totally integrated - Siemens Industry, Inc.

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totally integrated - Siemens Industry, Inc.

Flexible, comprehensive and customized.

Automation solutions

for the Chemical Industry.

totally integrated


Your competent partner in

automation

Siemens – a name recognized all over the world. A name

that stands for innovation, customer orientation and a

global competitiveness. Not only for 400,000 employees

and millions of customers, but also for hundreds of thousands

of suppliers and partners in more than 190 countries.

Chemicals are part of the fabric of life – from the ingredients

in our shower gels and the shoes on our feet, to the colors

that surround us and the electronic devices that make life

so convenient. Chemicals help to make our world a safer,

more comfortable, more pleasant place to live.

It also stands for a unique range of products, systems and

solutions.

Siemens also embodies the timeless vision of its founder,

Werner von Siemens: “Progress serving mankind”.

With more than 50,000 employees in 70 countries, Siemens

Automation and Drives (A&D) is one of the largest groups

within Siemens AG. As a technology and market leader in

automation and drives technology, we are continually

making rapid advances in this field – and setting new

standards again and again.

Siemens A&D offers a unique, complete range of innovative

products, systems and solutions. Totally Integrated Automation

(TIA) and Totally Integrated Power (TIP) form the

backbone of our portfolio – and the basis for customerspecific

solutions in the field of automation and energy

distribution.

2


Industry Suite Chemicals –

the customized solution for you

In the Industry Suite Chemicals, the worlds of automation

and power engineering merge into one comprehensive and

modular offer for your needs – including the required services

across the entire life-cycle of your plant.

Industry Suit

Totally Integrated Automation

Optimization of the complete workflow

With Totally Integrated Automation, Siemens

is the only supplier of an integrated range

of products and systems for automation of

chemical plants – from the field level and

production control level to the enterprise

level. Your benefit: considerably lower lifecycle

costs for the plant, shorter time-tomarket

and consequent improvement of your

competitiveness.

Process know-how

On the basis of our comprehensive industry know-how, we

implement solutions that guarantee optimum fit and maximum

process transparency for your plant – while requiring

a minimum of manpower.

Tailor-made energy concepts

With our solutions in the field of energy supply, we make a

decisive contribution to the smooth, economical and environmentally

friendly operation of your plant.

Process optimization by means of MES solutions

Our MES solutions are essential to enable you to optimize

your processes throughout the plant. They ensure integrated

data transfer – vertically from the field to the enterprise level

and horizontally from your suppliers to your customers.

3


industry

Basis of the Industry Suite Chemicals: Totally Integrated

Automation and Totally Integrated Power – plus our

comprehensive know-how in your industry.

e Chemicals

Totally Integrated Power

Power management and distribution

from a single source

On the basis of Totally Integrated Power (TIP),

we implement integrated solutions for power

distribution across all chemical production

units and industrial buildings, from the medium-voltage

supply to the outlet. Equipped

with the same communication standards as

Totally Integrated Automation, all resources

– for automation, power distribution, energy

management and building automation – can

be seamlessly integrated and comprehensive

solutions can be implemented in your plant.

Drive solutions

Innovative technology, precisely coordinated components

and comprehensive engineering know-how are your

guaranty that our drive solutions will meet even your highest

requirements – in terms of performance, torque, dynamics,

availability, diagnostics capability and cost effectiveness.

Life-cycle services

Our comprehensive range of services is an efficient lever

ensuring continuous optimum performance of your plants.

With our solutions we cover the entire life-cycle of your

plants – from planning and implementation to modernization

and maintenance.

System integration

In addition to our own established competence and expertise

in the field of system integration we work closely together

with Siemens Solution Partners. The result: a global network

of automation professionals that you can use to your advantage.

Throughout the world, the quality seal of Siemens

Solution Partners has long been a guarantee for world-class

services.


Content

Your Partner in Automation .............................. 2

Industry Suite Chemicals .................................. 3

Totally Integrated Automation .......................... 4

Process Competence ......................................... 6

Process Control System..................................... 8

Manufacturing Execution System ..................... 13

Field Devices .................................................... 14

Industrial Communication ................................ 16

Drive Systems .................................................. 18

Process Instruments and Analytics ................... 20

Industrial Controls ............................................ 22

References ....................................................... 24


Improve your competitiveness

in your industry.

With Totally Integrated Automation

With Totally Integrated Automation (TIA), Siemens offers a unique,

integrated portfolio of products and systems for the implementation of

automation solutions. TIA fulfills your objectives with Siemens technology

and products providing an impressive and unique level of integration.

This not only reduces the cost of interfaces, but also ensures maximum

transparency across all levels – from field, through the production level

to the corporate management level. For all processes in the Chemical

Industry from bulk chemicals, specialty chemicals to consumer products.

It goes without saying that you benefit with TIA throughout the life-cycle

of your plant – from the product design phase, through the operation to

the modernization. With a high level of consistency and integration of

our products and systems, we provide you a high security of investment

– avoiding unnecessary interfaces in the system.

On the basis of Totally Integrated Automation,

we implement solutions that are perfectly

tailored to your special requirements in the

Chemical Industry and which are characterized

by their excellent integration. In this way,

TIA makes an essential contribution to the

optimization of your production processes.

ERP

Enterprise

Resource

Planning

Ethernet

Totally Integrated

Automation

MES

Manufacturing

Execution

Systems

Ethernet

Production

Order

Management

Production

Operations

Recording

Material

Management

Equipment

Management

SIMATIC IT Framework

Production Modeler

Plant

Information

Management

Detailed

Production

Scheduling

Control

SIMATIC NET

Industrial

Communication

SINAUT Telecontrol

System

SIMATIC

Software

SIMATIC Controllers/

Automation System

PROFINET

SIMATIC

Sensors

SENTRON

Circuit Breakers

SIMATIC PCS 7

Process Control System

Industrial

Ethernet

Safety Integrated

PROFIBUS

PC-based Automation

Field Instrumentation/

Analytics

AS-Interface

KNX/EIB

Building

Technology

HART

GAMMA instabus

Micro Automation and

Actuator-Sensor Interface Level

ECOFAST IP65

Distributed

Automation System

SIMOCODE pro

Motor Management

System

SIRIUS

Soft

Starter

SIMATIC

Distributed I / O

PROFIBUS PA

4


The answer to growing demands

Productivity, flexibility, safety and resource efficiency are the key to

economic success in the production processes of chemical plants. Only

companies that can successfully master these challenges can meet the

market demands for short delivery times, ensured quality and prices that

are always in line with the market.

You know the factors required to achieve higher productivity in chemical

plants: a maximum degree of automation, consistent quality – and, last

but not least, the highest possible availability.

Thanks to the system-oriented engineering

environment as well as the integrated communication

and diagnostics options of TIA,

your plant will benefit in every phase of the

life-cycle. What is more, the consistency in

ongoing product innovation offers you

maximum security of investment in case of

modernization.

Product Specification

Management System

Advantages for plant operation

The Siemens range of products and solutions is specifically tailored to

your requirements. Top priority is placed on integration and openness –

in all key areas from automation to drives right up to process instrumentation.

These solutions are based on proven industrial standards and are

optimized to achieve the highest possible degree of economic efficiency

throughout the entire life-cycle of a plant.

Advantages for system integration

Growing pressure on the production side, ever shorter product life-cycles,

rising production demands and an ever greater complexity. On the one

hand, the end customer demands for you as a system integrator are

immense. On the other hand you require solutions, which let you execute

and engineer your customer projects more quickly, precisely and economically

– from the design to commissioning.

Totally Integrated Automation is the foundation for:

shorter time-to-market from the planning to the delivery

higher system availability and flexibility

improved quality of engineering

shorter and easier engineering and commissioning

cost savings in projects

Laboratory Information

Management System

Advantages for the EPC

As an EPC, you must respond to a continuously rising competitive pressure.

At the same time, more is being expected of your solutions all the time

and the demands that you must meet are becoming increasingly complex.

SIMATIC HMI

Human Machine

Interface

SIMOTION

Motion Control

System

SINUMERIK

Computer

Numeric Control

Totally Integrated Automation is the foundation for:

standardized interfaces between E&I engineering packages

highest availability of plant equipment

lower design and engineering costs

faster project execution

higher productivity and flexibility

Drive Systems/

SINAMICS

SINAMICS

SIMODRIVE

SINAMICS

5


Competence for the processes in the Chemical Industry

To ensure economic success in the chemicals business, you

need top productivity, highest flexibility, maximum safety

and the efficient use of resources in all your production

processes. This is the only way to meet the demands for fast

delivery, high and constant quality, and competitive prices.

Typical process units in chemical plants

Reaction

The reaction process is at the heart of chemicals production,

and the greater the efficiency and performance of the catalyst,

the better the product yield and quality. To ensure the best

possible results, key process parameters such as temperature,

pressure and flow must be controlled with great precision.

Heat Exchange

When process media are being warmed or cooled, it’s crucial

for heat exchangers to quickly and precisely reach the right

temperature. At the same time, of course, it’s important to

prevent any contamination or unnecessary energy loss.

Extraction

Using the best possible extraction agents, together with

seamless integration of heat with downstream columns,

brings long-term cost savings in extraction while maximizing

product quality and minimizing environmental impact.

Distillation

Two key parameters determine the economic efficiency of

the distillation process: how much energy is used for vaporization

and condensation, and – as with heat-sensitive

substances, for example – whether environmental conditions

can be completely controlled.

Absorption

Successful, efficient absorption of gaseous product mixtures

depends on selecting the right absorbing agent and controlling

all process parameters. High process and product

quality can only be achieved when all factors are optimally

combined and coordinated.

6


Tailored to the demands of the Chemical Industry:

Siemens automation solution with SIMATIC PCS 7

SIMATIC® PCS 7 is the Siemens distributed control system

(DCS), based on TIA, using standard hardware and software

components and can easily be connected to the Manufacturing

Execution System level (MES).

SIMATIC PCS 7 benefits for the Chemical Industry:

One common engineering tool PCS 7-ES for the complete

process – saves engineering time

One common visualization of all data in all PCS 7 operator

stations with a standard alarm visualization – reduces

production downtimes

Field instrumentation, motors and drives are fully integrated

in TIA and PCS 7, relative to engineering, operation, maintenance

and diagnostics

Pre-configured function blocks and libraries, adapted to

different industry requirements, simplify configuration

High performance automation systems with SIMATIC

S7-400 controller on Ethernet up to 1 Gbps. At the field

bus level, PROFIBUS DP and PA is provided

Redundant controller and PROFIBUS communication for

high-availability processes keep the process running and

reduce production downtimes

Safety Integrated with the PROFIsafe profile on a single

PROFIBUS cable, using one controller and one engineering

tool. This saves time and the expense of additional

components

Standard and fail-safe remote I/O modules on PROFIBUS DP

ensure reliable data transmission and diagnostics.

SIMATIC ET 200M remote I/O modules provide a large

variety of digital and analog input and output channels.

8


Flexibility and scalability – from a small laboratory

system up to distributed client/server architectures

As a result of its modular and open architecture that is based

on selected hardware and software components from the

standard SIMATIC range, SIMATIC PCS 7 can be applied

effectively in small and large plants. It allows easy expansion

or system modification (online) to enable customers to meet

the changing production requirements of their facility.

SIMATIC PCS 7 is scalable from a small single system consisting

of approx. 160 measuring points (motors, valves, PID controllers),

such as might be used for a laboratory system or

a pilot plant, up to a distributed multi-user system with

client/server architecture and approx. 60,000 measuring

points, such as might be used for automation of a very large

production plant or for groups of connected facilities.

Depending on the plant’s requirements, the operator and

the planning engineer can

Select from various automation systems with graded

performance characteristics

Use distributed (remote) or central I/Os step-by-step

Layout an optimum architecture for the operator system:

from single-user standalone stations up to distributed

multi-user system

Select the engineering and runtime system software

according to the size of the system (scaled by process

objects)

Configure communication networks and determine network

components to support required levels of redundancy

and availability

Extend the functionality of the operator stations by

adding various hardware and software modules, e.g. using

SIMATIC BATCH or with a standalone, redundant archive

server

Integrate applications connecting SIMATIC PCS 7 to legacy

systems and the IT system.

Stand-alone systems

Production facilities

Various plants of a production site

Scalable from small applications

(~160 process objects) …

… to the distributed system in client/server

(~ 60,000 process objects)

9


SIMATIC PCS 7:

the distributed control system in Totally Integrated Automation

Open DCS for the future

SIMATIC PCS 7 is based on modular SIMATIC hardware and

software components. The innovative process control system

is fully harmonized with TIA. It is flexible, expandable and

open for future enhancements through the use of standard

interfaces with long-term stability.

SIMATIC PCS 7 consistently applies state-of-the-art, powerful

technologies together with internationally established

industrial standards such as IEC, XML, PROFIBUS, Ethernet,

TCP/IP, OPC, ISA S88 and ISA S95, to mention just a few.

The openness of SIMATIC PCS 7 covers all levels and applies

equally to automation systems, process I/Os and field devices

as to operator and engineering systems, industrial communication

networks or the SIMATIC IT framework. Furthermore,

the system offers completely integrated function blocks for

motors, valves and control devices.

Common and integrated system

SIMATIC PCS 7 can be used on its own or in combination

with Motion Control and further SIMATIC components.

High performance, flexibility and ease-of-use, together with

common data management, communication and configuration,

guarantee that the typical demands placed on a process

control system can be met and exceeded by SIMATIC PCS 7:

Simple and safe process control

Intuitive operation and visualization

Powerful system engineering tools with a common interface

simplify the engineering and save money throughout

the entire plant life-cycle

Online modifications possible throughout the system

System openness at all levels makes plant enhancements

easy

Redundancy at all levels makes high availability scalable

to your needs

Flexibility and scalability simplifies plant improvements

Automation solutions avoid any injury to humans and

damage to equipment and provide high process availability

at the same time

Comprehensive fieldbus integration makes the connection

of field devices easy and optimizes the handling

Direct interfacing to the IT system opens the DCS.

10


Maximum plant availability, with overall

redundancy through all levels

Availability is one of the most important criteria in a chemical

production, and consequently the availability of the automation

solution itself plays a key role in the economical effectiveness

of the plant. On the one hand the capital investment

for a chemical plant is extremely high, and on the other

hand, any production loss due to shut-down and start-up

operations can imply huge economical loss. Plant shut downs

must then be avoided as far as possible – with periods usually

reaching from once a year to less than one shut-down every

5 years for example for a steam cracker.

To guarantee the highest availability of the automation

system, all system facettes have to be taken into consideration:

starting from the controllers up to the operator level

and including the whole plant communication networks,

from the field to the production control level.

optionally with

redundant

power supply

Redundant OS clients and

SIMATIC BATCH clients

OS-LAN (Ethernet) segment 1 OS-LAN (Ethernet) segment 2

OS server

BATCH server

Double redundant Industrial Ethernet plant bus

S7-400H

high-availability automation system

ET 200M

ET 200M

BATCH server

Actuator/Sensor

Depending on each of your specific requirements, environmental

and vulnerability aspects of your plant, TIA and

SIMATIC PCS 7 can provide you the best adequate redundancy

configuration. Based on a flexible, comprehensive concept

we can offer up to the highest availability levels, seamlessly

integrating all plant levels, from the sensor/actuator to the

control room – while responding to the harshest Chemical

Industry environment conditions.

Operator stations (OS) and batch clients

Operator station bus level (terminal bus):

• Use of standard off-the-shelf components (switches,

cards etc.)

Increased availability, with single ring architecture or

terminal bus split into several LAN segments

Multi-monitor operator stations, up to 4 monitors per

client

Batch client/server architecture, permitting up to

32 OS/SIMATIC BATCH clients to access the data of a

single OS/Batch server.

OS- and batch servers

Redundant OS server, with automatic and transparent

switch-over of the OS client stations, between primary

and backup server

Redundant batch server

Process data can be archived on each OS server or can be

stored on a standalone, and optionally redundant, plantwide

historian

Critical OS/SIMATIC BATCH running as a background task

on the server are continuously monitored for faults that

would result in a client switchover

Process data and alarm messaging archives can be automatically

synchronized when a partner server is returned

to service, thus eliminating data gaps.

Redundant PROFIBUS DP

Redundant

DP/PA Link

ET 200M

fail-safe

PROFIBUS PA

Y-Link

Connection of

non-redundant

PROFIBUS DP devices

on redundant

PROFIBUS DP

11


Automation system and plant bus

Dedicated Ethernet LANs for client-server and server-server

communication

Communication between automation systems, engineering

stations, operator systems over Industrial Ethernet plant

bus, at up to 1 Gpbs; both line or ring topology possible

Increased availability with redundant ring architecture

Redundant, high-availability S7-400H automation systems,

connected to plant bus over dedicated Ethernet communications

processor (CP)

Optionally, for even higher level of redundancy, each of

the 2 automation station CPUs can be connected via two

separated CPs, thus each CPU to be connected simultaneously

to both networks of redundant plant bus architecture.

Redundancy at the distributed I/O level

Multiple PROFIBUS DP segments can either be connected

to distributed I/Os via the onboard PROFIBUS DP interfaces,

or using additional PROFIBUS communications processor

modules

Using the ET 200M distributed I/O system, redundancy can

be extended down to the I/O module level, whereby a

single sensor/actuator can be connected to redundant I/O

modules

Using redundant controllers, each ET 200M unit is connected

to the redundant PROFIBUS DP segments.

Redundancy of field devices

Intelligent field devices on PROFIBUS PA fieldbus segment

can be connected via a redundant DP/PA link

Non-redundant PROFIBUS DP devices can also be connected

to a redundant PROFIBUS DP network segment, using our

Y-link.

Asset Management for systematic automation and

maintenance of plants

Siemens offers an efficient solution for plant maintenance:

SIMATIC PCS 7 Asset Management. The particular highlight

here is that the new feature is simply integrated into the

SIMATIC PCS 7 process control system. No additional hardware

or software tools are required. Plant operators and maintenance

engineers use the same SIMATIC PCS 7 tools and

operator interfaces with information that has been filtered

and prepared for the relevant application area.

Complete integration of field devices

SIMATIC PCS 7 is optimized for integration of distributed field

equipment into the process control systems, and is based

on PROFIBUS technology. It supports redundancy and failsafe

architectures, in addition to online expansions, and can

be used in standard environments or in hazardous areas.

The plant can be equipped with conventional SIMATIC ET 200

distributed I/Os, or with state-of-the-art, intelligent field

devices.

12


SIMATIC IT: the basis for increased productivity

Maintaining a highly flexible and efficient production process

allows chemical manufacturers to maintain market position

and deal with competition. SIMATIC IT is the Manufacturing

Execution System from Siemens. It enables chemical manufacturers

to optimize production. This is possible by bridging

the gap between business systems and the control level and

by synchronizing operations all along the production and

product life-cycle. SIMATIC IT offers integrated quality assurance,

product specification management, tracking and tracing

and comes with functionality specifically tailored to the

needs of the Chemical Industry, complying ISA-95 standard.

MES – Manufacturing Execution System SIMATIC IT

SIMATIC IT links the plant floor with the business systems

and increases plant visibility. Due to its modular, object

oriented, open and scaleable architecture, SIMATIC IT enables

customers to standardize repeatable processes at the production

level while increasing flexibility at the operational

level.

SIMATIC IT Production Suite is composed of the SIMATIC

IT Framework and SIMATIC IT Components. These components

include MES functionality for order management,

material management, personnel management, report management

and messaging. SIMATIC IT Framework provides

the graphical environment to model the production process,

allowing for a clear understanding of the plant’s behavior

and visualization of the production.

SIMATIC IT Unilab is the Laboratory Information Management

System that models and manages the complete workflow

of all quality data in the laboratory and on the production

line, optimizing the collection, analysis, retrieval and reporting

of laboratory data. SIMATIC IT Unilab is able to manage all

types of analysis in a lot of languages and helps organizations

to deal with critical issues in communication between the

laboratory and customer service, by making it easier to share

information with internal as well as external customers.

SIMATIC IT Unilab complies with regulatory rules such as FDA

(cGMP, GLP, 21 CFR 11), GALP, GAMP4, ISO 9000:2000, and

ISO17025.

SIMATIC IT Historian is a collection of software modules

to collect, store and quickly retrieve process and production

information for Quality Assurance, Reporting, Certifications,

Statistical Analysis, Performance Monitoring, Down Time

Management, Overall Equipment Effectiveness (OEE) etc.

SIMATIC IT Historian delivers business information for decisionmaking

and plant optimization and complies with the FDA’s

21 CFR 11. SIMATIC IT Historian is part of SIMATIC IT or can

be implemented separately.

SIMATIC IT Interspec is the specification management

system that handles product specifications for raw materials,

semi-finished and finished products, as well as packaging

materials. This incorporates company-wide specifications as

well as individual specifications for a single plant, supplier

or customer. SIMATIC IT Interspec can be implemented

separately or as integrated part of SIMATIC IT.

SIMATIC IT Report Manager is an optional component of

SIMATIC IT and offers advanced, fully integrated and userfriendly

reporting functionality. The Report Manager meets

regulatory requirements for standard and ad hoc reporting

(for example, the upcoming REACH and Global Hazard Classification

System) and offers valuable operational insights.

13


SIMATIC S7: the comprehensive range of controllers –

highly reliable and powerful

SIMATIC S7 controllers provide network communication,

IT service functionality etc. with the help of highly efficient

operation processing, flexible communication extension and

reliable, powerful control capabilities. That is why SIMATIC

S7 controllers have the highest global market share.

SIMATIC S7 controllers can be installed and operated in

different environmental conditions, such as dry tropical, low

temperature, humid tropical etc.

Our controllers meet the following standards: DIN, EN, IEC,

UL certification, CSA certification, Class FM1 Sec.2; group A,

B, C, D, temperature group T4 (°


SIMATIC ET 200:

decentralized field devices for all requirements

SIMATIC ET 200 distributed I/O modules can all be connected

to PROFIBUS DP, some of them like ET 200S can even be

connected to PROFINET. They are used to connect various

field devices to the industrial control system, e.g. switches,

sensors, transducers, pushbuttons, panel lights, valve positioners

etc.

SIMATIC ET 200 offers a complete product range for any

application needs – ET 200M with multi channel design,

ET 200S for bit granular I/Os and function modules, ET 200iSP

for intrinsically safe applications, ET 200pro for high protection

in IP65 and ET 200eco in a cost-effective design with IP65

protection.

Advantages

Powerful functional modules – internally integrated standard

and safety motor starter module, frequency converter module,

pneumatic system modules, standard and safety I/O modules,

local intelligent and technological modules and safety technology

modules. Hot swapping means fast replacement of

I/O modules or motor starters during operation in order to

keep production downtimes and maintenance work at a

minimum.

Powerful system diagnoses, offering three levels of diagnoses

for the interface module and bus communication. This means

that faults are immediately detected and can be solved easily,

resulting in lower service and maintenance costs.

Distribution with SIMATIC ET 200iSP in hazardous areas

In most companies, time and cost pressures belong to everyday

life. Increasingly shorter production times and reduced

costs are requested in all operational areas. In order to

manage these demands, many users in the process and

production industries apply distributed solutions, with remote

I/O devices allowing sensors and actuators to be connected

to a bus system in a cost efficient way.

Cabling costs and the number of standard terminal blocks,

junction boxes, IS barriers, which are normally used, are

clearly reduced. PROFIBUS has become the standard fieldbus,

also extending into hazardous areas.

The SIMATIC ET 200iSP (iSP stands for intrinsically safe for

process industry) from Siemens is a modular, intrinsically

safe I/O system with IP30 degree of protection for hazardous

areas. It can be used both in gaseous and dusty atmospheres,

and offers many convincing advantages.

SIMATIC ET 200S motor starters: for simple parameterization,

diagnostics, and monitoring

The communication-capable motor starters of the distributed

I/O system ET 200S offer integrated safety and diagnostic

functions in one device. The motor-starter is a pre-wired and

remote-parameterized unit consisting of a circuit breaker,

an electronic overload relay and a contactor or soft starter

which switch the motors up to 7.5 kW. By means of PROFIBUS,

the motor starter reports diagnoses, for example short-circuit,

phase asymmetry, operating current or overload, to the

control system. This helps to reduce downtime costs by a

quick and detailed diagnosis.

15


SIMATIC NET:

industrial communication for plantwide automation

The business drivers in industrial communication are improved

efficiency and safe data transfer in the plant. These

criteria are crucial to ensuring that process in your plant

works perfectly. This can be achieved by using open, transparent

communication not just on the process level, but

also through ERP systems.

The SIMATIC NET industrial communication products provide

the technology you need to:

Realize true distributed automation

Enable data transparency from the field level through to

the management level

Integrate IT technologies.

Industrial Ethernet: today’s leading local area

and cell network

Across all applications, Ethernet is number one worldwide

in today’s LAN landscape. Ethernet provides important

features and performance characteristics which can provide

many important benefits for your application:

Virtually unlimited communication capabilities and

scalable performance

Company-wide communication thanks to Wide Area

Network (WAN) technologies.

SIMATIC NET provides important additions to traditional

Ethernet technology for use in industrial environments:

Network components designed for use in rugged industrial

environments

High-availability networks using redundancy

Constant monitoring and diagnostics of network

components

Fast on-site industrial cable assembly.

SIMATIC NET communications processors:

connecting controllers, computers and notebooks to

Industrial Ethernet

Utilize Industrial Ethernet for programming, monitoring,

peer-to-peer communication, connection to IT

Ability to function as Web and FTP server and client for

communication of production information

OPC server included with the communications

processor.

SCALANCE W: industrial mobile communication

Install a plant-wide Ethernet network without running any

wires

Wireless flexibility with the reliability of a wired network

Eliminate wireless “dead zones” with active antenna

diversity – the strongest signal is constantly used

Deterministic data transmission allows time-critical

connections to be realized

Industrial WLAN adheres to the specifications defined in

IEEE 802.11 and Wi-Fi 802.11 in order to enable a high

degree of interoperability

Security wizard enables Wi-Fi Protected Access (WPA)

with encryption for maximum security

Designed for industrial applications with enhanced

resistance to vibration, shock, and environment (IP65,

temperatures from –20 to +60 degrees Celsius) with

options for redundant power supply.

SCALANCE X: switches for Industrial Ethernet

This product family provides a graduated portfolio of industrial

switches, some of which feature comprehensive diagnostic

functions via PROFINET, SNMP and the Web, for a

variety of requirements (e.g. network structure, data rate,

degree of protection, number of ports). These network

components are optimally tuned to one another. They have

been designed for a rough industrial environment and

facilitate consistent, flexible and safe structuring of highperformance

networks.

16


PROFIBUS: the world’s leading field bus

PROFIBUS network technology provides rich benefits for

almost any application in industrial automation. Devices

such as remote I/Os, drives, controllers, identification systems,

motor starters, weighing & dosing systems, human

machine interfaces etc. are connected via a single cable.

PROFIBUS is primarily used at the field level with interfacing

capabilities downward to the sensor/actuator level as well

as upwards to the production and enterprise levels.

SIMATIC communications processors:

connecting controllers to PROFIBUS

Utilize PROFIBUS for connecting distributed devices,

peer-to-peer communication, and programming

Independent communications coprocessor ensures

consistent scanning of distributed devices regardless

of controller scan

Multiple communication processors can be used to

segment distributed devices

Support for redundant I/Os in conjunction with

redundant controller

OPC server included with the communications

processor.

AS-Interface:

communication for sensors and actuators

Sensors and actuators play an important role in automated

processes. Whether it concerns the detection of valve states

or the correct level in a reactor or tank: sensors are the eyes

and ears of process control.

For a long time the cabling of transmitters and recorders

followed the old pattern: each sensor or actuator was

connected individually and with parallel wiring to the higherlevel

controller. Because the AS-Interface now provides you

with a bus system that implements the connection of all

automation nodes in the field to the higher-level controller

– simply, securely and cost-effectively. The AS-Interface

transmits process-level digital and analog signals and

connects proximity switches, valves, indicator lights and

other actuators and sensors to the higher-level controller.

17


Drive systems: reliable, precise and efficient

In many applications in the Chemical Industry, the use of

frequency drives to regulate motor speed makes drive

technology more efficient. Variable speed allows much

more precise control of processes, such as the transport

and dosing of products, and at shorter response times than

do mechanical control concepts. In addition, soft starting

and deceleration in the variable-speed mode goes easy on

the entire drive train’s mechanical components. This prevents,

for example, pressure waves in pipeline systems.

Unfavorable operating conditions, such as cavitation, parallel

transport of gas or solids, ultrasonic compression shocks

and vibration can be avoided by using a frequency converter.

Savings potential

Variable-speed mode also saves a very significant amount

of energy, particularly in applications involving quadratic

load torque, like fans, pumps and compressors, as compared

to fixed-speed motors. Depending on the plant characteristic,

energy savings may reach 50%. Because of this, a frequency

drive soon pays for itself, often within only a few months.

For the most part, variable-speed drive tasks in the Chemical

Industry are covered by MICROMASTER 440 frequency drives

and SINAMICS G150 frequency drives.

SINAMICS: the new drive family

All members of the new SINAMICS drive generation profit

from the same core technology and have the same ”look

& feel“. An example are the standard engineering tools –

SIZER to engineer drives and STARTER to commission them.

In addition, all high power cabinet units of SINAMICS are

equipped with an AOP 30 operator panel with its selfexplanatory

menu prompts, which are output in plain text

via the user-friendly graphic display. This permits extremely

simple operator control and diagnostics. For the Chemical

Industry with its pumps, fans, mixers and extruders, the

SINAMICS G150 cabinet units and the SINAMICS G130

chassis units are the primary choices for consideration.

MICROMASTER 440 frequency drives: packed with

functionality for a wide range of applications

Whether it involves mixing drives in conjunction with offset

shaft geared motors, agitators in hazardous areas, extruders

requiring a high starting torque or, for example, foil processing

machines where several drives run in synchronized

operation – our MICROMASTER 440 frequency drive is the

best selection where maximum functionality and higher

dynamic performance is demanded. Typical applications:

Transportation of fluids or gases and solid substances,

metering and mixing, filtering, extruding, lifting.

18


Specially for pumps, fans, compressors, mixers

and extruders

The units are specially geared toward drive tasks without

regenerative feedback in applications with quadratic torque

characteristics, such as pumps, fans and compressors, but

also constant-torque drives such as extruders, mixers, mills

and conveyor belts.

SINAMICS G150 cabinet units cover voltage classes from

380 V to 690 V. Power ranges are from 75 kW to 1500 kW.

The clear, well-structured design of the SINAMICS G150s

makes the units rugged and reliable. In case of service, the

modules can be replaced in just a few steps.

Simple and user-friendly

Above all, however, the units are appealing thanks to their

user-friendly operation. Preconfigured and thanks to the

clear operating concept, customers take profit from

functionalities that they really need. The easy-to-use

operator and commissioning functions are shown on the

graphic display in plain text. In addition, SINAMICS G150

cabinet units have a footprint that is up to 70 percent

smaller than the footprint of conventional converters. Noise

levels of only 69 db(A) during full operation, even in the

case of cabinet units with a power output of several 100 kW,

make additional soundproofing measures unnecessary.

Demands of the Chemical Industry are fully satisfied

SINAMICS G150s fulfill all demands made by the Chemical

Industry. For example, the units are equipped with NAMUR

terminal blocks as well as NAMUR functionalities specifically

for the Chemical Industry. As alternative to NAMUR terminal

blocks, it is possible to use the PROFIBUS Profile PROFIdrive

3.1, ”Process Engineering“ mode. Safe electrical isolation

according to PELV is also ensured.

In order to restrict the steep voltage edges customary for

IGBT voltage source converters as well as phase-to-phase

voltage on the motor, dV/dt filters are available which limit

the voltage gradients. In addition, the phase-to-phase

voltage is also limited in the case of long motor wires. An

EMC filter for secondary environment category C3 to EN61

800-3 is integrated as standard. Sinusoidal filters are also

available for particularly high demands.

SINAMICS G150 covers the majority of drive tasks with high

power requirements. If required, the SINAMICS G130, a

chassis unit with the same functionality and performance,

is also available. SINAMICS S150 cabinet units and

SINAMICS S120 chassis units represent a viable alternative

when the energy supplier places particularly high demands

on the network quality or in the case of weak networks.

With these units, the active infeed technology reduces

phase effects on the system to a minimum and protects

the drive system against power dips. For drive tasks requiring

several megawatts – such as very big mixers or extruders –

SINAMICS GM150 medium-voltage frequency drives are

the most cost-effective solution.

19


Process instruments and analytics:

the full range for all measuring tasks

Siemens offers a broad product portfolio of process instruments

and analytics. All devices fulfill the needed certifications

in the Chemical Industry.

Process Instruments

Throughout the Chemical Industry, measurement requirements

can be extreme. Every substance is different and

needs an individual solution. As the measurements are

often done in extremely harsh ambient conditions, specialized

process instruments (e.g. pressurized enclosures) are

often required for the relevant approvals (ATEX, FM, SIL,

WHG etc.)

Siemens process instruments offer advantages on the

automation level as well as for the asset management of

your plant.

Level

Continuous measuring or point level detection is based on

radar, ultrasonic or capacitive methods. From a storage

tank to stirring machines with high pressure, foam and

steam – with the product family SITRANS L and POINTEK,

we can fulfill the most common challenges in the level

measuring technology.

Flow

Especially in the Chemical Industry, the tasks in measuring

the flow are versatile, just as our products are.

Magnetic-inductive and ultrasonic flowmeters or Coriolis

flowmeters are used for this. “Classical” mechanical methods

are also available: Rotary piston meters, variable-area

flowmeters, or measuring orifices remain an integral part

of our product family SITRANS F.

Temperature

Whether high temperatures, high pressures, or aggressive

media, temperature measurement applications are not

always easy and are often done in harsh ambient conditions.

Our SITRANS T transmitters are available in different types,

from simple to intrinsically-safe with diagnostics and simulation

options.

Pressure

Whether relative, differential or absolute pressure, the

SITRANS P pressure transmitters provide precise pressure

measurements. The SITRANS P DS III instrument is ideal

where highly aggressive media and harsh ambient conditions

require experienced solutions and can be used for

safety-related measuring points in accordance with SIL 2.

Weighing

The SIWAREX weighing systems can easily be integrated

into the automation structure of the process, and the

SIMATIC PCS 7 process control system. In addition to electronic

weighing systems and cells, you can select from an

extensive range of Siemens-Milltronics belt scales, weigh

feeders and solids flowmeters.

Diagnostics

Reducing production downtimes is an increasing challenge

for a plant operator. Easy and versatile diagnostic functions

help to achieve these requirements.

To parameterize these functions, you can use our Process

Device Manager (PDM) software tool, usable for all field

devices. It facilitates the manufacturer-independent operation,

adjustment, maintenance and diagnostics of intelligent

process devices. Regardless of the automation system, it

can be applied via PC, or programming devices, or integrated

into the SIMATIC PCS 7 automation system.

With our SIPART PS2 valve positioner e.g., which is the most

frequently used intelligent positioner for linear and rotary

actuators, leakages at valve drives can be detected immediately.

A created warning message helps the maintenance

team to keep the process in optimized run.

20


Analytics

The capabilities of modern process analytics can be the key

to a significant increase in efficiency, productivity, or safety

of chemical processes.

Continuous process analytics

The continuous gas analyzer of the Siemens series 6,

ULTRAMAT, OXYMAT, FIDAMAT, and CALOMAT, were originally

designed to fully meet the requirements for process analytics

in the Chemical Industry. Except for the FIDAMAT, based on

flame ionization detection, all analyzers are available in field

housings for operation in hazardous environments.

The intrinsic design of the analytical part of ULTARMAT and

OXYMAT and the materials in contact with the process gas

stream are chosen to withstand even highly corrosive gases.

Because the measuring system has no moving parts and

can be ordered in corrosion resistant materials like titanium

or tantalum the OXYMAT became the standard oxygen

analyzer in chlorine chemistry. Beside this, the excellent

analytical performance of the series 6 analysers make them

first choice in critical process applications in terms of

sensitivity and stability.

Optimized production of ethylene oxide

The efficiency of the ethylene oxide process increases with

the concentration of oxygen, while it is crucial to stay below

the lower explosion level (LEL). Due to its outstanding

stability, only the OXYMAT allows the process to be operated

at a set point of 5% O 2 , where competitive analyzers only

allow 4% O 2 . Thus, the process efficiency is increased by 1%.

21


Industrial controls and power distribution

More often the data of the motor feeders are also integrated

into the process control system. Intelligent motor management

systems, communication-capable motor starters and

circuit-breakers support this trend and make all relevant

data available via PROFIBUS. This increases the transparency

of your process and ensures a significantly greater density

of information in the control system – at no extra cost.

Standardized motor function blocks, for example, simplify

the integration and the engineering.

SIMOCODE pro: the flexible and modular motor

management system

SIRIUS motor management and control devices (SIMOCODE

pro) are the first choice for constant speed motors in the

low voltage range. SIMOCODE pro optimizes the connection

between control system and motor feeder, increases the

plant availability and achieves considerable savings in the

construction, commissioning, operation and maintenance

of your plant.

It also involves an extremely compact design, a straightforward

and efficient service and maintenance as well as a

range of graduated functions. In addition, SIMOCODE pro

meets all requirements for future-proof energy management

and offers advantages in all areas: in process management,

operations management or in switchboards.

Some extensive features:

Multifunctional, electronic full motor protection,

independent of the automation system

Flexible software instead of hardware for the motor

control

Detailed operating, service and diagnostics data

Open communication via PROFIBUS DP

Integration and monitoring of additional process values

Detection and monitoring of power-related measurements

ATEX-certified (overload protection of explosion-protected

motors).

SIVACON systems: for customized communication

solutions

SIVACON systems are low-voltage communication-capable

switchboards and busbar trunking systems with a high

degree of flexibility and availability. All of these features

provide a seamless integration into the automation environment.

Using switchgear and switching devices we offer a common

integrated communication concept for customized solutions:

e.g. with SENTRON circuit-breakers, SIMOCODE motor

management system and SIMATIC.

So SIMOCODE pro is likely to be used in SIVACON lowvoltage

Master Control Centers (MCC) and allows load

feeders to be configured. Load feeders that have a higher

performance and at the same time are extremely compact

and able to communicate.

The high degree of modularity allows all communication

components to be simply retrofitted. Innovative software

products offer user-friendly parameterization, diagnostics,

operator control and visualization locally via PROFIBUS DP

or Ethernet/Internet.

22


SENTRON: power distribution

With only a few modular components, you have the possibility

of thousands of different combinations for all of your

energy distribution applications. The products in the

SENTRON circuit protection system tie into your automation

architecture giving you the power to increase production

system availability. In addition, you can further optimize

the energy distribution process with a networked power

management solution. Never before have circuit-breakers

been so versatile and so simple.

SENTRON: optimized energy solutions

SENTRON circuit-breakers address your critical needs for

less installation space, reduced operating costs and optimized

energy usage for molded-case circuit-breaker 3 VL

from 16 A up to 1600 A and for air circuit-breaker 3 WL

from 630 A up to 6300 A. Web Server – Breaker Data Adapter

(BDA) is the first circuit-breaker communication device with

integrated web server to parameterize, operate and monitor

SENTRON circuit-breakers. Circuit-breaker data can be

accessed from any device supporting an Internet browser

with Java Virtual Machine. The BDA Plus incorporates an

Ethernet interface for direct connection to Ethernet / Intranet /

Internet. Switch ES Power, a configuration software, offers

complete integration into the automation engineering

environment.

The parameterization, operation and monitoring of the

SENTRON circuit-breakers can be done via the PROFIBUS DP

network. SENTRON circuit-breakers are completely integrated

into the SIMATIC world and the STEP7 engineering software.

Data management, configuration and programming is

integrated into the automation project SIMARIS manager

– Power Management Software to manage energy distribution

systems.

This modular and integrated power management software

is based on SENTRON switching devices and Totally Integrated

Automation. This not only facilitates efficient diagnosis,

alarm, and maintenance of SENTRON circuit protection

devices as part of a Totally Integrated Power solution but

also optimizes laboratory, investment and energy supply

costs through continuous analysis of energy data.

23


Best practice example:

INEOS Phenol production site in Gladbeck, Germany

INEOS Phenol is the world’s largest manufacturer of phenol

and acetone, with production sites in Gladbeck, Germany;

Antwerp, Belgium; and Mobile, Alabama, USA. In the course

of the company’s history, the Gladbeck site has experienced

significant development. The capacity of the plant at the

beginning of production in 1954 was a relatively modest

8,000 tons of phenol and 5,000 tons of acetone. Today,

Gladbeck is the largest phenol plant in the world, with an

annual capacity of 630,000 tons of phenol and 390,000

tons of acetone.

Customer requirements

When INEOS was looking for a partner to modernize the

existing process automation system for the entire factory,

the company first performed an extensive comparison of

various control system suppliers. SIMATIC PCS 7, though

facing strong competition, was able to establish itself as

the winner.

The INEOS order included replacement of all the installed

control technology on the entire site, with about 8,000

I/Os, and the merging of two control rooms. One decisive

factor for awarding the contract to Siemens, aside from the

previous positive experience INEOS had made with Siemens

in low-voltage projects, was the fact that PCS 7 offered a

modern, innovative, and efficient control solution that is

based on future oriented standards and Totally Integrated

Automation. The integrated safety technology and the high

system availability due to redundant solutions were also

decisive. In addition, PCS 7 offered the possibility of replacing

installed control technology during ongoing operation –

allowing the Gladbeck plant to continue to operate without

interruption.

Siemens solution

The new solution is based on a total of eight SIMATIC

S7-400FH automation systems. One redundant OS Server

and ten Clients plus one MultiClient as well as one

Engineering System were installed in the new control room

that resulted from merging the legacy system. The entire

plant was upgraded with no shutdown of production –

a very important aspect in high throughput continuous

processes such as phenol synthesis. The legacy systems

were changed over “loop by loop“, and the application

software of the legacy controllers was also converted.

Customer benefits

The conversion from the previous control solution to SIMATIC

PCS 7 went smoothly, without interrupting plant operation.

With SIMATIC PCS 7, INEOS now benefits from increased

safety and system availability through redundancy on all

levels, and integrated fail-safe technology.

24


Best practice example:

Jilin Fuel Ethanol Co. Ltd., China

Jilin Fuel Ethanol Co. Ltd., a subsidiary of China National

Petroleum Corporation (CNPC), is a joint venture formed

by CNPC, Jilin Grains Group (JGG) and China Resources

Group. This project was the first plant dedicated to the

production of fuel ethanol from corn in China with a capacity

of about 600,000 tons of ethanol per year. The plant consists

of two production lines and the capacity of a single line is

300,000 tons per year. The first production line was started

on September 22, 2001 and was launched on August 31,

2003. This ethanol fuel pilot plant in China has become a

prestige project for the Chinese government.

Customer requirements

This significance and the fact that the application is quite

large regarding the extension and the number of I/Os were

asking for a state-of-the-art automation solution. When

choosing the appropriate automation solution, high availability,

safety, and a future-oriented solution were central

criteria for Jilin Fuel, as was local expertise and know-how

for project engineering and maintenance.

Seamless integration of the safety technology, the great

openness of the system, an excellent price/performance

ratio of the concept, and last but not least the benefits of

the uniform automation solutions based on Totally Integrated

Automation tipped the balance in favor of automating the

plant using SIMATIC PCS 7.

Siemens solution

The entire system, which comprises a total of 9,000 I/O

points, is controlled from two PCS 7 control rooms. Eight

safe and fault-tolerant S7-400FH automation systems and

two fully redundant optical Industrial Ethernet rings form

the reliable backbone of the control system. The system

also collects and transfers all production and units data,

including the corn storage facilities and other utilities, to

a real-time production monitoring system. The devices at

the process level are connected to the PCS 7 systems via

PROFIBUS DP fieldbus, using the fiber-optic technology to

bridge distances of up to 1100 meters on the plant field.

Customer benefits

The production and process management has been optimized

and plant efficiency has been improved. Production

cost, such as materials cost and management cost, have

also been reduced.

The data management has become more transparent, with

the implementation of Manufacturing Information System

(MIS) and the web functionality at the operator-station

level. At the same time, the maintenance workload has

been reduced, due to the high stability and reliability of

the SIMATIC automation systems and components. At the

bottom line, product quality has been improved and now

meets one hundred percent of the market requirements.

25


Best practice example:

Bayer polycarbonate production facility in Map Ta Phut, Thailand

Global companies are increasingly relying on standardized

processes and systems – in order to exploit rationalization

potential for spare parts, training, and service across all

their locations. Bayer is no exception. The company-wide

specifications were recently implemented with the SIMATIC

PCS 7 process control system in the modernization of a

small batch line in Thailand.

Customer requirements

Bayer operates a polycarbonate production facility in Map

Ta Phut in Thailand that supplies base materials for a number

of applications. The company wished to equip a small-lot

compounding line that produces colored thermoplastics

resin with an automation system that was state of the art

and also complying with Bayer’s worldwide technology

standards. The aim was an integrated solution for the automation

of the entire production process – a task that was

completed through close cooperation between Bayer and

Siemens directly on-site in Thailand. The SIMATIC PCS 7

process control system provided the basis.

Siemens solution

SIMATIC PCS 7 and the Bayer toolkit control all processes

in the plant. The compounding line is one of the first in the

world to use the latest version 6.0 of PCS 7. SIMOCODE and

SIMOREG (DC Drives), linked to the control system by

PROFIBUS, were used as well. The feeders are also integrated

with the control system via a gateway.

The front end is a graphical user interface that is now being

used in all Bayer plants throughout the world. It is characterized

by a flowchart that displays the entire production

process so that the operating personnel have a complete

overview of the current production steps at all times. New

recipes can be created using a PC in the lab sector and then

simply up- or downloaded to the control system in the form

of Excel tables. After completion of a batch, all the production-related

data are returned for documentation, and can

also be displayed as an Excel table.

Customer benefits

The automation concept was implemented jointly with

local partners and uses standard routines developed by

Bayer and Siemens Thailand. The application is a typical

example of a company-wide strategy encountered today

in more and more globally active companies: exploiting

rationalization potential in production through the standardization

of processes and systems. With the company’s

unique combination of a local presence and global knowhow,

Siemens is able to optimally support this strategy.

26


Best practice example:

RohMax Additives production facility, Germany

RohMax Additives GmbH, a Degussa AG´s Company of the

Specialty Acrylics Group, develops and produces innovative

and customized additives for lubricants. With a wide product

portfolio of roughly 120 products RohMax belongs to the

high-yield companies on the specialty chemicals market.

Customer requirements

The production of additive is a complex multi-phase batchoriented

polymerization process – with numerous ingredients,

that have to be selected and batch recipes, that lead

to the highest requirements in the matter of batch planning,

batch control, recipe management and route control. Among

several goals of the production improvement, the plant

operational safety was also important. A further optimization

potential in this plant has been exploited in creating a direct

coupling between the production and business level. The

existing ERP-legacy system SAP, via the Production Planning

Module for process industries (PP-PI interface), is seamlessly

integrated into the management execution level with

SIMATIC IT, thus enabling the tightest synchronization

between production orders and the plant operation, and

avoid any wrong production orders.

Furthermore, the SIMATIC IT MES functions work perfectly

with SIMATIC PCS 7 batch flexible at the batch and control

levels. It provides the required extensive and flexible production

order and material and resource management as

well as the necessary archiving and reporting functions in

an efficient and user-friendly graphic environment.

Customer benefits

A higher plant availability was also a decisive factor – with

the high standardization level of using TIA components

throughout the whole plant, the stock of spare parts was

reduced. Maintenance times could also be reduced thanks

to the efficient diagnostic and error identification of the

system.

During and after this project, improvements could also be

reported at several levels of the plant life-cycle. For operators,

processes have been made easier to control and at the

same time, the production has become more flexible. At

the bottom line RohMax can now deliver products with

higher and more stable quality.

Siemens solution

Heart of the modernized plant are the SIMATIC PCS 7 process

control system and the innovative Manufacturing Execution

System (MES) based on SIMATIC IT. The openness, use of

standards and the scalability of this solution are securing

ability for quickly and economically adapting the additives

production with high flexibility to changing demand.

27


Further information:

www.siemens.com/chemical

www.siemens.com/totally-integrated-automation

Subject to change without prior notice 10/06 | Order No. E20001-A310-P200-X-7600 | Dispo 06303 | 41C9847 MK.GC.LT.YTIA.52.7.06 WS 10062. | Printed in Germany | © Siemens AG 2006

Siemens AG

Automation and Drives

www.siemens.com/automation

All product designations may be trademarks or product names of

Siemens AG or supplier companies whose use by third parties for

their own purposes could violate the rights of the owners.

The information provided in this brochure contains merely general

descriptions or characteristics of performance which in 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 only exist if expressly agreed in the

terms of contract.

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