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Systems and Solutions for the Process Industry
processnews
2nd edition September 3|2003
s
MES solutions ensureeconomic performanceand quality
Beck & Co. put theirtrust in Braumat
Innovative automation solution at Südzucker
PCS 7 Builds Up Steam
6 10 13
Using innovative and powerful IT concepts,companies in the food and beverage industrycan optimize their processes. Moreover, IT systems like Simatic IT are indispensablefor tracking production processes
Component reliability is the key issue in thesugar industry – and that was why Südzuckerchose failsafe automation systems made bySiemens and the PCS 7 process control system
The Orange Sky is one of the firstships to store and transport liquidorange juice. Siemens GlobalSupport contributed to the successof this multi-national project
CONTENTS2
procen
3 EDITORIAL
4 NEWSBayer and Siemens Sign Global Skeleton Supply and Service Agreement
Fairs and Events for the Food and Beverages Industry
Simatic WinCC V6.0: New FDA options
Sweet Success in Thailand
Charting the Future – at the Process Automation Annual User Conference
CASE STUDIESSugar Industry
10 PCS 7 Builds up SteamInnovative boiler automation at Südzucker AG
Global Player in the Food and Beverage Industry13 Orange Sky – Successful Teamwork
Freshly pressed orange juice from Brazil on the way to North America and Europe
Filter Technology16 Operating Ease “To Go”
Large filter presses flexibly equipped with Simatic Mobile Panel 170
Breweries18 A Clear Advantage
Braumat process control system successfullyimplemented at Beck & Co. in Bremen
Beverages20 A Closer Look
Sitrans LR 300 level-monitoring devices at Wesergold in Rinteln
Chemical Industry21 Productivity Upgrade
PCS 7 Batch control system for Clariant in Indonesia
TRENDS
IT in Food & Beverage6 Clever Use of Information
MES solutions are playing an increasinglyimportant role in the food and beverage industry
Tobacco8 Setting Standards
Siemens MES Technology for the Chinese Tobacco Manufacturing Industry
process news 3/2003
18
Dear readers,humans do not live bybread alone. Consumers in our time make manydemands on what they eatand drink. Naturally, theywant food and beveragesthat taste good and that
are healthful. At the same time, people wanta balanced diet and wish to buy productsadapted to their individual expectations – all this, of course, at a reasonable price.
This means that companies in the food andbeverage industry not only need to optimizetheir processes under the aspect of costeffectiveness but also need to be flexible inproducing a wide range of individualproducts. At the same time, the number offoodstuffs enriched by health-conduciveadditives, which therefore need to beproduced under conditions similar to those in the pharmaceutical industry, is growing. In addition, the demand for greatertransparency is becoming increasinglyimportant – for reasons of product liability onthe one hand and to make production moreeffective and economical on the other. High-performance, integrated IT and automationsystems are central instruments forintroducing this transparency.
For more than 30 years, Siemens hasaccommodated its customers in the food andbeverage industry with tailor-made products,systems, and solutions. In this issue, we showyou some of the latest examples of thiscooperation and demonstrate how companiesfrom so many different fields, such as thesugar, brewing, or soft drinks industries, haveachieved their goals using our systems andsolutions. These success stories are anincentive for us to increase our range evenfurther – for example, by developing newtechnologies in field devices or by expandingour IT portfolio.
We will also remain a reliable and competentpartner who will face the challenges of thefuture at your side. Here’s to a goodpartnership!
Gerd TrummerSiemens Automation and DrivesCompetence Center Food and Beverage
At Beck & Co. the process control system Braumat was ableto continue a successful tradition. The challenge: switchingover to the new filtering system without interruptingproduction
3
essnews
Field Devices9 Better Together
Danfoss flow-monitoring technology reinforcesSiemens process automation
Field Devices and Process Analytics22 A Forum for the Chemical Industry
Siemens relies on a continuous dialogue with users
Service & Support25 Faster, Simpler Information
Optimized online support
TECHNOLOGY
Liquid Analytics23 Robust Sensor
Enamel pH sensor for Sipan liquid analyzer
Level Monitoring24 More Choices
New radar device enlarges Siemens level monitoring portfolio
26 SHORT LISTVeltins
German BP
Burger Knäcke
27 DIALOGUE
EDITORIAL
process news 3/2003
process news 3/2003
4 NEWS
At this year’s Achema, Bayer AG andSiemens signed a global Skeleton Supplyand Service Agreement, which concernsthe worldwide supply to Bayer produc-tion plants of Siemens Sitrans P pressure
transmitters. The contract runs for fouryears. The agreement was reached basedon the good results of thorough tests ofthe Sitrans P DS III pressure transmitter,which has been in operation as a stan-
Bayer and Siemens Sign Global Skeleton Supply and Service Agreement
On September 17 and 18, 2003, the fac-ulty for Information Technology in Me-chanical Engineering at the TechnicalUniversity of Munich will be holding itssecond symposium on the topic of Infor-mation Technology in Food Production.Together with well-known manufactur-ers of automation and IT solutions, thefaculty has assembled an interestingprogram dealing with plant planning,process automation, and production lo-gistics.
The first day of the symposium con-centrates on the visions of leading com-panies and research institutes regard-ing questions of automation, packing,logistics, and quality assurance. On the
second day, users from the sugar, deli-catessen, dairy, beverages, and meat in-dustries report on how IT solutions arehelping them to meet their require-ments.
The event closes with a podium dis-cussion under the motto “Quo vadis,food and beverages industry” focusingon automation, globalization, and mar-ket and health aspects.
In November, there are two im-portant dates to note in your diaries:Brau 2003, from November 12 to 14 inNuremberg, and Tabexpo, the world’smost important fair for the tobacco in-dustry, from November 25 to 28 inBarcelona. ■
Fairs and Events for the Food and Beverages Industry
Simatic WinCC V6.0:New FDA Options
Extensive new functionality has beenadded to the new Simatic WinCC Version6.0, giving users even greater supportthan before in the validation of theirplants in accordance with FDA 21 CFRPart 11.
WinCC/Audit enables the simple config-uration of audit trails that can be usedboth for tracing changes in the engineer-ing and for the runtime mode of theWinCC application. Changes are saved,
Dr. Klaus Schäferof Bayer (right)and Hans-GeorgKumpfmüller ofSiemens (left)close the deal atthis year’s AchemaSi
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Second Symposium on Information Technology in Food ProductionSeptember 17 – 18, 2003 Garching near Munich www.it-lebensmittel.de
44th European Trade Fair for the Beverages Industry Brau 2003November 12 – 14, 2003 Nuremberg www.brau-beviale.de
Tabexpo 2003November 25 – 28, 2003 Barcelona www.tabexpo.com
dard field device at Bayer AG since No-vember 2001.
In addition to the high technical com-petence and the global presence of Sie-mens, especially in the Asian market, itwas the excellent worldwide Siemens sup-port that tipped the balance in favor ofsigning the agreement.
The contract supports the efforts ofBayer AG to pursue further standardiza-tion in equipping its plants. In order toachieve this goal, Bayer needs reliablepartners such as Siemens and is thereforevery keen on further cooperation – also inthe field of process control systems, ac-cording to Dr. Klaus Schäfer, senior vicepresident of Bayer Polymer Technology.
In addition to Bayer Polymers, the otherthree Bayer divisions – Chemicals, Health-care, and Crop Science – will also be ableto benefit from the agreement. ■
Klaus-Peter Frehse, KarlsruheE-mail: [email protected]
and the audit trails are storedand protected against manipu-lation in the archive. Audit trailscan be searched for, displayed,exported, and printed in anydatabase in the network using anaudit viewer. The traceability ofchanges provided by the audittrails already satisfies FDA re-quirements. Additionally, Auditnow supports project versioningwith document management in
the engineering phase.Maximum protection of the entire plant
against unauthorized access is guaran-teed by the central systemwide user man-agement capability. Simatic Logon inte-grates itself with the safety system andWindows user management and meetsFDA requirements in this way. ■
process news 3/2003
5
For more then 5 years Siemens is nowworking together with the United FarmersIndustry Corporation (UFIC), one of thelargest sugar mills in Thailand. With thesuccessful implementation of the firstPCS 7 process control system combinedwith the sugar application software Nah-mat crystal control for a sugar factory inThailand, this joint project started into thecardinal step of the modernization of theentire plant.
At the beginning of the project, Siemenstogether with UFIC calculated the newautomation solution’s Return of Invest byperforming a detailed factory audit. A sec-ond step was the installation of a Nahmat
Pan Control local automation unit for theautomation of one out of 26 batch crys-tallization pans. After that, UFIC manage-ment decided to modernize the factory us-ing the Simatic PCS 7 and Nahmat.
The new system was successfully im-plemented and is running to the full satis-faction of the customer ensuring that therefinery section is always producing sugarto a predefined and reliably excellentquality. ■
Sweet Success in Thailand
Bernd Langhans, ErlangenE-mail: [email protected]
The Siemens ProcessAutomation User Com-munity will hold its an-nual conference in Balti-more, Maryland, USA,from October 8 to 10,2003. All users of Siemensprocess automation sys-tems are welcome to at-tend this extraordinaryevent, which providesopportunities for theusers of the Siemens process automationsystems to come together to exchange in-formation, learn from each other, andprovide feedback to Siemens. Users sharebest practices, presenting their applica-tions to their peers, resulting in real-world uses and knowledge sharing.
This year’s conference theme is“Charting Our Future” and will includepresentations and discussions lead byUser Community members, as well asSiemens’ experts. Preceding the userconference, on October 6 and 7, severalin-depth training courses on process au-
tomation and process safety topics willbe offered.
The conference delivers a view intothe future direction of Siemens, its cur-rent products, and even an opportunityfor input into future products and en-hancements.
For more information on the confer-ence, as well as a brief video clip, pleasevisit our website. ■
Charting the Future – at the Process Automation Annual User Conference
Steve Morales, Spring HouseE-mail: [email protected]/process
Birgit Gottsauner, NurembergE-mail: [email protected]/wincc-fda
Thailand is one of thebiggest sugar-producingcountries in the worldSi
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Siem
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With new functions, SimaticWinCC V6.0 supports validationof FDA 21 CFR Part 11 compliance
process news 3/2003
6IT in Food & Beverage
TRENDS
Successfully fighting off competitionis becoming more and more diffi-cult for companies in the food and
beverage (F&B) industry. In addition toproduct quality, they also need a widerange of products in order to discover andexploit market opportunities, as well ashigh process flexibility in order to adaptproduction quickly to changes in con-sumer habits. At the same time, con-sumers are placing more and more impor-tance on whether they can trust the brand,the company, or the particular product.
The growing desire of consumers to dosomething for their health with their daily
nourishment is reflected in the trend to-ward “nutraceuticals” – that is, foodstuffsthat are enriched by vitamins, minerals,or other healthy additives. The borderbetween foodstuffs and drugs becomesblurred in this field, and production mustincreasingly comply with regulations forthe production of pharmaceuticals.
Uniform regulations soon to reach Europe
Many aspects of pharmaceutical produc-tion are therefore becoming increasinglyimportant in the F&B sector – the key istraceability. With the American FDA (Food
and Drug Administration) already rulinginternationally where food safety and riskmanagement are concerned, now the Eu-ropean Union holds the belief that it isnecessary to establish a common legalframework that requires the F&B industryto establish comprehensive systems oftraceability. The creation of the European
IT systems like Simatic IT help companies in exploiting their know-how
Siem
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MES solutions are playing an increasingly important role in the food and beverage industry
Clever Use of InformationBuzzwords such as supply chain management, time-to-market, traceability, and so forth are the decisive criteria for successful production, even forproducts such as yogurt, bread, and apple juice. Reacting quickly to marketdemands, launching new products on the market faster and faster, and at thesame time continuously increasing the quality of the products – as in manyother industries, that’s the only way to survive in this market segment. Withhigh-performance systems such as Simatic IT, companies can better exploittheir know-how and at the same time meet increasingly strict legalrequirements.
process news 3/2003
7
Food Safety Authority (EFSA) in 2002 illus-trates this trend, and the effects of EU pro-posals to consolidate food safety regula-tions in the EU will probably be concludedwith the introduction of traceability regu-lations in 2005.
A new concept provides a network
This will mean that food and feed busi-nesses will have to be able to identify bothsuppliers and customers, and they musthave in place systems and proceduresthat will allow the information to be madeavailable to the authorities upon demand.To achieve this, a well-designed IT struc-ture that records and processes all therelevant information – even beyond thecompany borders – is crucial. With a com-mon platform, potential for rationaliza-tion can also be exploited all along theproductivity chain, from the productionof the raw materials right through tosales of the end products. The foundationfor more efficient and, above all, moreflexible production can be created. Trans-parent process management in produc-tion can contribute to faster reactions tochanging market demands and a reduc-tion in waste.
Production and business administra-tion can be linked by manufacturing exe-cution systems (MES) such as Simatic IT.The basic MES functionality, such as foundin Simatic IT Production suite, includesSimatic IT Framework with modeling ca-pabilities. Production modeling allows tovisualize every blender, mixer, heater,weighing and measuring station, packag-ing line in the process environment, coor-dinating functionality and creating trans-parency and visibility in the plant. An-other important functionality is materialmanagement, which makes it possible totrace a batch upstream (to raw materials)or downstream (logistics) from every op-erational sequence to the batch record.
In addition to basic MES functionality,there are other more specific applica-tions like plant information managementtools and the evaluation of the processinformation according to key perform-ance indicators. The current state of pro-duction can be assessed and directly opti-mized in this way.
Laboratory information managementsystems (LIMS) manage the entire work-flow in the laboratory – from obtainingand recording samples, to automatic log
files and management and archiving ofstandards (standard operating proce-dures, SOP), right up to monitoring com-pliance with regulations and guidelines.This process guarantees product qualityand allows early recognition of problemsand prompt introduction of countermea-sures.
Production specifications are without adoubt among the most important compa-ny assets. Suitable specification manage-ment systems such as Simatic IT Interspecmanage all information associated with aspecific product, including the nutritionalvalue data, storage conditions, materialcalculations, types of packaging, andproduct-specific recipes.
Harmonization of product specifica-tions and the ability to make them avail-able for all plants and divisions in an en-terprise is particularly important in man-aging product liability in F&B industries.It also allows more global buying, whichcan lead to significant savings. ■
Inez Costenoble, NinoveE-mail: [email protected]
Simatic IT Unilab: Number 1 for F&B
With the laboratory information management system (LIMS) Simatic IT Unilab, the qualityand availability of lab results can be increased and at the same time personnel costsreduced. The system can be used both as a standalone solution and together with acomplete Simatic IT MES package. Thanks to integrated Web interfaces, the information isavailable not only to lab personnel but is also directly accessible for process optimization, for example.
Version 5.0, presented in May this year, has also had a few important features added.The new version of Simatic IT Unilab supports 21 CFR 11 compliance, the FDA guideline thatdefines the conditions of use for electronic records and signatures. Data can now also becollected and transferred through pocket or tablet PCs and copied into the system. Thestability module supports lab personnel in determining how raw material or product proper-
ties vary with time under the influence ofenvironmental factors or conditions such astemperature, humidity, and light, thussimplifying proactive quality management.
Simatic IT Unilab has set new standardswith its efficiency and reliability, as the ARCAdvisory Group confirms in its latest LIMSWorldwide Outlook (2003). The study ranksUnilab as the number one reference soft-ware for LIMS in the F&B market. “TheSiemens system is by far the most solid LIMSsolution for the food and beverage industry,”says Will Chin, research director at ARC.Si
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process news 3/2003
8
process news 3/2003
Tobacco
TRENDS
This deal is a vote of confidence in the renewed and extended SiemensSimatic IT MES product portfolio
and marks the first time MES-technologyis being implemented in the Chinese to-bacco industry. After very hard competi-tion with other competitors, Siemens as amajor industrial automation innovator fi-nally won the project to set an MES-stan-dard, integrating the ERP business sys-tems and the automation level.
Entire Simatic IT portfolio will beimplemented
The goal of the implementation will be todrive production with business informa-tion in real time, which will result in sig-nificant business benefits translated inmanufacturing efficiency, cost reduction,better quality and higher responsivenessand thus higher profitability.
The project includes the entire SimaticIT portfolio, covering the basic MES func-tionality comprised in Production Suite,
but also more specific functionality suchas Quality Management using Simatic ITUnilab, Product Specifications Manage-ment with Simatic IT Interspec, Simatic ITHistorian as a Plant Information and KPImanagement, and Detailed ProductionScheduling. The benefits of implementingSimatic IT are crucial for the end user tomaintain and secure the competitive posi-tion now and in the future.
First project in Qingdao
The customer is a major government heldChinese tobacco producer, employing morethan 10.000 people and with an annualturnover of 5 billion Euro. The Etsong To-bacco Corporation Ltd. has decided in favorof the Simatic IT MES-portfolio for a pilotplant in Qingdao because it enables the re-alization of the business and manufactur-ing strategies of the company. ■
Inez Costenoble, NinoveE-mail: [email protected]
Siemens MES Technology for the Chinese Tobacco Manufacturing Industry
Setting StandardsSiemens and its Chinese partners Siemens Factory Automation Engineering Ltdand Jiu Hui Information Technology Limited have closed a major MES-dealworth one million Euro with a major tobacco manufacturer in China. The contract, signed in April 2003, the Etsong Group CEO, the plant managersand the general management of Siemens A&D in China, includes the entireSimatic IT Manufacturing Execution Systems (MES) portfolio.
zefa
The new cooperation made its debut atthe Achema in Frankfurt: Peter Madsenof Danfoss and Renate Breuer of Siemensboth attended to the visitors on the jointfair booth featuring the joint portfolio
process news 3/2003
9TRENDS
W ith the acquisition of the DanfossFlow Division, Siemens has ex-tended its range of magnetic-
inductive and ultrasonic flow meters. Inaddition, Siemens can now offer coriolis-based flow-monitoring devices, which de-termine mass flow using the coriolis forceprinciple and therefore operate com-pletely independently of material vari-ables, such as density or volume.
Securing and extending know-how
The combination of the expertise of twoindustry leaders provides customers the benefit of being able to purchase allflow-monitoring instruments from oneprovider. Over the years, Danfoss has es-tablished specialists in the company’sheadquarters who concentrated on thevarious flow measurement tasks in thefields of water and sewage, pharmaceuti-cals, chemicals and utilities as well as inthe process industry, including the foodand beverages and tobacco industries.Siemens will maintain this great wealth ofexperience and add its own process au-tomation know-how to advise customersand provide solutions to flow-measuringproblems.
Siemens Flow Instruments is takingover almost the entire staff of the DanfossFlow Division, including the regional salesforces. By doing so, Siemens can ensurethat in most cases, customers will stay incontact with their partners and can choosethe ideal solution from the extendedrange of Siemens Flow Instruments.Siemens will also guarantee the samespare parts supply and warranty obliga-tions for all flow products delivered byDanfoss as for all Siemens’ own products.
Important future market
Anton S. Huber, director at the SiemensAutomation and Drives Division, sees thislatest acquisition as the logical continua-tion of Siemens’ commitment to the im-portant future market for process automa-tion. About one-quarter of today’s processinstrumentation requirements are instru-ments for flow measurement. Accordingto Huber: “With the takeover of the flow-measuring technology activities fromDanfoss, we have consistently expandedour process automation. Danfoss flow-measuring technology is an excellent ad-dition to our process instrumentation andcloses an important product and techno-
logy gap in our portfolio. We have also im-proved the market access to importantcustomers and regions. The extendedproduct portfolio considerably strength-ens our competitive position and makesus even more attractive as a partner.” ■
Danfoss flow-monitoring technology reinforces Siemens process automation
Better TogetherThis year, Siemens has expanded its portfolio of flow-measuring instruments byacquiring the Flow Division of the Danish company Danfoss. The Danfoss flow-monitoring portfolio has been added to Siemens’ range of process instrumentationdevices and solutions. The Siemens Competence Center for flow-monitoringtechnology will be established in Nordborg, Denmark – pooling the know-how ofDanfoss and Siemens.
Field Devices
Leopold Streit, KarlsruheE-mail: [email protected]
Siem
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process news 3/2003
10 CASE STUDY
T he main season for the sugar in-dustry is the time of the sugarbeet harvest in early fall. The ma-
chines are in full swing and operatingaround the clock. Just in time for thesugar beet campaign of 2002, SüdzuckerAG of Mannheim/Ochsenfurt had the
existing automatic measuring and con-trol equipment and the control technol-ogy at the company’s factory in Wabernoverhauled with Siemens automationtechnology. Previously, the factory hadoperated with a steam generator in-stalled in 1976.
The boiler contains four parallel-stream burners that are equipped forburning heavy heating oil and naturalgas. It produces an output of 60 and 80tons of steam per hour respectively, at asuperheated steam pressure of 51 bar anda superheated steam temperature of 465degrees Celsius. Measurements were pre-viously acquired by the individual con-trollers, display instruments, setpoint po-tentiometers, recorders, and signal lampsthat were integrated in the control room.The conventional control technology orig-inally consisted of five Simatic S5-110Fcontrollers for the interlocks and the fourburners.
The decision to modernize was made in2001. The existing process measuring andcontrol technology were to be upgradedwith Siemens automation technology,with the aim of simplifying operation andmaintenance, increasing cost-effective-ness, and reducing emissions. A lambdacontrol for optimizing the fuel-air ratiowas added to the boiler controller for this
Innovative boiler automation at Südzucker AG
PCS 7 Builds up SteamA crucial phase for the Südzucker AG sugar factories begins every year in the fall when all machines are in full swing. The trouble-freeoperation and unrestricted availability of all machines, pans, anddevices is an absolute must during the sugar campaign. That is whySüdzucker AG chose the Simatic PCS 7 process control system with thefail-safe and highly available automation system AS 417-FH, whichoperates on a redundant principle and practically rules out faults forthe company’s factory in Wabern.
Sugar Industry
process news 3/2003
11
purpose. Of prime importance, however,was increasing the availability and opera-tional reliability of the boiler. The conver-sion took into account the existing func-tions and did not result in changes in theuse of the boiler or the boiler’s operatingparameters. Südzucker AG chose the fail-safe and high availability AS 417-FH au-tomation system for the new equipmenton the basis of the Simatic PCS 7 processcontrol system already installed at the fac-tory.
Redundancy guarantees safety
The conversion was to be complete by thebeginning of the harvest season in the fall of 2002. The factory works around the clock during harvest time. For threemonths, approximately 6,600 tons of sug-ar beets are processed per day. It takes 10hours with the machines in full swing toturn the beets into consumer-grade sugar.
The project was executed in close co-operation between Südzucker AG andSiemens. Südzucker AG coordinated the
plant conversion, operation and visualiza-tion functions, and the software of thedrive control, and Siemens was responsi-ble for the switch gear cabinets, softwareprogramming, and integration. The com-missioning, testing, and trial runs weredone in one step at the end of the project.
A major feature of the new automationtechnology is the redundant design of thesystem up to the I/O periphery. Trouble-free operation is guaranteed even in theevent of a fault. The “hot standby” opera-tion of the central unit of the automationsystem and the bus system guaranteesgreater safety as well. The “hot swap” ca-pability of the I/O periphery also avoidsfailures by enabling modules to be ex-changed even with the machines running.
By consistent integration of all the reg-ulation and control functions – includingthe fail-safe control – in a high availabilitysystem, the system complexity and num-ber of external interfaces and componentsare minimized. Possible signal faults dueto EMC coupling and cable and connection
Sugar crystals grow from sugar beet or sugar cane thick juice that has a yellow-brown color. In order to obtain whiterefined sugar, the sucrose that accounts for more than 99 percent of the sugar must be skillfully crystallized from theoversaturated solution in the sugar pans. Control of this crys-tallization process requires a great deal of expert knowledge.Because the quality requirements for sugar as an end productare becoming ever greater, the demands on productioncontrol are becoming increasingly rigorous. Through an opti-mized crystallization rate, temperature influences are mini-mized and energy consumption reduced. A narrow, uniformcrystal size distribution simplifies further processing andincreases the yield.
Siemens has been working with the sugar industry formore than 50 years on automation solutions that can monitorand control the complex crystallization process. At the begin-ning of the 1980s, Siemens used the know-how it had gainedfrom this long partnership to launch a comprehensive soft-ware package for controlling the crystallization processparallel to the development of the Teleperm M processcontrol system: the Nahmat crystallization software. WithNahmat the process can be reliably controlled and sugarproduced in the desired quality. This increases the yield of theprocess, and the investment in the new automation solutionusually pays off within 200 to 300 days of operation. Morethan 900 sugar pans automated with Nahmat are evidenceenough of this success.
One of Siemens’s satisfied customers is Hellenic Sugar. Atthe company’s factory in Larissa, Greece, Siemens replaced a30-year-old Siemens relay-technology-based control packagewith Simatic PCS 7 and Nahmat. Now Hellenic Sugar hasalready completed the second sugar season with the newsystem and is totally satisfied.
Crystallization know-how from Siemens
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The complex crystallization process in the sugar pans canbe controlled reliably with Simatic PCS 7 and Nahmat
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About 6,600 tons of sugar beets perday are processed in Wabern duringthe sugar campaign
process news 3/2003
12Sugar Industry
CASE STUDY
vidual values can be traced very simplywith trend diagrams.
The high degree of transparency is en-abled by TIA (Totally Integrated Automa-tion) and the simultaneous integration ofall the regulating and control componentsinto one control system. The entire sys-tem, including the I/O periphery, is moni-tored closely. The service personnel havea uniform package of functions for hard-ware and software engineering and diag-nostics at their disposal.
The new plant and the boiler had to gothrough a trial by fire in the literal senseduring the sugar beet harvest. Siemensand the Simatic PCS 7 passed this test ad-mirably and fully met the customer’s ex-pectations. The boiler in the Wabern fac-tory is now building up steam – with allthe advantages of state-of-the-art controltechnology, thanks to PCS 7. ■
errors are successfully reduced by adistributed arrangement of the pe-riphals, which minimizes wiring as aresult.
Transparency due to TIA
The operating personnel also benefitfrom the PCS 7 system. The boiler iseasier to operate because its relevantprocess parameters are displayed in aconcise layout. A sophisticated signal-ing system gives warnings long beforea fault occurs and provides informa-tion about the causes of the fault. Indi-
Bernd Langhans, ErlangenE-mail: [email protected] Scharvogel, WürzburgE-mail: [email protected]
… or in the central control room
B
TIA provides the necessary transparency: The personnel have a watchful eye on all theprocesses – locally …
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Freshly pressed orange juice from Brazil on the way to North America and Europe
Orange Sky – Successful TeamworkThe Orange Sky is one of the first ships transporting juice directlyfrom the orange in a liquid state. Getting the ship fit for this task was not only a technical challenge it was also dependent on anexcellently functioning international management of the partiesinvolved in the equipping – Brazilian juice producer, Atlanship ShipManagement Company, Lloyd Werft, Bremerhaven and Siemens.
Pete
r Bi
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CASE STUDYGlobal Player in Food and Beverage Industry
14Global Player in Food and Beverage Industry
CASE STUDY
Whether nectar, orange juice drinkor pure orange juice – most or-ange juices you will find in su-
permarkets are made of concentrate dilut-ed with filtered water. A new term has re-cently been added to the range of orangejuice products: NFC (not from concen-trate). “Directly pressed and filled” – print-ed on the pack, this indicates that the juicecomes exclusively from the fruit, e.g. fromoranges, and is not made from concen-trate and is therefore an NFC drink.
The largest quantities of NFC juicescome from Florida and Brazil. There, it ismanufactured and exported all over theworld by large companies. One of thesecompanies is the Brazilian outfit Cutrale.
With more than 30 million trees, Cutraleis the world’s largest producer of citrusfruits. After the harvest, the citrus fruitsare processed in plants similar to refiner-ies as concentrate or NFC. In the produc-tion of NFC, the juice and the pulp are sep-arated during pressing. The pulpless juiceis then usually first heated and then deepfrozen as a preservative and finally loadedin a frozen state in refrigerator holds forshipping all over the world.
As good as freshly pressed …
… frozen juice isn’t – at least according toconsumer opinion. That’s understandablebecause it’s quite probable that pulp fromFlorida is mixed with juice from Brazil
Two things are very important for transporting or storing freshorange juice in the high-grade steel tanks. For one thing, thejuice must be kept at an exactly defined low temperature. Foranother, the tank must be absolutelygerm-free and may therefore have nocontact at all with air or oxygen. This isguaranteed by blowing in nitrogen (N2).Both the temperature and the N2
pressure must be measured continuously(every second) and regulated. An hourlyreport is printed automatically. Cooling, pressure and temperatureregulation and filling level measurementall take place fully automatically. Everytank is fitted with a Siemens radar levelmonitoring device, two Siemenspressure transmitters (for measuring thefilling level by the static pressure andmeasurement of the N2 pressure), aSiemens temperature transmitter andseveral flow meters, position controllersand switches. A Simatic PCS 7 process control system isused. The communication between thecontrol system, cooling system control(Simatic S7-300) and the SCADA system(two redundant Simatic WinCC servers)is taken care of by Industrial Ethernet.The link to the rest of the periphery aswell as various drive systems (Micro-master) is made via Profibus DP (somesegments apply fibre optic versions), thelink to the process instrumentation via
Profibus PA. The AS-Interface bus system connected to Profibusvia DP/AS-I-Links is also utilized and integrates various motorswitches and valves in the overall system.
DP/AS-i-link
Micromaster
Field instruments(pressure, temperature, flow measurement)
DP/PA link
Micromaster
AS-I interface modulesAS-i valves
AS-I Network
RedundantWinCC server
OLM
Prof
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DP
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Control system
Drives
Industrial Ethernet
OLM
OLM
Profibus PA
Field devices
TCP/IP
Simatic PCS 7
Process automation on the Orange Sky
process news 3/2003
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15
during thawing. To meet the demand foreven more “genuine” freshly pressed or-ange juice, Cutrale has decided to trans-port liquid orange juice on appropriatelyconverted ships and to store it at suitabletank farms.
The freighter “May Oldendorff” set outon its maiden voyage three years ago. InAugust 2001 the owners, Adriatic ReeferCorp. Inc., La Tour-de-Peilz (Management:Atlanship S.A., La Tour-de-Peilz, Switzer-land), bought the ship and converted itinto a juice tanker which first went intoservice in October 2002, now renamed“Orange Sky”. Ever since, the Orange Skyhas been carrying the valuable juice fromSantos, the São Paulo harbor, to the Unit-ed States (Florida and New York) and infuture will also be sailing to Europe (Rot-terdam).
The ship which still sails under Liber-ian flag (approx. 172 meters long, 27 me-ters wide and a draught of 9.7 meters)reaches a maximum speed of almost 15knots with a drive of 9600 hp. Four of the15 tanks are filled with liquid orange juiceat the moment. The rest of the holds stillcontain deep frozen juice.
To turn the freighter which used to car-ry grain into a tanker, a complete overhaulof the electrical installations was neces-sary in addition to the reconstruction. Theconversion itself was done by Lloyd’s at
their shipyard in Bremerhaven. Lloyd’scontracted Siemens Industrial ServicesGermany to plan, install and commissionthe electrical installations.
To avoid expensive pasteurization pro-cesses, the juice must be stored in ab-solutely germ-free tanks. These must notonly be pre-cooled but must also be kept ata defined atmospheric pressure and tem-perature. Such a sensitive process requiresan appropriately sophisticated process au-tomation. The contract for the process au-tomation on board the Orange Sky wasawarded to the Process Solution Division ofSiemens Energy & Automation (SE&A) inSt. Louis in the United States (whereby thecontracting company was not the Bremer-haven shipyard but the Swiss shippingcompany). SE&A had already provided theprocess automation for another tank farmfor fresh orange juice in Newark.
Apart from the American engineers, theexperts for process instrumentation inKarlsruhe (see inset for technical details)were also involved. The general manage-ment for the process automation projectwas in the hands of Ingo Magura fromSE&A, St. Louis.
Global player with high efficiency
Siemens’ significant involvement in theretrofitting of the Orange Sky with thesetwo projects – electrical installation and
process automation – was not only due totheir suitable, wide range of products andservices, worldwide presence and their ex-perience as a highly efficient global playeralso played an extremely important role.“Certainly all the more so where – as inthe project described here – different cus-tomers from different countries with dif-ferent relationships to each other are in-volved,” Corporate Account Manager SteveAppleton confirms. The function of a Cor-porate Account Manager as a “string-puller” on the Siemens side has certainlypaid off. “The CAM knows the customersand through local Siemens account man-agement – in this particular case M.Brunetti in Brazil and J. Ducharme in theUSA – opens the appropriate doors. To-gether, they can best judge who should ormust be involved within the company.They can also give the customer or cus-tomers a general idea of the competenciesand possibilities on site.” ■
Stephen Appleton, NurembergE-mail: [email protected]
The “Orange Sky”, the world’s first fresh juice tanker
process news 3/2003
16Filter Technology
CASE STUDY
N etzsch Filtrationstechnik GmbH inSelb, Germany is the world marketand technology leader in the field
of filter presses and was the first manu-facturer to develop fully automatic andthus virtually-continuously operatingchamber and membrane filter presses.High-performance pumps from Netzschfeed the presses with slurry. More than100 filter chambers and filter plateswith a size up to two-by-two meters en-able maximum throughput.
The filtration specialist has developeda sophisticated solution for removingeven very adhesive filter cake quickly andcompletely from the filter cloths in anautomatic process: The filter press is fit-ted with an automatic scraping devicewhich travels along the whole length ofthe plant. After the filtration process, thefilter chambers are separated from eachother so that two scrapers supportedfrom the inside can scrape the filter cakefrom the top to the bottom of the filtercloth on both sides.
To reduce the scraping cycle time evenfurther, the engineers at Netzsch have in-troduced two successful measures. First,they equipped the pneumatically operat-ed scrapers with efficient electronic Simo-drive 611U servo drives. Second, they de-veloped an innovative mobile set-up andreadjustment solution from the productrange of the world market leader. Thefirst improvement reduces the cycle timefor a scraping process from 25 to only 15 seconds per filter chamber. The second
brings advantages in the hardware costsand also makes set-up much more flexi-ble, more convenient, and also cheaper.A Spanish company, the first beneficiaryof these innovations, extracts about 140tons of minerals every day on two fullyautomatic diaphragm filter presses fromNetzsch.
Simatic Mobile Panel 170 – easy mobileoperation
Using the Simatic Mobile Panel 170,Netzsch has found a smooth mobile solu-tion for greater HMI flexibility and effi-ciency. It replaces a more complex in-house solution – a Simatic Operator PanelOP7 converted into a mobile device thatwas connected to the control in the oper-ating cabinet by a Profibus cable and sup-plied information locally in text form. Toset up the filter press, one person stood atthe main operating panel in the switchcabinet and another person at the OP7 onthe moving scraper. These two had tocommunicate by hand signals and shout-ing. Only the main operating panel hadthe full range of operating and monitor-ing functions.
Identical user interfaces
Roland Schelter, who is responsible forthe electrical engineering of all Netzschmachines, appreciates the advantages ofthe new mobile operating panel. He par-ticularly appreciates the identical graphi-cal user interfaces on the main operatingpanel Simatic OP 170B and the Mobile
Large filter presses flexibly equipped with Simatic Mobile Panel 170
Operating Ease “To Go”Mobile operating panels are the ideal solution when it comes to settingup several plants or plant sections – and that’s not just because of thelower hardware costs. The mobile operating concept also reduces staff.For example, on the up to 18-meter-long filter presses made by Netzsch,one person can perform the set-up instead of two. Moreover, MobilePanel 170 makes the whole procedure much more flexible andconvenient.
Panel 170 on site. “This will save us atleast two days’ configuration work in thefuture,” he says, “because we can takeover the identical configuration and nolonger need to take other devices intoconsideration.”
A junction box is mounted directly onthe scraper, which communicates withthe Simatic S7-315-2 DP plant control viaProfibus or MPI and supplies the MobilePanel with power and data. The MobilePanel 170 can be plugged into or un-plugged from the junction box “Plus”even with the filter press running withouttriggering the emergency stop circuit andthus interrupting production. This is animportant feature for many customersbecause producers often have two ormore filter presses of the same type inparallel production. A Mobile Panel canthen be used to control these alternately.The operator has the full range of operat-ing and monitoring functions at his dis-posal on the scraper so that he can set thepress alone without assistance.
Netzsch has developed about 10 screenmasks with the ProTool configurationsoftware that has been used until now.Now process parameters such as the hori-zontal and vertical travel distances of thescrapers, the pump pressures, or timescan be set locally by 14 function keys. Fortime-critical switching and control pro-cesses with very short reaction times, themembrane keys can also be used as DPdirect keys (I/O periphery). The Profibusdiagnostics are also available directly on
Filter presses with a plate size of up to
two-by-two meters area specialty of Netzsch
process news 3/2003
17
the scraper, which further simplifies op-timization of the plant. Like all Simaticpanels, the Mobile Panel 170 fits easily in-to Totally Integrated Automation.
Robust, reliable, and safe
The decision to adopt the new panel wasalso influenced by its unlimited indus-trial compatibility. The compact, light-weight device is resistant to vibration andshock – it even takes a fall from a heightof 1.5 meters without damage. Suchstress can only be withstood by an oper-ating system without a hard disk, such asWindows CE 3.0. The system also offersthe possibility of a full graphic display in16 colors. The housing of the Mobile Pan-el 170 is robust, designed to IP65 (NEMA4) standards, and is thus optimally pro-
tected against water jets in the event ofleaks or when the plant is cleaned.
The Stop button on the Mobile Panelwas a very important feature for the elec-trical design engineers. It is used to shutdown the press immediately and safely inthe event of danger. According to safetyregulations, the Stop and Release buttonsmust be designed with two separate cir-cuits – this meets the requirements ofsafety category 3 in accordance with EN954-1. To avoid confusion with the emer-gency stop device, the Stop button is grayin color.
Expandable solution
“The Mobile Panel 170 will become theHMI standard for all our filter presses,”Roland Schelter believes. “It makes set-up
and tooling much more convenient andflexible, and a lot cheaper.” Illuminatedpushbuttons, key-operated switches, anda hand wheel may not have been used onthe first two plants but they are a usefuloption for the future. The latter, for exam-ple, can be used for exact, continuous po-sitioning or traversing of the scraper’sservo drives. Several junction boxes arealso conceivable on the larger filter press-es – and different visualizations on press-es that are not identical would even betheoretically possible with the MobilePanel. ■
Birgit Gottsauner, NurembergE-mail: [email protected]
All the data readilyat hand: SimaticMobile Panel 170with graphical userinterface
alle
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process news 3/2003
18Breweries
CASE STUDY
The existing filter cellars had beenoperating at their production limitsfor some time. Beck & Co., one of the
largest breweries in Germany and a fullsubsidiary of the Interbrew company, de-cided to modernize its entire beer logis-tics and further improve the quality of thepopular brew with new filtration technol-ogy.
At Beck & Co., practically all the impor-tant areas were upgraded, beginning withthe so-called unfiltrate binding and distri-bution – that is, the feeding of the unfil-tered beer to filtration. In addition, 46pressure tanks, flow and follow-up tanks,and a residue beer tank were newly in-stalled and automated. The valve nodesfor distribution to the pressure tanks – aswell as for distribution of the pressuretank contents on the 14 filling plants forbottles, barrels, and cans – were newly in-stalled and automated. The four new filterlines are equipped with diatomite filters,carboblending units, and particle filters;an additional fine filter for a filter linerounds off the equipment.
Siemens won the order as general con-tractor for the subproject providing au-tomation technology for the new centralfilter cellar at Beck & Co. Together withATM GmbH and Filtrox AG; Siemensformed the “new central filter cellar” workteam. Within the project, ATM was respon-sible for the entire piping construction – atotal of 30 kilometers of new pipes – andthe machine assembly. Filtrox was respon-
sible for the process technology and in-stalled the machines for all of the filterlines, subplants, CIP (Cleaning in Place)systems, and the new pressure tank cellar.
Siemens took over responsibility forthe electrical and automation technologyfor all sections of the new central filter cel-lar – including the measuring technologyand its mechanical interfaces. SiemensSolution Process Automation in Würzburgcarried sole responsibility, from the plan-ning to the hardware and software designand engineering, up to delivery, installa-tion, and commissioning of the new plant.Siemens also managed the integration of existing facilities such as the fillingplants, electrical and pneumatic installa-tions, and switch gear cabinet construc-tion and was responsible for project man-agement and the training of operatingand service personnel.
All brewery sections equipped with a uniform control system
In the course of the project Beck & Co. alsoupgraded the existing Braumat systems inthe brew houses and brewing wort coolinglines to the Braumat V4.6 version of thefilter cellar so that the brewery sectionsare all operated by a common and homo-geneous process control system. Highlyefficient Braumat data links transfer theorder, operating, and production data to the management information system(MIS). Simatic ET 200S I/O devices pick upthe signals in the field.
The new electrical and automationequipment of the facility supplies, records,and controls all the measurements: flowmonitoring, temperature and referencevalue monitoring, filling level limits, andvolume monitoring, as well as pressuremonitoring. Added to these are the brew-ery-specific measurements such as oxy-gen, turbidity, carbon dioxide content,original wort, and color units. The controlsystem also includes 3,500 mix-proof andflap valves with position feedback, and250 motor and pump drives, of which 90percent are controlled by frequency con-verters.
The nucleus of the system is formed bytwo Braumat servers, five Braumat clients,and seven Braumat S7-400 controllersconnected with more than 300 distributedET 200 systems via Profibus. The systemprocesses more than 700 analog valuesand over 8,000 digital signals.
Braumat is connected via Profibus DPdirectly with the instrumentation, thepower components such as motor contac-tors and converters, and the valves andtheir process terminating devices. Thefield devices of the carbo-blending unitsare connected to the control system viaProfibus PA. The communication with theoperating data entry system takes placevia the BDE-CIS link of the Braumat sys-tem. In this way, all order and batch datawith the associated logs, signals, and rele-vant data can be transferred up-to-date forfurther processing. This expensive con-
Braumat process control system successfully implemented at Beck & Co. in Bremen
A Clear AdvantageThe renowned German brewery Beck & Co. in Bremen produces several million hectoliters of beer every year –and that figure is rising. In view of increased sales and the demands of future production growth, Beck & Co.replaced the existing filter cellars with a new, central, fully automatic plant with four filter lines when thecompany was performing extensive modernization of the beer logistics. For the automation of the new filtercellar, Beck once again chose the Braumat process control system as it already had for other sections of thebrewery. The existing Braumat systems in other sections of the brewery were simultaneously upgraded to thenew Braumat V4.6 version that is also used in the new filter cellar.
process news 3/2003
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version required additional switch gearcabinets and boxes, but in some cases(such as the integration of the existing fill-ing systems) the new components couldbe integrated into existing switch gearcabinets on site.
Changeover on the fly
At the end of the project, the new systemhad to surmount another challenge. The
two old filter cellars were shut down, theexisting pressure tanks disconnected, andthe new filter cellars put into operationwithout interrupting production. The fill-ing lines were also integrated during on-going brewery production. Thanks to theexcellent advance planning of the projectteam, the changeover to the new systemtook place without a hitch. The new cen-tral filter cellar went into operation in Au-
Beck & Co.’s new valve hub(right and left) Pi
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Bec
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gust 2002 and was able to live up to all ex-pectations. The filter cellar and Braumatare also prepared for further increases inproduction. The plant can be extended toup to six filter lines. ■
Edgar Huth, WürzburgE-mail: [email protected]
process news 3/2003
20Beverages
CASE STUDY
A lmost 50 years ago, Richard Har-tinger decided to enter his father’scider business, and in 1956 he
founded the first plant for juice produc-tion in Rinteln in Lower Saxony. Today, in addition to the Wesergold factory inRinteln, the Richard Hartinger BeveragesGroup has production plants at two otherGerman locations as well as factories inSwitzerland and Spain. Together they pro-duce about 50 million units of fruit andvegetable juices, soft drinks, mineral wa-ter, and fruit juice drinks every day.
One of the products made at the Rin-teln factory is carrot juice, which is storedin 25-foot-high sterile tanks. The tanksare operated at an excess pressure of
0.3 bar. Moreover, the juice tends to frothexcessively. Conventional methods weretherefore unable to reliably monitor thefilling level in the tanks, and Wesergoldwas consequently searching for an alter-native solution.
Pulse-radar technology masters a difficult task
The Sitrans LR 300 measuring instru-ments were tailor-made for this job. Theadvanced radar level-monitoring deviceuses sophisticated microwave-pulse tech-nology, which enables a reliable, continu-ous level monitoring of liquids or pulpseven under extreme process conditions.The Sitrans LR 300 operates reliably un-
der extreme temperatures and pressuresand is insensitive to steam, dense froth,smoke, dust, or condensation. Aggressivechemicals, materials with a tendency toform crusts, or strong turbulence and theuse of stirrers in the tank have practicallyno effect on the measuring procedure.
More applications
Sitrans LR 300 is thus also able to monitorthe filling level reliably in Rinteln – eventhrough the froth. The first Sitrans LR 300was installed in Rinteln two years ago.Now a total of seven tanks have been fittedwith LR 300 measuring instruments – andWesergold is totally satisfied with this so-lution. ■
Sitrans LR 300 level-monitoring devices at Wesergold in Rinteln
A Closer LookThe Wesergold brand is an important segment of the traditional RichardHartinger Beverages Group. The products manufactured by Wesergold inRinteln include vegetable juices as well as fruit juices. The storage of carrotjuice initially posed a problem for the company: high temperatures and a strongdevelopment of froth made things difficult for conventional filling-level meters.Wesergold finally found the right solution in the Sitrans LR 300 devices fromSiemens – and has since installed LR 300 on seven tanks.
Markus Veit, KarlsruheE-mail: [email protected]
Despite excessive amounts of froth,Sitrans LR 300 devices are reliablymonitoring the tank level
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process news 3/2003
21CASE STUDY
The two original production lineswere commissioned in 1996 and au-tomated with Siemens S5 PLCs. The
third line was originally manually oper-ated and is being automated during re-installation in Cilegon. The new processcontrol system is based on Siemens’ PCS7with the tightly integrated Batch flexiblebatch management system.
The control system uses redundantservers, which also act as Operator Sta-tions. A third Operator station and an En-gineering Station are connected as clients.Siemens’ MIS-Light database software isdeployed on a dedicated server for longterm archiving of batch reports and otherprocess data. The MIS-Light package wasselected because it provides standard in-terfaces to Batch flexible and PCS 7, sim-plifying the database implementation.HMI process graphics have been devel-oped using the PTE400 library, a PCS 7add-on providing a set of function blocksand faceplates for the process industries
which has been adopted by Clariant as astandard on several of their sites. At thecontrol level, Siemens Siwarex M weigh-ing systems have been utilized to inte-grate high resolution weighing of the bulkraw material storage directly into the con-trol system.
System design and prototyping
The project is being executed by SiemensIndonesia with initial project design andprototyping assistance provided by theProcess Automation Solutions RegionalHeadquarters in Singapore. Configurationprototyping was a key feature of the initialdesign process allowing demonstration tothe client of the capabilities and designopportunities available with PCS 7 andBatch flexible. The prototype review provedinvaluable in crystallizing the client’s re-quirements, deciding key design philoso-phies and identifying areas where addi-tional client input was required. The exer-cise also served to bring the client’s key
project stakeholders and the Siemens’ de-sign engineers into close cooperationfrom the early stages of the project.
Increased plant productivity expected
Plant Manager Utun Sutrisna commentedthat the old S5 system proved reliable overmany years and that they expected thesame reliability from the new PCS 7 sys-tem. Anticipated benefits of the new sys-tem included a greatly enhanced operatorinterface with good visibility of the batchoperations and improved scheduling andreporting capabilities. This will increaseoperational effectiveness with consequentimprovements in plant productivity. Thefirst line was commissioned in July 2003,with the remainder of the plant beingcommissioned in December. ■
Chemical Industry
Abram Ziegelaar, SingaporeE-mail: [email protected] Hendrata, JakartaE-mail: [email protected]
PCS 7 Batch control system for Clariant in Indonesia
Productivity UpgradeP.T. Pulosynthetics in Indonesia, a subsidiary of Clariant GmbH of Germany,decided in 2002 to rationalize and upgrade their polymer productionfacilities by consolidating production at their plant in Cilegon, West Java.The plant produces a wide range of water based emulsion polymers, someof which are used in the important local textile industry for the sizingprocess, with others used as key components in emulsion paint coatings,emulsion glue and other chemical products. The project involvesupgrading two existing production lines and relocating a third line from Jakarta to the Cilegon site.
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22Field Devices and Process Analytics
TRENDS
The chemical industry’s requirementsfor automatic measuring and controltechnology are as diverse as the pro-
cesses in which the devices are used.Explosion-hazardous production areas,plants with life cycles of 30 years andmore, harsh ambient conditions or partic-ularly strict safety requirements – theseare the kinds of environments in whichthe field devices must prove their capabili-ties.
Pooling of interests
For this reason, leading chemical industrycompanies joined forces early on to collectand express their requirements for pro-cess control technology. As early as 1949,BASF, Bayer, and Hüls formed NAMUR, amanufacturer-independent interest groupfor automatic measuring and control tech-nology users in the chemical industry.
NAMUR was established as the standardsassociation for measuring and controltechnology. Then as now, the main goalsof NAMUR were to improve functionalityand reliability of the measuring technol-ogy, analyze control system technology,standardize interfaces, and exchangemeasuring and control instrumentationexperience with other users.
NAMUR’s activities cover the whole lifecycle of process control systems, from thedesign phase to the final dismantling of a plant, and include all fields ofprocess control technology. Today,NAMUR boasts 85 member com-panies in Europe. Although itis still concentrated mainly inEurope, NAMUR is gainingmore and more influence onan international level. Theaim of all NAMUR activities is
to organize and influence the develop-ment of automatic measuring and con-trol technology from the chemical indus-try user’s viewpoint to achieve better con-trol of the processes and to minimize thetotal cost of ownership. NAMUR then sum-marizes these results in worksheets andrecommendations.
Continuous dialogue duringdevelopment
NAMUR exploits the know-how of field de-vice manufacturers. For example, Siemensworks as NAMUR’s competent guest in ap-propriate workgroups. This means Siemenscan integrate important trends and futurerequirements at an early stage of productdevelopment and its customers have theopportunity to use innovative productssooner.
To further promote the dialogue withusers, Siemens has founded its own forumfor field and analysis device users in thechemical industry. The aim of this forumis to provide background information anddiscussion points on important topics infield instrumentation and analysis as wellas to answer frequently asked questions.In the industry portal, users will find amade-to-measure portfolio of products,systems, and solutions to help them opti-mize their processes. ■
Siemens relies on a continuous dialogue with users
A Forum for the Chemical IndustryAlways being ready to listen to customers’ wishes and needs is an importantpart of Siemens’ company strategy – even and especially in processautomation. Constant cooperation with users in the chemical industry istherefore an important concern of the Forum for Field and Analysis DeviceUsers, which Siemens recently founded. The aim of this forum is to take thechemical industry’s requirements increasingly into account in thedevelopment of field devices.
Hans-Jürgen Huber, KarlsruheE-mail: [email protected]: [email protected]/processinstrumentationwww.siemens.com/prozessanalytics/chemicalwww.namur.de
Koer
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ditions for reliable and ex-act process measurements.Ideally, this measuringprinciple requires either aconstant, or nearly con-stant, sodium content inthe process medium or aknowledge of the possiblefluctuations. The presenceof fluoride ions in the solu-tion limits the area of thesensor’s application be-cause these ions damagethe enamel. The sensor issuitable for use with clean-in-place systems, but onlywhen certain specificationsregarding alkali and acidconcentration and temper-ature and cleaning dura-tion are observed to mini-mize the influence on theenamel. Higher-concentra-
tion acids can also be used briefly forcleaning the removed sensor.
Versatile alternative
Provided that all sensor elements are fullywetted during the measurement and airentrapment is avoided, the differential pHsensor can be installed in virtually any po-sition. The differential pH sensor requiresno regular maintenance, making the costof ownership very low by comparison.Therefore, the sensor is an interesting al-ternative to conventional glass pH probes,which are prone to breakage in many in-dustries. ■
A pH measuring system alwayscomprises the respective measur-ing electrode, the reference sys-
tem, and the analyzer. Both the measuringelectrode and the reference electrode inthe enamel probe are extremely large, re-sistant, ion-sensitive enamel layers melt-ed onto a steel carrier. The enamel layersallow the sensor to be independent ofwatery electrolyte systems, enabling it tobe stored dry for an unlimited period. Thesensor can be connected to the Sipananalyzer by two symmetrical, high-ohmicinputs, thus extending the applicationpossibilities of the proven Sipan liquid an-alyzers, especially for processes in chemi-cal, pharmaceutical, or food and bever-ages industries.
The upper enamel (measuring elec-trode or pH enamel) reacts to hydrogen
Enamel pH sensor for Sipan liquid analyzer
Robust SensorThe differential enamel pH sensor has technical measuringproperties designed specifically for process industry requirements. It is extraordinarily resistant and operates without a separatereference electrode, thus avoiding the aging effects of conventionalmethods and supplying reliable measured values that remain stableover a longer period of time.
process news 3/2003
23TECHNOLOGY
ions (H+) and supplies a concentration-dependent potential. The lower enamel(reference electrode) reacts to the saltsdissolved in the liquid (especially to sodi-um ions) and supplies a product-specificreference potential. Unlike conventionalglass electrodes, the differential pH sen-sor is calibrated with process or productsamples rather than the usual buffer solu-tions.
Stable and resistant to aging
The differential pH sensor exhibits a lin-ear response behavior between pH 3 andpH 11. Both electrodes are stable over thelong term in their technical measuringproperties and do not age. Therefore, it ispossible to program the probe to a prod-uct or control point by setting a predeter-mined slope, thus creating optimum con-
Liquid Analytics
Klaus Dickmann, KarlsruheE-mail: [email protected]
Thanks to its two ion-sensitiveenamel coats,the pHdifferentialsensor doesnot need anexternalreferenceelectrode
P. K
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process news 3/2003
24 TECHNOLOGY
C ommercially available radar unitswere first installed in the chemicaland petro-chemical industries for
high accuracy measurement on liquidchemical storage. Today, Radar now formsthe mainstay technology for long-rangehot and dusty applications, finally replac-ing mechanical technologies that werepreviously the only option.
Until recently however, relatively highinvestment costs for radar devices wereoften an obstacle in applications whichhad only moderate requirements for ro-bustness and precision. This was whySiemens developed Sitrans LR 200, a new2-wire, loop-powered pulse radar instru-ment from Siemens, offers a cost-effectivelevel measurement solution for liquidbulk storage or simple process vessels.
Literally seamless construction
A special new feature is the Uni-Construc-tion rod antenna. The threaded connec-tion, shield and antenna wetted materialsare all made of the same polypropylenematerial and hermetically sealed to pre-vent chemical ingress. The Uni-Construc-tion antenna features an internal, inte-grated shield that eliminates nozzle inter-ference. It fits easily into a threaded flangeof even very small diameter nozzles. Inaddition to the Uni-Construction version,a Flange Adapter model offers modular fit with process connections and antennaoptions currently available from Siemens.This flange adapter version can be easilyremoved without breaking the processseal, making the instrument easy to main-tain or upgrade.
The compact electronics are mountedon a rotating head, and the unique designallows you to program it without opening
New radar device enlarges Siemens level monitoring portfolio
More ChoicesWhenever there is dust, heat or foam, radar level monitoring is the technologyof choice. The Sitrans LR 400 and LR 300 devices from Siemens have alreadyestablished themselves for difficult tasks – now Siemens has developed a new2-wire device that features modern radar technology at a reasonable price:Sitrans LR 200 offers a cost-effective level measurement solution for liquid bulkstorage or simple process vessels.
Tim Little, PeterboroughE-mail: [email protected]
The powerful Sitrans LR 400 issuited for very dusty environmentsor monitoring liquid media with lowdielectric properties
Level Monitoring
Unique design, innovative featuresand advance radar technology: Sitrans LR 200
All
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the lid, even in hazardous areas, using theinfra-red, Intrinsically Safe handheld pro-grammer.
High-performance measurement
The low frequency of 5.8 Gigahertz in Eu-rope and 6.3 Gigahertz in North Americais ideally suited to liquid level measure-ment. The high signal-to-noise ratio pro-vides ample signal for a measuring rangeup to 20 meter. Rigid components makethe device extremely robust, so thatSitrans LR 200 can resist pressures up to40 bar and process temperatures up to200 degree Celsius.
Sitrans LR 200 features patented SonicIntelligence signal-processing technologyfor superior reliability, along with AutoFalse-Echo Suppression that detects andsuppresses false echoes from tank ob-structions. For use in hazardous areas, theSitrans LR 200 is also available with ATEXapproval. ■
Sitrans LR 300 uses advancedpulse radar technology to providereliable level measurement evenin environments with strongturbulence or agitation
Radar devices are a reliable solutionfor level monitoring under difficultconditions – for example throughfroth in a wort tank
TRENDSService & Support
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Awell-functioning Service & Sup-port portal on the Internet is a pre-requisite for the effective support
of customers in all project phases. It is an integral part of the Service & Supportportfolio as an initial point of contactavailable all the time from anywhere.
In addition to its revised appearanceand content, the new home page alsotakes users to the desired Service & Sup-port item in German, English, French,Spanish, or Chinese faster than ever be-fore. Direct links from the main naviga-tion items “Product Support,” “Services,”“Info,” and “Support Shop” lead to allsubcategories. There is also a context-re-lated search engine and the opportunity
to adapt the information on offer to one’sindividual requirements. The “Contact”box leads to contacts all over the world forlocal service, spare parts orders, or tech-nical support.
Info on more than 60,000 products
One of the portal’s basic tasks is to pro-vide detailed information about thegroup’s more than 60,000 products. Thisinformation can now be called up from aproduct tree structure adapted exactlyfrom the Internet catalog and the A&DMall. The portal covers a broad variety oftopics, including answers to FAQs, tipsand tricks, downloads, and latest news forthe selected product. More than 5,000
Optimized online support
Faster, SimplerInformationSiemens Automation & Drives (A&D) has further extended and optimized itsService & Support portal on the Internet. Users can now find detailed productinformation, support, contacts, spare parts, and much more – faster, aroundthe clock, and worldwide.
Werner Leidig, NurembergE-mail: [email protected]/automation/service&support
Clear and simple:Modified home page of the extensiveSiemens A&D Service & Support portal
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Use of the Service & Support-Portals
product manuals or instruction manualsare available in PDF format. The intelli-gent search engine speaks the automa-tion engineer’s language: whole sen-tences or questions can be entered orterms linked logically. The result is a listof relevant articles from sources that canbe pre-selected in the Knowledge Base,which holds about 170,000 documents.Users who can’t find what they are look-ing for can e-mail technical support.
Users registered for the free MySup-port service can adapt the newsletter,bookmarks, forms, and product tree totheir individual requirements and signifi-cantly simplify handling. They also haveaccess to the Technical Forum, a world-wide user communication platform.
The Support Shop offers special sup-port tools, including detailed program ex-amples and complete solution elementsthat Service & Support has prepared fromcustomer inquiries. These can be paid forwith the Automation Value Card (AVC),which is rechargeable and is therefore aconvenient means of payment for techni-cal support. ■
The number of users of the Siemens A&D Service & Supportportal has almost doubled from year to year
Velt
ins
Burg
er K
näc
ke
process news 3/2003
26 SHORTLIST
At the C. & A. Veltins brewery in Grevenstein, the Swiss
Siemens Automation Solution Provider bürge-fischer AG
used ten Simatic S7-400 automation systems to modernize
the pallet transport with 1,071 conveyor elements. This, the
most powerful of the Simatic controllers, is, in many senses,
a gain for Veltins. It optimizes the material flow, offers inno-
vative material flow monitoring, and can be extended as
needed thanks to its modularity. Using the communication
module CP 443-1 IT, the brewery can save time and money
by using remote maintenance through the Internet.
With a plant availability of more than 98 percent, the
Chemicals Production Köln-Worringen of the German
BP AG has an excellent reputation in the BP group – an
achievement of which the people at Köln-Worringen are
very proud of. The new ethane cracker was equipped
with a high-performance, fast-reacting process analy-
sis, which meets the high demands of the German BP.
Köln-Worringen had already had good experience with
the Maxum process gas chromatographs and is now
using this technology in the new cracker.
The traditional Burger Knäcke GmbH & Co. KG company
in Burg to the northeast of Magdeburg replaced the man-
ual control of the material feed with weigh feeders when
they were modernizing three different production lines.
To follow the specified recipes in proportioning the ingre-
dients, a high-precision flour feed is an absolute must.
Therefore, Burger Knäcke chose the highly accurate
Siemens Autoweigh Feeders 600 Series, which is ideal for
such applications.
BP
You can find more detailed information about these case studies at:
www.siemens.com/processnews
One-Stop Information andSolutions: Industry Portals for theBeverages and Tobacco Industry
Which controller is right for my process? How can I link my pro-duction data to the ERP system? How can I make my processes moreefficient? Siemens’ industry portals for the beverages and tobaccoindustry answer all these questions.
www.siemens.com/beverageswww.siemens.com/tobaccoVisitors to the tobacco portal can take a virtual tour of tobaccoproduction and can obtain extensive information about Siemens’industry-specific services.The beverages portal is divided into the main areas of malt house,brewery, and soft drinks. For each step in the process, visitors areguided through Siemens’ portfolio of products, solutions, andservices, ranging from sensors for the field level to automation andprocess control systems to complete MES and energy supply solu-tions. Extensive services from plant planning to training measuresround out the program. The portal for the dairy industry should beready by the end of the year.
infosinfosDo you want to know more about the Siemens Automation andDrives systems and solutions for the process industry? Simplyvisit our information portal on the Internet:
www.siemens.com/processautomation
onlineonline
e-business
www.siemens.com/processnewsHere you can download the current issue and past issues of Processnews in PDF format, and search directly for articles about specifictopics, technologies or systems in the Reference Center.
e-business
Impressum process news 3-03PublisherSiemens Aktiengesellschaft,Automation and Drives Division (A&D), Gleiwitzer Str. 555, 90475 Nuremberg
www.siemens.com/automation
Group Executive Management Helmut Gierse, Anton S. Huber, Alfred Ötsch
Responsible for ContentPeter Miodek
Responsible for Technical ContentCornelia Dürrfeld
ConceptChristian Leifels
EditorCornelia Dürrfeld, Siemens AG, A&D SPSiemensallee 84, 76187 Karlsruhe, GermanyTel.: +49 (0)7 21/5 95-25 91Fax: +49 (0)7 21/5 95-63 [email protected]
Editorial CommitteeRichard Ahearne, William Dalton, Dr. Michael Gilluck,Achim Heim, Walter Huber, Michael Lang, Harald Mag,Yves Masson, Hartmut Oesten, Rolf Panzke, Manfred Schirner, Roland Wieser, Deborah Wolin
Publishing HousePublicis KommunikationsAgentur GmbH, GWACorporate Publishing ZeitschriftenP.O. Box 3240, 91050 Erlangen, GermanyTel.: +49 (0) 91 31/91 92-5 01Fax: +49 (0) 91 31/91 92-5 96
Editorial Staff: Dr. Beate Bellinghausen, Robert Engelhardt, Dorit Gunia, Christoph Manegold,Kerstin Purucker (ChR)
Layout: Axel Kornemann, Reinhard Sorger, Jürgen Streitenberger, Werner Völkl
Copy Editors: Regina Severing, Olaf Wolff (Editor in Chief), Sabine Zingelmann
Jobnumber 002100 RPE33
DTP: Doess, Nuremberg
Print: Stürtz AG, Würzburg
process news is published quarterly
Circulation: 26,000
© 2003 by Siemens Aktiengesellschaft Munich und Berlin
All rights reserved by the publisher.
This edition was printed on environmentally-friendlychlorine-free paper.
ISSN 1430-2292 (Print)
The following products are registered trademarks of Siemens AG:BRAUMAT, ET200, NAHMAT, PROTOOL, S7-400, SIMATIC, SIMODRIVE, SIPAN, SITRANS, SIWAREX,TELEPERM, 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 containsmerely general descriptions or characteristics ofperformance which in case of actual use do not alwaysapply as described or which may change as a result offurther development of the products. An obligation toprovide the respective characteristics shall only exist ifexpressly agreed in the terms of contract.
Order No.: E20001-M6303-B100-X7600
Printed in Germany
27DIALOGUE
The market for crop protection products is highly competitive: an extremely wide variety of activesubstances and intermediate products has to be manufactured in customer-specific batches, newproducts brought to market in the shortest possible time and patent lifetimes exploited to the full. BayerCropScience AG is setting new standards with its new multipurpose plant in Dormagen, Germany.Through consistent use of fieldbus technology using PROFIBUS DP Siemens has implemented for thefirst time a fully integrated plant management system. This system collects information plant-widefrom the process automation to the production control level, processes it and incorporates it seamlesslyinto the SAP system on site using SIMATIC IT Framework – all based on Totally Integrated Automation.And linked into this concept is the SIMATIC® PCS 7 process control system with SIMATIC Batch. Themodular design of the plant supported by the MES solution permits highly flexible control of theproduction facilities, which can quickly be converted to other applications. Would you like moreinformation on TIA? Of course! Send us a fax: 00 800/74 62 84 27 with reference AD/1010.
www.siemens.com/totally-integrated-automation
Bayer CropScience AG. Leaders in process engineeringand production management:Making complex processes more flexible with TIA.
totally integrated
