligent Simocode motor starters. This sys-tem provides Water Corporation with access to a wider range of diagnostic information, thus acting as an en-abler for predictive maintenance, which is key to en-suring that all of the plant’s demands are met.

With a 25-year operational and maintenance license to run the plant, Water Corporation needed the guar-antee that the lifecycle considerations of the selected process automation system would be taken into ac-count. Simatic PCS 7 is part of the Totally Integrated Automation family; thus, as technology advances, key components will always be designed to be backward compatible. This means that compatible replacements are available, extending the life of the system beyond normal expectations and reducing the total cost of ownership.

To meet the plant’s stringent operational require-ments, four sets of redundant high-availability PCS 7 controllers were used, with redundant Industrial Eth-ernet and Profibus networks. According to Degrémont engineer Eric Garcin, “PCS 7 allows access to all inter-nal parameters from a single point, which also is a major advantage during commissioning. At such a critical point in the project, ease of access in this man-ner can drastically reduce the time required to com-mission devices of all types.”

Completion on schedule

Bloch Technologies, a company well known to both Water Corporation and Siemens and with a strong track record of delivering projects on time and within budget, was appointed to undertake the system inte-gration. The first water was delivered on time in No-vember 2006. PCS 7 allowed Bloch to define a data structure that is easily accessible by the numerous management information and reporting packages, in-cluding detailed reporting from an environmental perspective, as well as plant performance and diag-nostic data access to all key components.

When completed, the plant was the largest of its kind in the Southern Hemisphere and the third larg-est in the world. It is also extremely eco-friendly, as it is powered by renewable electricity generated by Emu Downs Wind Farm near Cervantes on the Western Australia coast.

» Power monitoring is a major issue. If managed correctly, it can lead to significant

power and cost savings. Through the use of the extensive information available

from key devices, power intensity and power factor can be monitored, enabling

efficient reconfiguration of power usage. « Eric Garcin, Degrémont

Quenching the thirst

The plant was officially opened in April 2007, when the business of day-to-day plant operations started in earnest. Operations and maintenance personnel added a PCS 7 Web server to extend their coverage. The server gives them the tools to access plant data off-site in a secure environment, which aids plant maintenance, especially outside normal working hours, and provides access to plant parameters for op-timization or reporting purposes.

Less than 12 months after its formal opening, plant director Greig Mercer points out that the plant is “ex-ceeding output expectations”, which is testament to the advanced level of technology employed across the plant. The spirit and expertise of the project team and the excellent performance of the facility were also noted on a broader level: the facility won a prestigious PACE Zenith Award in the water and wastewater cate-gory in 2008. The plant provides extensive environ-mental and operational data in order to meet the de-mands of the plant as well as environmental agencies. Such data can only be made available through em-ploying one of the most powerful integrated process control and device solutions, combined with market-leading bus technology – technologies that were de-signed to quench even the most voracious thirst for knowledge.


The Sitrans F M flowmeters

(left top) enable high-precision

monitoring of water outflow and

inflow in the tanks

The installation work in the

tanks was performed by divers.

Prefabricated assemblies simpli-

fied the work considerably

(top right, middle, right)

One of the reservoirs of Sydney

Water that was equipped with the

Sitrans devices (far right)

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Sydney Water, Australia

Underwater PrecisionBy fitting flowmeters inside its reservoirs,

Sydney Water improved the management

and utilization of its water assets without

disrupting supply.



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

Water is a precious resource, especially when dry conditions create the combination of peak demand and reduced availability. To

improve its water management and conservation, Sydney Water needed to find an accurate and effective way of measuring the inflow and outflow of water through its reservoirs.

The traditional way to install flowmeters at a reser-voir is to dig up the pipe work and build new valve pits. This involves emptying the reservoir and is labor intensive and disruptive. Sydney Water found a bet-ter solution by fitting Sitrans F M electromagnetic flowmeters. The F M MAG 5100 W flowmeter is ideally suited for water applications and can be supplied with an EPDM liner specifically for drinking-water applica-tions requiring special approvals.

The Sitrans F M MAG 5100 W sensors were adapted for this application with a customized junction box on top of the mag sensor supplied by SFI Stonehouse. This design is unique in the market and was initially developed for North Sea offshore applications. It is double sealed and is waterproof to 30 meters without potting. The inside cabling was fully potted in Austra-lia for the application. Sydney Water installed more than 10 internal flowmeters to both inlets and outlets in its reservoirs. With the F M MAG 5100 W meters, it is possible to fit the flowmeters inside the reservoirs while they remain full of water. Moreover, by fitting the flowmeter inside the reservoir, it is possible to fit a single meter to the main outflow before it splits into multiple pipe connections.

Installation dive

Each reservoir presented a variety of wall- or floor- located outlets; uneven floor areas; and obstructing walls, posts, and floor joints. Following site surveys, custom-made pipe work, adapters, and supports were constructed for each installation. The entry and exit pipes of high-density polyethylene (HDPE) were made to a length of three times the flowmeter diameter at entry and exit to ensure a laminar flow through the meter. These pipes were tapered to ensure a mini-mum flow rate of 0.25 meters per second through the meter for measurement accuracy.

After the first installation, when divers did much of the assembly work under water, the team decided to fabricate complete assemblies in a factory environ-ment, even though this involved handling large as-semblies on-site. For some larger units it was neces-sary to remove roof sheets from the reservoirs to gain access. This inconvenience was more than outweighed by shorter dive times, especially in cold winter tem-peratures.

Once in the water, complete units weighing up to 1,000 kilograms could be “walked” around inside the reservoir using flotation lift bags to take the weight. The first stage was to mount an HDPE adapter flange

to the existing outlet and bolt and epoxy seal it in place. The flowmeter assembly was then moved into position and bolted to the inlet or outlet penetration. After supporting legs had been fixed in place, the weight could be transferred from the lift bags.

Lifetime calibration

A stainless steel guide wire was run from the control unit on the flowmeter up to the reservoir roof. Heavy-duty marine cables were then attached and connected. The Sitrans flowmeter features a Sensorprom mem-ory unit that stores sensor calibration data and trans-mitter settings for the lifetime of the product. Using this feature, each flowmeter could be set up on com-missioning and left to transmit flow measurements without any further supervision. All the flowmeter in-stallations were completed successfully without dis-rupting water supplies or requiring major work – a success enabled not least through the commitment and excellent performance of the Australian Siemens team with Col Gassman, Allan Pogonowski, and John Kearton. Now, after 18 months’ operation, the data provided by the Sitrans flow-meters have enabled Sydney Water to achieve significant savings and effi-ciency improvements.

S i t r a n s F M M A G 5 1 0 0 W e l e c t r o m a g n e t i c f l o w m e t e r

Suitable for measuring the flow of almost all electrically conducting liquids, pastes, and slurriesMeasurements independent of temperature, pressure, density, and viscosityAvailable in nominal sizes ranging from DN 25 to DN 1200 (from 1” to 48”)Rugged hard rubber liner for all water and wastewater applicationsEPDM liner specifically for drinking-water applications requiring special approvals (MID [EU], OIML R49, and MCERTS)Increased low-flow accuracy for water leakage detectionSuitable for direct burial and constant flooding (IP68)Integral grounding electrodes as standard Easy commissioning, as Sensorprom unit automatically uploads calibration values and settingsVerificator unit for verification and performance testing


Bulla Dairy Foods, Australia

Cream of the Crop

Bulla Dairy Foods is an Australian-owned family company producing premium-quality dairy products. Since 1910, it has manufactured

cheeses, yogurts, and ice creams in Colac, Victoria. Bulla Dairy Foods is one of Australia’s most recog-nized dairy brands and is also established in the Asia-Pacific region.

Monitoring and tracking challenge

Bulla Dairy Foods has 160 stock-keeping units (SKUs), of which 99 percent are manufactured in a seven-day cycle. This strenuous production cycle requires im-mense planning, execution, monitoring, and docu-mentation in order to achieve the required produc-tion quotas in a smooth process.

This demanding task was not made any easier by the company’s paper-based documentation system. Bulla realized the pressing need to develop a secure, reliable, and efficient manufacturing execution sys-

Happy with its Siemens automation, Australia’s renowned dairy manufacturer

took the next step and increased plant efficiency even further.


» With this new MES, we can enhance

our output by having a more detailed

understanding of the impact of

running various products on the line

at various times. « James Downey, operations manager, Bulla Dairy Foods


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The new Simatic IT system at Bulla Dairy was welcomed for its ease of use – from management to plant operators and maintenance staff

tem (MES). This system would streamline the docu-mentation process, convert all systems to electronic format, and provide data for strategic business man-agement, enabling operators to easily manage pro-duction. Upgrading the system would also minimize disruptions and problems.

Upgrading production efficiency

Bulla Dairy Foods had already used Siemens technol-ogy in 2002 to automate its state-of-the-art chilled dairy plant. Because Bulla was extremely satisfied with Siemens programmable logic controllers and service, the company chose Siemens again to deliver the new MES. In particular, Bulla wanted to integrate the existing factory control system with the new MES system planned for the production process and knew that Siemens’ suite of technology solutions would make this migration easy.

Bulla was impressed with Siemens’ long-term view of the project. Siemens thoroughly assessed the com-pany’s entire production plant, with particular focus on long-term benefits, cost-effectiveness, and opera-tional efficiency. Bulla found that Siemens’ detailed understanding of production philosophies was un-paralleled in the industry.

Initially, Bulla committed to a pilot MES project that concentrated on the plant’s overall equipment effec-tiveness. If this pilot was successful, Bulla intended to use the software across the entire plant. The Simatic IT MES is a key means for manufacturers to optimize production while efficiently managing and improving the complete supply chain. More important, it does this in real time. Simatic IT harmonizes and inte-grates all production processes by synchronizing and simplifying them so that they are more flexible and effective.

Using Simatic IT also reduces island solutions, paper-related methods, and nonstandard processes, while providing a seamless connection between pro-duction and business processes. It creates user- oriented key performance indicators (KPIs), making the production process more effective.

Versatile and easy-to-use reporting options

After a smooth installation, with Siemens providing on-site support and the flexibility to make last-minute changes, Bulla Dairy Foods was more than pleased with its new, world-class system. The new system was welcomed by everyone – from plant oper-ators to maintenance employers and management – for its ease of use.

The newly installed Simatic IT system provides practical and useful reports, such as “Top Five Down-time Causes by Reason,” as well as customized reports specific to Bulla. One such customized report moni-tors production output against targets on a second-by-second basis, enabling the plant to identify areas of high and low production. Another mimics the for-mer paper-based system so that enterprise resource planning-related data can be maintained.

With the completion of the pilot system, Bulla Dairy Foods was able to identify and rectify many long-standing downtime causes that had been hidden for years. The company managers can now see detailed and macro trends in their facility, which al-lows them to better identify problems and facilitate solutions.

K e y p o i n t s

Bulla Dairy Foods maximized its plant performance by installing Simatic IT MES.Simatic IT increases operational excellence through standard KPI measurement, optimization, and exception handling.Simatic IT provides product safety and traceability, as well as real-time interoperability, to standardize processes and exchange information across the manufacturing operation.

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IDT, Australia

Time-to-Market Benchmark

V ictoria-based IDT, formerly known as Insti-tute of Drug Technology Australia Ltd., pro-duces high-potency drugs for research and

development, clinical trials, and commercial supply. All IDT production complies with Good Manufactur-ing Practice (GMP) regulations. IDT, one of the few drug manufacturers that can deliver drugs on a flex-ible scale or one-off run, is particularly attractive to pharmaceutical companies that only have facilities for large batches and long production runs.

Many hurdles

IDT wanted to increase production capacity tenfold. However, its available budget was limited to AU$ 10 million, and the project requirements were high.

Simatic technology helps set up a facility for manufacturing new active

pharmaceutical ingredients in record time, ensuring future success in a business

where time to market is critical.

When developing the new facility, IDT had to conform to both local and international regulatory standards

– from Australia’s Therapeutic Goods Association (TGA) and the US Food and Drug Administration (FDA) – for traceability of production and engineering. With high-potency drugs, even the smallest amount has therapeutic significance, so containment is crucial for laboratory and production areas. In addition, be-cause potentially explosive materials are used, the fa-cility was classed as a Zone 1 hazardous area. Finally, although drug batches are small, their dollar value is high. A small batch of drugs could be worth mil-lions. This posed another challenge to IDT – finding the appropriate automation solution that would be capable of handling the processing of the drugs with-out jeopardizing quality. The importance of process

» The return on investment

for this project is based not on

the outlay for the facility, but

on the reduced time to reach

full production of high-potency

drugs at the new facility. « Jacob MacDonald, project and validation manager, IDT

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From left to right:

Marek Lisik, PCS 7

product manager,

Siemens, Jacob

MacDonald, project

& validation

manager, IDT; and

Chris Vains, HMI

product manager,

Siemens



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control in the new facility was a critical requirement to ensure that the high-value goods were appropri-ately handled and maintained. Adding to all this, the long lead times of European-sourced processing equip-ment meant the process control system had to be in-stalled and operational within a short time frame.

Integrating strengths

To address these issues, IDT opted for a standardized architecture based on Simatic technology. Previous collaboration with Siemens had resulted in positive outcomes that led IDT to appreciate Siemens’ reliabil-ity in offerings and service delivery. IDT ensured easy integration by requesting that all individual equip-ment suppliers use Simatic S7-300 as their automa-tion platform and Simatic WinCC as the Supervisory Control and Data Acquisition (SCADA) solution. Simatic Logon and WinCC Audit options would provide strict access control and an audit trail of production and en-gineering activities, which are needed to comply with TGA and FDA regulations.

The integration of the separate systems of the pro-duction equipment sourced from several manufactur-ers across Europe turned out to be relatively straight-forward compared with other products, and the SCADA was easy to modify and program – both of which were attractive features for IDT. The close proximity of Siemens’ Australian headquarters in Bays-water, Vic-toria, proved helpful, as local, on-hand support and service were especially crucial given the short time frame in which the process control system had to be installed.

Engineered and installed by systems integrators ZI-ARGUS and ARA Electrical, the Simatic-based auto-mation solution provided a robust, compliant, and in-

tuitive process control system that enabled IDT to achieve its production goals. With the help of these two companies, the automation solution was imple-mented on time. This solution included communica-tion between the OEM-supplied machinery and con-figuration of the plantwide human-machine interface (HMI) based on Simatic WinCC, Logon, and WinCC Audit, enabling IDT to achieve GMP compliance.

Benefits for today and tomorrow

With improved automation systems and production auditing in place, IDT can provide drugs for clinical trials and for research and development in shorter time frames. This will ultimately benefit end users due to shorter time-to-market cycles and faster drug development. IDT was able to win a contract from a multinational client in large part because IDT’s time to design, install, and qualify for FDA standards was just 15 to 18 months, which is much less time than is taken by a multinational company.

Collaborating with Siemens and its partners has en-abled IDT to build its system knowledge and to estab-lish the automation standards that will assist in any future system modifications. The positive feedback from plant operators has also confirmed their accep-tance of the automation system. Users are particularly pleased with the system’s design and operator inter-face.

With improved

automation systems

and production

auditing, IDT can

provide drugs in

shorter time frames


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Henkel Adhesives, Sealants and Surface Treatments, Australia

Passing the Acid TestSimatic PCS 7 helps Henkel Australia obtain an award-winning control system that

ensures worker safety at a hydrofluoric acid facility and metal pretreatment plant.

C o v e r A u s t r a l i aA w a r d - w i n n i n g s y s t e m

Recognizing the system’s excellence, Australia’s Process & Control Engineering (PACE) Web site awarded Henkel and ZI-ARGUS the 2008 Zenith Award in the category of chemicals and petrochemicals.The annual PACE Zenith Awards were established by PROCESS & CONTROL ENGINEERING magazine to publicly recognize and reward companies that show leadership in engineering and technological excellence and innovation. The Zenith Awards are the most prestigious awards program specific to process, control, and automation across the main industries.


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The manufacturing plant in Kilsyth, Victoria, is one of the Henkel Group’s eight facilities across Australia and New Zealand. The plant

manufactures specialized adhesives and sealants for a broad range of industries. As part of its plans to de-velop a new hydrofluoric acid facility, Henkel Austra-lia required a new, modern batch control system, as well as a system upgrade for the existing metal pre-treatment plant in its Kilsyth facility.

Henkel intended to implement an integrated sys-tem that would provide the platform for a standard-ized and holistic approach in operations and control across the entire plant. The company sought a system that was user-friendly, modern, and well supported. Topping Henkel’s objectives was its commitment to ensuring the highest level of process and factory safety, in adherence to the company’s stringent inter-nal safety requirements. The key challenge was to up-grade the plant with minimal disruption to produc-tion and at a reasonable cost.

Committed to the highest standards

In close consultation with Siemens, Henkel chose an integrated control and safety system (ICSS) solution based on the Simatic PCS 7 process control system. The specific attraction was the system’s ability to com-bine conventional process control, batch control, and high-integrity safety functions on a common automa-tion platform. Moreover, Simatic PCS 7 is a fully inte-grated system, made up of modular hardware and software components that can be cost-effectively scaled and adapted to any process plant size and lay-out. This was an important aspect, as Simatic PCS 7 will also satisfy Henkel’s growing needs in the future, including integration into enterprise resource plan-ning and manufacturing execution systems.

Global expertise and local performance

Henkel Australia awarded the contract to design and deliver a modern batch control system for the Kilsyth plant to ZI-ARGUS, a globally active automation solu-tion provider with offices in Europe, Asia-Pacific, and Australia. Starting in September 2007, the engineer-ing teams of ZI-ARGUS and Henkel worked closely together to develop the state-of-the-art automation solution, which included Simatic Safety Matrix for im-plementing the process system safety interlocks and Simatic PCS 7 Web Client operator stations.

ZI-ARGUS designed and managed the turnkey solu-tion, with full electrical design, including safety sys-tem and Safety Integrity Level 2 instrumentation, electrical installation, supply of sensors, and Simatic PCS 7 software configuration and testing. The sophis-ticated process control solution had to be implemented under tight time frames, with minimal disruption to

production. The legacy programmable logic control-ler I/O was left in place to operate in tandem with the new facility, with a Profibus communication interface replacing the original processor at the end with easy swap over.

An award-winning foundation for growth

With the implementation of Simatic PCS 7, Henkel was delivered a fully integrated system that manages all plant control, batching, and safety requirements.

The facility now benefits from improved production transparency, not only within the plant itself but also with management. The graphical continuous function chart and safety matrix software is easily understood and accessible by engineers for troubleshooting.

The new control system is also a major milestone toward Henkel Australia’s vision of “Smart Operator

Interface,” which uses Web technology to combine pro-cess controls, work instructions, inventory manage-ment, and efficiency and downtime management. With the core platform now firmly established, any exist-ing and future plant additions can be progressively integrated, resulting in a system that grows with Hen-kel’s expanding capacity and market needs.

With uniform operator interfaces, Simatic PCS 7 ensures high plant and process visibility and contributes to maximum process safety


infocontact

www.siemens.com/processanalytics [email protected]

Phot

o:

TEM

CO

Tasmanian Electro Metallurgical Company, Australia

A Safer Process

Tasmanian Electro Metallurgical Company (TEMCO), which is owned by BHP Billiton, is located 50 kilometers north of Launceston,

Tasmania. This facility is the only manganese ferro-alloy plant in Australia. TEMCO ensures its high stan-dards through international certification of its qual-ity, environment, and safety management systems and a number of BHP Billiton management systems.

Critical safety issues

In line with its company policy, TEMCO places great emphasis on continually improving process safety, especially because the processing of manganese ferroalloys involves some very complex and poten-tially very hazardous procedures.

To address some of these critical safety issues for the mineral processing industry, TEMCO has trialed the LDS 6 diode laser gas analyzer over the past 18 months. The driving force of the trial was to address critical safety issues, such as TEMCO’s submerged arc furnaces, which were identified as the most danger-ous application within BHP Billiton worldwide. With submerged arc furnaces, water used to cool furnace components leaks into the furnaces over time, caus-ing a buildup of water in the furnace charge. Eventu-ally the water comes into contact with molten materi-als, triggering a steam explosion.

Monitoring process safety in harsh conditions

TEMCO approached Siemens for help in finding a monitoring solution to prevent this critical process state. The challenge was to find an analyzer that could perform under the most extreme conditions, such as temperatures of 500 degrees Celsius, as well as high water and dust levels in the presence of tar and other carbon volatiles. Together with a team of experts from Germany, Sweden, and Australia, the Siemens process instruments team adapted the LDS 6 analyzer to work in an application that had never been tried before.

With the LDS 6 analyzer unit installed, BHP Billiton engineer Paul Dennis was able to develop a safety pro-

cedure to handle any increase in water levels. Now, when the first increase in water levels in the furnace is detected, the plant control systems alert the fur-nace operators, who can then take action to reduce any operational risk. In a recent alert by the plant con-trol system, the investigation team detected a large hole that was causing a rapid rise in water levels in the furnace. The team confirmed that without the gas analyzer, pressure would have built up, and the furnace would have exploded.

The TEMCO plant is the only manganese ferroalloy plant

in Australia

In an innovative adaptation of this in situ measuring technology, the LDS 6

analyzer helps ensure process safety in a Tasmanian mineral processing facility.


Award-winning solution

After seeing such an impressive record of improving process safety, management at BHP Billiton has ex-pressed its appreciation of the TEMCO initiative: Paul Dennis recently won a BHP Billiton safety award for his work with the LDS 6. In addition, BHP Billiton now plans to install LDS 6 units at other mineral process-ing sites.



Qenos, one of Australia’s largest plastics and rubber companies, manufactures raw mate-rials for numerous household, consumer,

and industrial products. The company’s manufactur-ing plants in Sydney and Melbourne produce olefins, polyethylene products (HDPE, LDPE, and LLDPE), and a diverse range of specialty polymers. In 1999, Qenos implemented a new Simatic PCS 7 system in its resins plant in Altona, Victoria, and was also the first com-pany in Australia to install a redundant PCS 7 system. Qenos was extremely satisfied with its new system, and nine years on, the adaptability of the integrated Simatic PCS 7 process control system has enabled a successful new upgrade to be applied, boosting pro-ductivity and quality.

Upgrading the system

When Qenos decided to update the original PCS 7 Ver-sion 5 system, which was the first in Australia at the time of installation, Siemens worked together with Qenos to produce a comprehensive migration plan. This ensured a seamless upgrade and made it easy to align the plant’s customizations on the original PCS 7 with the new system functionality.

Geoff Scott, process / applications engineer at Qenos, commented, “I was surprised to see how easily the two systems migrated together. With the right mix of people and proper planning, we were able to imple-ment the whole upgrade on time and within budget, with hardly any impact on the plant or business.”

Changes to the Altona resins plant included the opti-mization of existing networks, upgrading server racks, combining control rooms, and installing Siemens 547B Industrial PCs using Web server / client architec-ture. Existing hardware such as the PCS 7 controller and I / O modules could be fully re-used; only the cen-tral unit’s extended memory, loaded with the newest firmware, was changed.

Immediate and positive return on investment

The return on investment for this upgrade was visible for Qenos within a short period: a reduction in down-time; increased capacity; and reduced training, main-tenance, and software costs. Craig Moore, plant engi-neer at Qenos’s resins plant, was directly involved in the original implementation back in 1999, as well as subsequent plant expansions. “We are more than sat-isfied with PCS 7; it has delivered on every aspect and the entire plant has benefited at all levels,” he said.

“Furthermore, the members of the Siemens team re-ally impressed us with their exceptional service and support, but above all else, their expertise and genu-ine interest in our business objectives made Siemens a perfect partner to work with.”

Qenos, Australia

Living with Simatic PCS 7Ten years ago, Qenos implemented its first Simatic PCS 7 system. Fully

satisfied with the system, Qenos chose to work with Siemens again in

migrating the installed PCS 7 Version 5 system to the new Version 7.

infocontact


Simatic PCS 7 in the control room provides Qenos all-round process control functionality: control, supervision, and diagnostics

All

ph

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s: Q

eno

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City of Luxembourg, Luxembourg

Small Plant with Huge Impact

Currently, the City of Luxembourg operates two wastewater treatment plants, one in the south and one in the north of the city. The northern

treatment plant is located in the town district of Beg-gen and was built in the 1970s. Since then, both the standards for treated water discharge and process and automation technology have advanced significantly, and the Beggen plant no longer met the city’s require-ments in terms of technology and capacity. Addition-ally, the City of Luxembourg is planning to close the second wastewater treatment plant in the south and to have all wastewater treated by the Beggen plant in the mid to long term. Consequently, the city launched a modernization and expansion project for the plant.

In a major building and retrofitting project, the City of Luxembourg upgraded one of its

water treatment plants with the latest technology. Siemens automation and instrumen-

tation systems make a significant contribution to improve process performance.

More capacity – but not more space

The expansion of the treatment capacity faced one major challenge. There was no land available for addi-tional treatment units, as the wastewater plant is lo-cated in a residential area. These premises also made it necessary to comply with strict requirements for odor and emission control in order to minimize the impact of the plant on neighboring housing areas.

The City of Luxembourg solved the space problem by choosing a process that minimizes the footprint required for wastewater treatment. The Swiss engi-neering company Alpha Umwelttechnik, part of Veo-lia Water Solutions & Technologies, won an EU-wide

The new sludge

treatment unit based

on a flotation process

is equipped with

Hach-Lange liquid

analyzers and a

Multiranger 100

ultrasonic level

monitor Phot

os:

Pu

blic

is

I n d u s t r y W a t e r T r e a t m e n t


infocontact

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

The reliability of

the process

instrumentation,

like the Multiranger

level monitors, is

crucial for overall

plant performance

in Beggen

bidding process in 2005 with a plant concept incorpo-rating the company’s BiostyrTM process, which uses biofiltration instead of conventional aerated basins for the removal of pollutants. Biostyr is a trademark of Veolia Water Solutions & Technologies. Since the 1980s, BiostyrTM plants have been built for wastewater treatment and have proven their effectiveness. Typi-cally, a treatment plant with the BiostyrTM process re-quires only 10 percent of the footprint of a “normal” activated-sludge wastewater treatment plant.

In order to meet the strict limits for nitrogen dis-charge into the Alzette River, the process is designed with a nitrification-denitrification and a post-denitri-fication stage. To prevent emissions of odorous gases, the plant is completely enclosed and equipped with a large ventilation and air treatment system and a stack. The air is post-treated in a complex chemical-free pro-cess (also supplied by Alpha Umwelttechnik) before it is emitted.

Three-phase project without plant downtimes

Another requirement of the expansion and modern-ization project was that the existing treatment plant was to remain in operation the entire time. Conse-quently, the project was split into three phases to en-able a sequenced changeover to the new technology. In Phase 1, which is already completed, the infeed, mechanical cleaning, and grease and grit separator were replaced by new systems. The infeed is 17 me-ters below plant level, and the water is lifted twice, once for pre-treatment and once before biofiltration. In Phase 2, which is currently under way, the biofil-tration unit will be built on the plant’s premises. This phase will be completed in 2010 during Phase 3. After that, the existing activated-sludge basin will be de-constructed in Phase 3. The existing sludge treatment will be retained and connected to the new wastewater treatment plant by a sludge line. When the project is completed, the plant in Beggen will be capable of treating 200,000 inhabitant equivalents of wastewa-ter, sufficient for the City of Luxembourg with its 80,000 inhabitants as well as additional wastewater from surrounding communities.

High-availability solution for maximum reliability

The entire plant is equipped with Simatic controllers that are networked via Profibus. All controllers are de-signed redundantly with S7-400H controllers in the mechanical and BiostyrTM units. The sludge treatment is equipped with S7-300 controllers. Simatic WinCC is used for operation and monitoring. This redundant architecture was a specific requirement of the plant operator, as downtime- and fault-free operation are essential in the treatment plant.

Siemens also supplied most of the process instru-mentation used in the plant. Marc Lambert, project lead engineer at Alpha Umwelttechnik, is especially

satisfied with the performance of the Sitrans F mag-netic flowmeters: “The meters have been working with no problems for six months now – which is quite something in a plant like this.” Liquid analyzers from Hach-Lange are used for pH, ammonia, and nitrogen measurement, and these devices are also performing very well. “The reliability of the measuring technol-ogy is crucial in such a plant,” says Lambert, “and we are very satisfied with the technology from Siemens and Hach-Lange.” The project is on schedule, and thus far all technology is living up to expectations. With technology from Siemens, the plant is well equipped to meet both current and future require-ments.

Automation:7 Simatic WinCC operating stationsRedundant Industrial Ethernet terminal bus with Scalance switches4 archive servers (hot standby) Redundant Industrial Ethernet system bus with Scalance switches

Mechanical stage:2 Simatic S7-400H 6 Simatic ET 200 peripheral systemsRedundant communication via Profibus

BiostyrTM:2 Simatic S7-400H 6 Simatic ET 200 peripheral systems

Redundant communication via Profibus

Sludge treatment:1 Simatic S7-400 6 Simatic S7-300 2 Simatic MP370 Multi Panels 8 Simatic ET 200 peripheral systems

Remote stations:Link by DSL with VPN, automation with Simatic S7-300 or S7-200 controllers

Instrumentation:63 Sitrans P pressure transmitters 64 Sitrans F M magnetic- inductive flowmeters39 Multiranger 100 ultrasonic level monitorsLiquid analytics from Hach-Lange

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


GSK modernized a filling machine in the lyophilization unit with Simotion

The GlaxoSmithKline (GSK) factory in San Polo di Torrile near Parma, Italy, specializes in the development of sterile, lyophilized products

and has one of the largest clean-room areas in Europe. From this facility, GSK supplies the entire world with sterile ampoules and flacons, lyophilized drugs, nasal sprays, and tablets.

San Polo di Torrile is also one of the GSK sites in-volved in the development and introduction of new products, including biotechnologically produced highly active oral drugs and medicines, and therefore plays a special role within the company. Since the fac-tory in San Polo die Torrile produces for the interna-

tional market, the production must comply with the pertinent regulations, of course, especially those of the US Food and Drug Administration (FDA).

Several hundred flacons per minute

In 2007, the factory began a lyophilization optimiza-tion project, focusing on the modernization of a fill-ing machine. This machine fills the flacons with the active ingredient in a watery solution after washing and sterilizing. The product is then dried and fin-ished within 24 or 36 hours in one of the five lyo-philizators before finally being packaged.

GlaxoSmithKline, Italy

Precision FillingAfter the modernization of a filling machine with

Simotion, GlaxoSmithKline benefits from higher

availability and improved performance.

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

All

Phot

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Gla

xoSm

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Klin

e


infocontact


After the retrofit of the drive technology, the machine

benefits from higher performance and precision

The flacons are filled and transported to the lyo-philizator in a clean-room atmosphere. Since 2000, the flacons have been filled automatically by a ma-chine that can manage 10 different formats and fill several hundred flacons per minute.

However, the reliability of the drive system and the controller had begun to suffer. The motors and the axis control system were no longer state of the art either. In order to avoid possible unexpected fail-ures and bottlenecks created by problems with the spare parts supply, GSK was looking for alternatives that would also improve the filling accuracy at the same time.

The automation engineers at the Polo di Torrile site consulted the Italian Siemens Competence Center Packaging. Siemens is GSK’s preferred supplier for

S . I . A . s r l

The S.I.A. engineering company specializes in systems integration in industrial automation, consulting, the development of user software, and data management. S.I.A. srl has many years of experience in the fields of pharmaceutical processes, processes in the food industry and the chemical industry, and wastewater treatment.

Founded in: 1995

Address: Via Verdi, 26/F 37060 Castel d’Azzano (Verona), Italy Tel: +39 045 512900 Fax: +39 045 519091 [email protected] www.siavr.it

automation systems. Together, the experts at GSK and Siemens analyzed the motion control structure of the filling machine and evaluated possible solutions based on various modern components. The time nec-essary for the modernization was also an important factor. Only two time slots were available for updat-ing the entire motion control architecture: two weeks in December and three weeks in August, during the scheduled plant shutdowns.

Rapid retrofit

The modernization was carried out by the engineer-ing company S.I.A. srl in two phases. The machine’s five motors and drives were replaced during the two-week Christmas break at the end of 2007. In the three-week summer break in 2008, the old cam control was replaced by a solution based on the Simotion plat-form and the intelligent FM452 module.

The Simotion D motion control system handles the axis coordination and the management of all the re-lated functions. With the versatile Scout program-ming software, the application can be divided into modules that suit the structure of the machine. This enables the optimization of the software and makes it easy to add new machine modules. The Sinamics S120 drive system drives both brushless motors and asynchronous motors.

“The retrofit went absolutely to plan,” says Domen-ico Valente, the manager responsible for the modern-ization in the automation department at the GSK fac-

tory in San Polo di Torrile. “The prerequisites were the detailed planning and agreement on all the work, which we carried out jointly with Siemens. We now have a machine equipped with standard components in this key plant. This will ensure the availability of spare parts in the long term. We also benefit from bet-ter production results.” The new intelligent structure of the motion control system allows the performance of the machine to be improved and the accuracy of the filling process to be further increased. The percent-age of on-spec product has increased considerably as a result.

» The retrofit went absolutely to plan. «Domenico Valente, manager responsible for the modernization projekt in the automation department at GSK in San Polo di Torrile


R u b r i k U n t e r r u b r i kT e c h n o l o g y M a n u f a c t u r i n g E x e c u t i o n S y s t e m s

Baxter Healthcare, Ireland

Paperless ManufacturingElan Software, recently acquired by Siemens to

strengthen its MES portfolio, implemented an MES

solution for paperless manufacturing for Baxter

Healthcare in Ireland.


infocontact


W ith the acquisition of Elan Software Sys-tems SA, based in Toulouse, France, Siemens reinforces its manufacturing ex-

ecution system (MES) portfolio with process industry software. Elan Software Systems, an international software supplier for MES in the pharmaceutical and biotech industries, has excellent manufacturing pro-cess know-how in these industries, where it has been a recognized partner and preferred software supplier to many well-known companies for 20 years.

Elan Software’s business activities ideally comple-ment the Siemens process industry portfolio, such as the Simatic IT MES portfolio, the Simatic PCS 7 pro-cess control system, and the Comos lifecycle manage-ment systems added in 2008 through the acquisition of Innotec. Particularly for the pharmaceutical and biotech industries, the XFP software suite supple-ments the Simatic IT MES portfolio.

Going paperless in the pharmaceutical industry

One company that is already reaping the benefits of working with a solution developed and implemented by Elan is Baxter Healthcare in Ireland. With approx-imately 46,500 employees worldwide, Baxter Health-care applies its expertise in medical devices, phar-maceuticals, and biotechnology. Baxter Healthcare operates in three main businesses: bioscience, medi-cation delivery (MD), and renal. This case study fo-cuses solely on the MD and renal divisions that man-ufacture intravenous (IV) solutions and administration sets, premixed drugs and drug reconstitution sys-tems, prefilled vials and syringes for injectable drugs, and electronic infusion pumps, in addition to other products used to deliver fluids and drugs to patients. The type of products that the MD and renal divisions manufacture cannot be reinspected or reworked,

Baxt

er /

Hea

lth

care

which poses a serious challenge for Baxter: products need to be manufactured right the first time.

In 2003, Baxter’s European MD and renal divisions were eager to implement an electronic batch system, with the principal objectives of cost reduction, in-creased quality compliance, enhanced flexibility, and acceleration of batch release. They implemented Elan’s XFP software suite to manage all production operations, from the entry of raw materials into the workshop to the transfer of finished goods to the warehouse. The XFP implementation included mate-rial flow and inventory management, weighing, count-ing and dispensing, directed manufacturing, daily equipment checks, mixing, printing, filling, steriliz-ing, electronic batch records, batch testing and re-views, packaging and labeling operations, and data warehousing. All data are stored in a central reposi-tory available for use and review, enabling Baxter to perform trend analysis, such as laboratory trends, and scrap analysis and to measure manufacturing output and scrap.

Electronic batch recording offers multiple benefits

The e-batch system, as it is known internally, guides operators through the complete process, acting as an electronic router with controlled task execution and automatic calculations while also recording all ac-tions. With this system, human error risks have been significantly minimized, and quality has increased. It is now possible to manage more volume with fewer resources and better quality. In addition, less storage space is required.

Thanks to the traceability, electronic signature, and security features, the system helps ensure total qual-ity compliance with any industry regulations, includ-ing those of the US Food and Drug Administration. Fi-nally, the new system has led to the reduction of batch release time and, of course, cost. All data are gathered in one batch report, which is accessible at any time. Reviews are performed only on exceptions, which translates into significant time and cost savings.

T h e b u s i n e s s b e n e f i t s

Right First Time (RFT) ratio higher than 99 percent Production schedule reduced to 30 minutes before target time Batch-release cycle time reduced from days to hours US$250,000 saved due to reduced discards Improved compliance with manufacturing procedures Investigations reduced from days to hours

Baxter has eliminated more than 90 percent of the

paperwork from the process. The e-batch system is the

front line of the Baxter production process

R u b r i k U n t e r r u b r i kT e c h n o l o g y P r o c e s s C o n t r o l

Simatic PCS 7 APC portfolio

Performance Tools

APC methods are a critical tool for improving plant performance with respect to productiv-ity and effi ciency, product quality, operabil-

ity and availability, agility, and safety and environmen-tal issues. Facility operators, engineering companies, EPCs (engineering, procurement, and construction companies), and systems integrators alike recognize this fact and consider the topic of APC to be very im-portant – but also complicated. Consequently, there are many concerns regarding the potential costs of implementing APC in process plants.

Simatic PCS 7 APC: affordable and easy

These concerns are addressed in a white paper issued by Siemens. The white paper illustrates the benefi ts of using the embedded APC functions in the Simatic PCS 7 process control system, which are available in the PCS 7 standard free of charge.

Simatic PCS 7 offers APC functions for control per-formance management, APC extensions to PID (pro-portional-integral-derivative) control, and multivar-iable control functions. In addition to the core control algorithms, the APC Library of Simatic PCS 7 also pro-vides the related process tag types and software tools for computer-aided controller confi guration (avail-able without extra charge). Due to the reduced costs of a system-embedded and template-based imple-mentation, a large number of applications, including

small and medium-sized processes, become accessi-ble for APC – including processes in which it is not af-fordable (in the context of desired amortization times) to interface expensive external APC software pack-ages to the distributed control system.

The right APC for optimum results

To achieve maximum performance in process plants, however, it is essential to choose the optimum APC tool for the specifi c task. To facilitate the decision-making process, the Simatic PCS 7 APC white paper also provides an introduction to assessing and select-ing the appropriate approach for a given type of task or process, in order to improve plant performance and achieve the maximum benefi t with the minimum effort. It explains the APC tools by main principle, typical use cases, and typical applications, and also presents a case study as an example of how to improve process control using APC tools.

info

contact

www.siemens.com/pcs7 –> Technology Components –> Advanced Process [email protected]

A white paper demonstrates that Advanced Process Control (APC) solutions can be

implemented in a cost-effective way with Simatic PCS 7, using the standard function

blocks and the predefi ned CFC templates in the PCS 7 APC Library.



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

infocontact


Other features of the LDS 6 are also advantageous for use in engine test benches. The measured value is calibrated permanently without reference gases using a patented reference cell containing the measured gas. Measurements that are taken years apart or with various instruments can be compared directly, thanks to the permanent calibrations, which are all per-formed using one general base calibration at the Siemens factory.

Mobile option

If measurements are possible in the bypass, Siemens offers another very low-cost, mobile version of the compact measurement system. It consists of a mobile, heated measuring line that requires very little space and can be located virtually anywhere. This also en-ables monitoring of several test benches if there is only a temporary need for slip measurements and fixed installation is not required.

In situ measurement technology for engine test benches

Tested MeasurementThe LDS 6 laser spectrometer diode enables reliable, real-time measurement

of ammonia slip in engine test benches.

W ith the LDS 6 and the Sitrans SL, Siemens offers two infrared (IR) laser diode spec-trometers for in situ process gas analysis

that use the same measuring method but differ con-siderably in design and type of application. The Si-trans SL device is very compact and incorporates all the measuring technology – transmitter, receiver, and electronics – in one device. In the LDS 6 analyzer, in contrast, the measuring electronics are separated from the measuring unit comprised of the transmit-ter and receiver. This design is particularly suited to high-temperature applications.

Expert for test benches

One such high-temperature application is gas analy-sis in test benches for catalytic converters. These cat-alytic converters are destined for trucks. In order to comply with increasingly stringent exhaust gas lim-its, more and more diesel vehicles must be equipped with catalytic converters to meet the emission limits of the Euro 5 standard and planned regulations re-garding nitric oxide (NOx) emissions. To meet these requirements, the automotive industry uses selective catalytic reduction, a process in which nitric oxides are transformed into nitrogen (N2) and water (H2O) through symproportionation, using nitrogen com-pounds such as ammonia (NH3). The target is to fully eliminate the NOx without slip of surplus ammonia into the gas flow after the catalytic converter. Siemens has supported the development of truck catalytic con-verters with laser spectrometers for NH3/H2O inline measurements from the start. Approximately 100 sys-tems have now been installed worldwide in such ap-plications for monitoring the NH3 slip.

The exhaust temperature may be up to 600 degrees Celsius in the main flow. Measuring electronics di-rectly on the process are hard to insulate from heat, so there may be measuring errors. Another problem for compact systems with a combined measuring unit and electronics is mechanical engine vibrations that are transferred to a directly coupled measuring sys-tem. This can cause mechanical damage, such as cracks in the main board, over time. The LDS 6 is im-mune to such damage because of the separate elec-tronics in the central unit.

In addition to fixed

installed analyzers for

the slip measurement

in engine test benches,

there is also a mobile

version for measure-

ments in the bypass,

requiring little space

thanks to the vertical

design


infocontact


Treated water worth millions of dollars goes down the drain every year. In many cities around the world, water pipes and measurement equipment

are in such bad shape that up to 60 percent of the dis-tributed water cannot be accounted for.

Consequently, effort has been put into improving water supply management, which essentially requires knowing what is flowing. Ultrasonic flowmeters are an indispensable tool in achieving this. These flow-meters provide numerous advantages for treatment plants, including better measuring accuracy, less power consumption and stress on the water manage-ment system, optimized leakage management, and the ability to operate under any condition while being resistant to impurities, obstacles, and high aeration.

Monitoring the flow

Siemens offers a portfolio of highly versatile wetted and clamp-on ultrasonic flowmeters in its proven Sitrans F US series, which work especially well for monitoring flow in water pipeline networks. The three specific clamp-on ultrasonic product families cover the broadest range of requirements: The general-pur-pose Sitrans FUS1010 provides a wide range of ad-vanced features. The portable Sitrans FUP1010 is highly suitable for on-site measurement. For applica-tions with lower performance requirements, the Sitrans FUS1020 features the basic, most commonly needed functionalities. In addition, the battery-pow-ered, portable Sitrans FUP1010 is available as a check

kit that includes everything needed to perform field surveys and performance checks.

In addition to the clamp-on flowmeters, Siemens also offers two wetted product families suitable for the needs of the water and wastewater industries. The bat-tery-powered two-track Sitrans FUS380 can be installed in areas without main power supply and will operate re-liably for approximately six years between changes of battery. The retrofit Sitrans F US Sonokit, equipped with the Sitrans FUS060 high-performance transmitter, offers a simple, accurate alternative to traditional flow-meters. This kit consists of all the components required to install the wetted transducers into an existing pipe, either on an empty pipe or on a pipe under pressure (hot-tap installation).

Measurement for effective management

By providing accurate data on flow rates, the Sitrans meters ensure reliable, maintenance-free measure-ment of flow rates. They help detect leaks and main-tain both water quality and correct usage, and they help make sure this precious resource reaches the consumer safely.

Water losses can be contained through reliable and continuous flow measurement with Sitrans F US flowmeters

Siem

ens

AG

Flow measurement

Water AssetsSitrans clamp-on and wetted flowmeters are key in

detecting water losses in water pipeline networks.

S i t r a n s F U S : K e y B e n e f i t s

Simple installation and maintenance On-site installation of the meter without interrupting the flowFast and cost-efficient portable measurement Installation in areas without main power supplyBattery-operated solutions, with six years of reliable operationOptimal management through availability of extensive flow dataMeasurement of various liquids though bidirectional WideBeam transit time and Doppler flow measurement

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


MAN in Germany has been using a Sitrans CV device success-fully for one year. Since summer 2008, the device has been measuring calorific value and gas composition and is per-forming to the full satisfaction of MAN. Moreover, this installation serves as a best practice for other companies in-terested in implementing this solution.

Siemens supplied a Sitrans CV device with an application module and sample preparation for installation in ex zone 1 as a complete system solution in a protective housing. MAN is now considering a second measuring system.

MAN uses the Sitrans CV for monitoring and measuring calorific value and gas composition in test benches for gas

engines. During the commissioning of these engines at end customer locations worldwide, MAN uses a mobile gas chro-matograph with ex approval. The composition and calorific value of the measured gas vary considerably; the calorific value can range from 7 to 12 kilowatt hours per standard cubic meter. The Sitrans CV process gas chromatograph is a further development of the micro process gas chromato-graph technology from Siemens and can meet the require-ments of this measuring application.

www.siemens.com/sitranscv

Gaz de France Norge AS has chosen Comos for technical asset data management and maintenance management of the new Gjøa platform. Comos will be used to manage all operational engineering, documentation, and maintenance management tasks at Gaz de France Norge, especially in the operation of the Gjøa field. Terje Overvik, managing director of Gaz de France Norge, says: “Comos Industry Solutions GmbH won the contract after fending off 14 other competitors during the initial and final tender rounds. Comos Industry Solutions came across as professional and reliable during the negotiations and its sys-tems provided the best functionality to meet Gaz de France Norge’s requirements. In fact, the technology and commercial teams unanimously decided to award the contract to Comos In-dustry Solutions.”

“The systems will contribute greatly to us meeting our goals in Integrated Operations,” operations manager Kjell Ola Jør-gensen explains. With the new systems, the operational staff will be able to obtain all necessary information on their desk-tops without the need for manual interventions. This allows for faster, better, and more precise decisions and solutions in daily operations. Comos Industry Solutions will work closely with Gaz de France Norge to implement the new systems, and will also establish integration with other systems, third-party sup-port, and data import.

Gaz de France Norge AS is a wholly owned affiliate of GDF SUEZ, present in Norway since 2001. The company is a partner in several fields on the Norwegian Continental Shelf, and the asset portfolio is growing. In 2010, Gaz de France Norge will be-come an operator in the Gjøa field.

www.comos.com

I n b r i e f

Phot

o: S

tato

ilHyd

ro

The Gjøa gas field is being developed

in a joint venture between Gaz de

France Norge AS and StatoilHydro

Gaz de France Norge AS, Norway

Superior Functionality

MAN Diesel, Germany

Best Practice


I n b r i e f

New EDD for Sitrans LR250

New Features and Approvals

Siemens has added new features to the En-hanced EDD (electronic device description) of the Sitrans LR250 level transmitters to provide additional diagnostic functionality and ease of use. The enhancements include reorganizing the echo tools into one convenient location and a new cyclic echo-profile-saving feature, which allows users to save echo profiles at predeter-mined time intervals. This is one of the first Enhanced EDDs that makes use of a new harmo-nized menu and parameter structure between level, flow, temperature, pressure, and valve po-sitioners from Siemens. A new HART EDD for Emerson AMS configuration software is also in-cluded, and NAMUR NE43 is available as a con-figurable option that presets the fail-safe output to 3.6 milliamperes.

The Sitrans LR250 also has new explosion- proof safety approvals – CSA, FM, ATEX, and IECEx. These approvals allow the Sitrans LR250 to be used in hazardous locations containing flammable gases without the requirement for an intrinsically safe barrier. www.siemens.com/lr250

Milltronics MSI and MMI belt scales are now available for use on systems with flow rates of up to 12,000 tons per hour, an in-crease of 7,000 tons per hour. The MSI and MMI, combined with a Milltronics BW500 Integrator and a speed sensor, now have OIML (International Organization of Legal Metrology) and MID (Measuring Instruments Directive) approvals. These approvals guarantee that the MSI and MMI belt scales meet strict require-ments for weights and measures applications in terms of accu-racy and repeatability. The Milltronics MSI, a heavy-duty single- idler belt scale, is used for rugged applications in process and load-out control. MSI provides instant response to belt loading and overload protection to 300 percent. The MSI measures only the vertical load applied through the belt and the supporting suspended idler, and is so structurally sound that it can be ap-plied to the most demanding applications. Drop-in installation makes alignment easy and economical. The MSI and MMI mod-els can be installed without the use of cranes or other high-cost resources. The Milltronics MMI is a heavy-duty, high-accuracy multi-idler belt scale consisting of two or more MSI scales. Used for critical process and load-out control, the double-idler MMI-2 offers accuracy up to ± 0.25 percent. For even greater accuracy, the Milltronics MMI-3, a triple-idler belt scale, can be used on applications requiring accuracy to ± 0.125 percent.

www.siemens.com/weighing

AD

Imm

un

e

MSI and MMI belt scale systems

Increased Capacity, Approved Accuracy

ADImmune, Taiwan

Well Prepared

ADImmune, Taiwan, relies on Siemens automation and build-ing technology in its new production facility for vaccines and is well prepared for current and future challenges.

The facility commenced operation in June, and was almost immediately charged with the responsibility of preparing a vaccine for the H1N1 virus – commonly referred to as the swine flu virus. Currently, the facility is busy producing 250,000 doses of influenza vaccine a day to provide the five million doses ordered by the Taiwanese Department of Health for the population in Taiwan. The facility, originally designed for producing a vaccine for avian influenza, complies with both the standards of the European Union and US Food and Drug Administration.

Siemens provided the automation and building automation technology for the main Vaccine Manufacturing Control System (VMCS) and other process skids. ADImmune chose Siemens after extensive assessment of available solutions due to the superior technological capabilities and integra-tion performance and reliability of Totally Integrated Automation.

www.siemens.com/pharma

The new ADImmune production facility uses automation

technology from Siemens throughout the process and is

fully compliant with FDA and European standards

D i a l o g u e


process news 3-2009PublisherSiemens Aktiengesellschaft,Gleiwitzer Str. 555, 90475 Nuremberg, Germanywww.siemens.com/automation

Drive Technologies DivisionCEO Klaus Helmrich

Industry Automation DivisionCEO Anton S. Huber

Responsible for ContentArno Hoier

Responsible for Technical ContentCornelia Dürrfeld

ConceptChristian Leifels

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

Editorial CommitteeAlexandre Bouriant, Sean Cahill, Inez Costenoble, Sigrun Ebert-Heffels, Michael Gilluck, Walter Huber, Ivonne Luthardt, Rüdiger Selig, Roland Wieser

Publishing HousePublicis KommunikationsAgentur GmbH, GWACorporate Publishing Medien 1P.O. Box 32 40, 91050 Erlangen, GermanyTel.: +49 (0) 91 31 91 92-5 01Fax: +49 (0) 91 31 91 92-5 [email protected]

Editor in chief: Kerstin PuruckerLayout: Bettina RauneckerCopy editing: Sabine Zingelmann

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

process news is published quarterly.

Cover photo: corbis

Circulation: 35,000Job number: 002800 19877

© 2009 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:

ET 200, S7-300, SCALANCE, SIMATIC, SIMATIC IT, SIMATIC

PCS 7, SIMATIC Safety Integrated, SIMOTION, SIMOCODE,

SINAMICS, SITRANS, TIA, WinCC

If trademarks, trade names, technical solutions, or similar

are not listed above, this does not imply that they are not

registered.

The information provided in this magazine contains merely

general descriptions or characteristics of performance, which

in the case of actual use do not always apply as described

or which may change as a result of further development

of the products. An obligation to provide the respective

characteristics shall exist only if expressly agreed in the

terms of contract.

IWI: TPOG

Order number: E20001-M6309-B100-X-7600

Printed in Germany

onlineOn the Internet at

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

corporateSiemens Going Strong on Compliance

The recent corruption affair was a serious issue for Siemens. Addressing and eliminating the errors made in the past resulted in a company-wide anti-corrup-tion program with top management attention.

These efforts made by Siemens are reflected in the company’s Dow Jones Sustainability World Index ranking. The Dow Jones Sustainability World Index is one of the first global indexes tracking the financial performance of the leading sustainability-driven companies worldwide. Siemens remains in a top posi-tion in this index (as of September 2009).

Siemens will keep compliance on top of its priority list and promote responsible action in business envi-ronments together with all its partners.

Your contact for the Industry Automation& Drive Technologies Divisions: Dr. Jörg Flath – Compliance OfficerTelephone: +49 (911) 895-5769E-mail: [email protected]

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

www.siemens.com/processautomation

Do you want to change your address? Subscribe to process news? Comment on articles in process news or request more information? Just send us an e-mail:

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Answers for industry.

When will this be the standard on earth?

With the right manufacturing technology and innovative processes, maximized efficiency will become reality.

www.siemens.com/solar-industry

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