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ideas<br />

singapore<br />

The magazine for Industrial Innovations<br />

MICA (P) 045/11/2007 Issue 04/08<br />

<strong>Wireless</strong> solutions in the<br />

manufacturing environment<br />

<strong>Wireless</strong><br />

<strong>Flexibility</strong>


C o n t e n t s<br />

i d e a s s i n g a p o r e | 0 4 - 0 8<br />

<strong>Siemens</strong> AG<br />

<strong>Siemens</strong> AG<br />

<strong>Siemens</strong> AG<br />

Page 4<br />

WIFI promotes <strong>Wireless</strong> LAN<br />

standards with the aim of improving<br />

the interoperability of wireless local<br />

area network products.<br />

Page 10<br />

The fast growing photovoltaic<br />

market offers opportunities for<br />

sili-con producers and their<br />

suppliers.<br />

Page 18<br />

The Simatic Mobile Panel 277F IWLAN, is<br />

the first wireless HMI device with safety<br />

and has two enabling buttons and an<br />

emergency stop button.<br />

p Cover<br />

<strong>Wireless</strong><br />

04 <strong>Wireless</strong> <strong>Flexibility</strong><br />

<strong>Wireless</strong> solutions in the<br />

manufacturing industry<br />

p Industry<br />

Bioethanol<br />

08 Clever Alternative<br />

Bioethanol as a replacement for<br />

conventional fuel<br />

Photovoltaic<br />

10 The Power of the Sun<br />

The Photovoltaic (PV) Value Chain<br />

Pharma<br />

11 Compliance Made Easy<br />

Pharmaceutical Industry<br />

p Products<br />

Simocode<br />

12 Promoting Energy Efficiency<br />

Simocode intelligent motor<br />

management system<br />

Robicon<br />

14 Perfect Harmony<br />

The right medium-voltage AC drives<br />

for every application<br />

Mobile Panel<br />

18 HMI goes <strong>Wireless</strong><br />

First wireless machine control unit<br />

with safety functions<br />

TeleService<br />

19 Covering the Distance<br />

Simatic TeleService: Remote<br />

maintenance via modem<br />

p Training<br />

Sitrain<br />

16 Best in Class<br />

Sitrain - Training for Automation &<br />

Industrial Solutions<br />

p Technology<br />

Gas Emission monitoring<br />

20 Unique and Adapted<br />

Solution for the gas emission<br />

monitoring<br />

SIMATIC – 50 years<br />

22 Automation conquers the World<br />

Simatic- 50 years of proven<br />

engineering leadership<br />

23 In Brief<br />

ideas singapore | 2008


E d i t o r i a l<br />

“Innovation is the ability to see change as an opportunity –<br />

not a threat.“<br />

Driven by our scientific curiosity and commitment, we are<br />

constantly striving to inspire innovation – in our employees,<br />

our partners, and our customers.<br />

Dear Readers,<br />

In an increasingly global market, the industry calls for an<br />

efficient strategic production planning, higher production<br />

output at the minimal costs, and higher technical competencies –<br />

reliable and innovative partners who will support them with<br />

expertise and technology to achieve their aims.<br />

We at <strong>Siemens</strong> are proud to be one of these partners. Being the<br />

market leader in the field of industrial automation solutions, we<br />

are ready to give you the answer.<br />

In this issue, we will focus on products, which we believe that<br />

will help you achieve your objectives. We will discuss the latest<br />

on industrial applications and technologies such as wireless<br />

communication capabilities and energy efficiencies. Also allow<br />

us to celebrate the latest events and achievements we received on<br />

our decades of existence in Singapore – celebrating 100 years of<br />

<strong>Siemens</strong> in Singapore, 50 years of SIMATIC and strong PLC and<br />

software market leadership within Southeast Asia.<br />

We look forward to another 100 years with you and we will keep<br />

the anticipation of challenging ourselves to stay on being a true<br />

leader for the benefit of our customers in the industry here and<br />

overseas!<br />

The Editors<br />

ideas singapore | 2008


C o v e r<br />

W i r e l e s s<br />

p<br />

<strong>Wireless</strong> solutions in the manufacturing industry<br />

<strong>Wireless</strong><br />

<strong>Flexibility</strong><br />

WIFI promotes <strong>Wireless</strong> LAN standards with<br />

the aim of improving the interoperability of<br />

wireless local area network products based on<br />

the IEEE 802.11 standards and enhancing the<br />

user experience for wireless solution.<br />

Publicis<br />

ideas singapore | 2008


<strong>Wireless</strong> devices have become a part of everyday<br />

life and mobility is one the buzzwords<br />

of today. With the advent of WIFI<br />

into the computing world, being available anywhere<br />

and anytime has become almost given.<br />

Particular concern for many end users is the security<br />

and availability of such wireless system. Many<br />

may still harbor doubts about this technology, despite<br />

its benefits for better flexibility and lower costs as<br />

compared to a hardwired connection. All of this in<br />

view of the fact that methods for secure encryption<br />

and protection of industrial wireless communication<br />

had been available for several years.<br />

This article will discuss these issues and present<br />

valuable solutions arriving from the Scalance product<br />

line. It will also attempt to answer the solutions<br />

for IWLAN using the Scalance technology, which supports<br />

highly effective encryption mechanisms and<br />

intelligent radio field planning that will help ensure<br />

full data security.<br />

Security with Industrial <strong>Wireless</strong> Network<br />

The subject of data security when using WLAN was a<br />

particularly a hot topic at the time wireless data<br />

transfer was first introduced to industrial environments.<br />

Until 2002, no data encryption standards existed<br />

within IEEE 802.11, which defines wireless Ethernet<br />

communication.<br />

The 802.11i standard was developed to address<br />

this situation; it specifies the security mechanisms<br />

for <strong>Wireless</strong> LAN (WLAN) - encryption, identification<br />

and authorization. IEEE 802.11i is an amendment to<br />

the IEEE 802.11 standard specifying security mechanisms<br />

for wireless networks. The amendment has<br />

been incorporated into the published IEEE 802.11-<br />

2007 standards. They are commonly used today in<br />

their 802.11a, 802.11b, and 802.11g versions to provide<br />

wireless connectivity.<br />

With Industrial <strong>Wireless</strong> LAN (IWLAN), new IEEE<br />

802.11i mechanisms are available that are exactly<br />

the same as those for office networks. The security<br />

concept is made up of different mechanisms, such as<br />

encryption by means of temporary keys or the Advanced<br />

Encryption Standard (AES) – a highly secure<br />

encryption mechanism.<br />

Scalance W components represent a complete spectrum<br />

for the implementation of IWLAN networks and<br />

conform to the security standards defined in IEEE<br />

802.11i.<br />

Secured and Reliable Access Points<br />

Another interesting topic to discuss is the key piece<br />

of hardware for IWLAN which is the Access Point (AP)<br />

modules. These have to be design for industrial environments<br />

and performance. The access points are<br />

used for setting up radio networks in accordance<br />

with IEEE 802.11a/b/g/h up to 54 Mbit/s both at 2.4<br />

GHz and at 5 GHz in harsh industrial environments.<br />

Existing LAN and WLAN networks can easily be ex-<br />

A p p l i c a t i o n s o f W i r e l e s s T e c h n o l o g y<br />

In the manufacturing environments, acceptance of the wireless technology<br />

is growing in various applications such as:<br />

3<br />

3<br />

3<br />

3<br />

3<br />

3<br />

Automated guided vehicles and overhead monorails<br />

prevention of wear and high flexibility in the choice of route due to<br />

wireless transmission of data to the vehicles<br />

Cranes high flexibility through access to data communication with the<br />

moving unit independent of the location<br />

Mobile control desks<br />

reliable intervention in the process due to data communication over<br />

IWLAN with mobile units; the number of operator panels is therefore<br />

determined by the number of personnel and no longer by the number<br />

of control points<br />

<strong>Wireless</strong> access to field devices for configuration and testing without<br />

the need for prolonged modifications in the control cabinet<br />

Online access to service and maintenance drawings<br />

Immediate updating of the measures performed in the system over<br />

IWLAN; Optimized processes and reduced error ratios due to online<br />

information regardless of the location of the machine<br />

Communication with moving stations (e.g. mobile controls and<br />

devices), container logistics, storage and retrieval machines, conveyor<br />

systems, conveyor belts, rotating machines, trucks<br />

100<br />

10<br />

1<br />

0.1<br />

0.01<br />

Transmission rate Mbits<br />

HART<br />

IEEE 802.154<br />

<strong>Wireless</strong><br />

IEEE 802.11n<br />

IEEE 802.11g,a<br />

IEEE 802.11b<br />

IWLAN<br />

Bluetooth<br />

<strong>Wireless</strong> modem 4,33,868,915 MHz (U.S. only)<br />

Personal Area (PAN) 10m Local Area (LAN) 100m Wide Area (WAN)<br />

panded through these Scalance W-780 access points<br />

to include Industrial <strong>Wireless</strong> LAN.<br />

The AP that deployed in manufacturing plants need<br />

to withstand the operating conditions such as high<br />

temperature, ability to manage redundant power<br />

source, diagnostics alarm output, easy and quick replacement<br />

of faulty devices, and environments with<br />

steel structures.<br />

EDGE<br />

GPRS<br />

GSM<br />

Range, mobility<br />

Transmission rates and range of wireless protocols<br />

ideas singapore | 2008


C o v e r<br />

W i r e l e s s<br />

With its compact,<br />

space saving design,<br />

the Scalance W-784<br />

line of access points<br />

for industrial wireless<br />

LANs (IWLAN)<br />

specifically targeted<br />

at indoor radio<br />

networks and can be<br />

installed in a control<br />

cabinet or directly in<br />

a machine.<br />

Pictures: <strong>Siemens</strong> AG<br />

W i r e l e s s c o m m u n i c a t i o n s t a n d a r d s<br />

IEEE 802.11 is a set of standards for wireless local area network (WLAN) computer<br />

communication, developed by the IEEE LAN/MAN Standards Committee (IEEE 802) in<br />

the 5 GHz and 2.4 GHz public spectrum bands.<br />

Protocol<br />

Release<br />

Date<br />

The Scalance W-780 is the perfect solution for practically<br />

any access point requirement. The access points<br />

of the Scalance W-780 product line are optimized for<br />

the configuration of Industrial <strong>Wireless</strong> LAN (IWLAN)<br />

wireless networks for 2.4 GHz or 5 GHz with data transmission<br />

rates up to 54 Mbit/s. They can be used in all<br />

applications that require a high degree of operational<br />

reliability especially under extremely harsh environmental<br />

conditions.<br />

Suitable AP is available for specific applications,<br />

such as Scalance W-786 for demanding climatic requirements,<br />

Scalance W-784 for installation in a cabinet<br />

or integration in devices, and Scalance W-788 for<br />

cabinet-free assembly.<br />

Op.<br />

Frequency<br />

Data Rate<br />

(Max)<br />

Range<br />

(Radius Indoor)<br />

Depends, # and<br />

type of walls<br />

Range<br />

(Radius Outdoor)<br />

Loss includes one<br />

wall<br />

802.11a 1999 5 GHz 54 Mbit/s ~35 Meters ~120 Meters<br />

802.11b 1999 2.4 GHz 11 Mbit/s ~38 Meters ~140 Meters<br />

802.11g 2003 2.4 GHz 54 Mbit/s ~38 Meters ~140 Meters<br />

Different wireless technologies based on different requirements<br />

The devices were designed to be rugged, with impact-resistant<br />

housing, protected from water and dust<br />

(IP65), with high-resistance to shock, vibration and<br />

electromagnetic fields.<br />

Due to the high degree of protection (IP65) and the<br />

extended temperature range from -40°C to +70°C, the<br />

access points are ideally suited for use in the food and<br />

beverages industry (e.g. cooling technology) and in<br />

logistics. Scalance W products are silicone-free and<br />

can therefore be used in paint shops.<br />

Scalance W conforms to IEEE 802.11 standards, with<br />

additional functional expansions especially for applications<br />

demanding high reliability. It offers protection<br />

from unauthorized access, espionage, listening<br />

in and corruption of data due to effective<br />

encryption mechanisms.<br />

Several operating modes are available<br />

in one device: Set up of wide area wireless<br />

networks (infrastructure) with range<br />

up to 30 m indoors and approx. 100 m<br />

outdoors; point-to-point connection of<br />

Industrial Ethernet segments over large<br />

distances (several 100 m).<br />

The Scalance APs have quick commissioning<br />

capabilities with the swap medium<br />

PRESET-PLUG and quick device exchange<br />

in case of faults with the swap<br />

medium C-PLUG (Configuration Plug).<br />

Coordinated accessories with antennas,<br />

plugs, cables including RCoax cable<br />

(leaky wave cable) for a reliable radio<br />

link along the cable.<br />

ideas singapore | 2008


The Scalance W-786<br />

family of access points<br />

for industrial wireless<br />

LANs (IWLAN) is<br />

particularly suitable for<br />

installation in outdoor<br />

radio networks, for<br />

instance in public areas,<br />

mass transit systems,<br />

ports, offshore<br />

equipment, or container<br />

logistics<br />

Rugged Scalance W788 cabinet free<br />

assembly is needed in harsh industrial<br />

environments that are installed outside the<br />

control cabinets. IWLAN components from<br />

Simatic NET have been designed with IP65<br />

degree of protection and for operating<br />

temperatures between – 20 °C and + 60 °C<br />

with condensation and fulfill the strict<br />

Simatic requirements with respect to shock<br />

and vibrations. The connectors are<br />

vibration-proof and shakeproof. Sinema E<br />

(Simatic Network Manager Engineering) is a<br />

software tool for efficient planning,<br />

simulation and configuration of industrial<br />

WLAN applications in accordance with the<br />

802.11 a/b/g standards. It allows the design<br />

and simulation of entire IWLAN networks.<br />

The new software for industrial and office<br />

networks, including outdoor areas, is<br />

suitable for network engineers in the field<br />

and planning engineer<br />

Radio Field Planning Tool<br />

Prior to the installation of any wireless devices, detailed<br />

planning of the required radio field is an important<br />

element of the security concept. Using the<br />

right tools, the radio field can actually be designed so<br />

that reception is possible only where the receivers<br />

such as robots or transport systems are located. This<br />

will significantly deter attempts to tap communication<br />

without authorization from outside the permitted<br />

facility zone.<br />

With Scalance Sinema E software, <strong>Siemens</strong> provides<br />

a planning, simulation and configuration software for<br />

IWLAN applications that makes IWLAN networks visible.<br />

It displays field strengths, data rates, signal-tonoise<br />

ratios and overlaps between different radio<br />

fields, taking environmental aspects and device properties<br />

into account. With Sinema E, users gain a detailed<br />

overview of the radio field prior to start-up.<br />

Optimizations of the radio field zone can be easily<br />

and transparently carried out on the PC in a short<br />

amount of time. The software simulates and detects<br />

obstacles that could affect signal strength and uses<br />

simulation functions to calculate the required number<br />

and optimum installation points and parameters<br />

for the IWLAN devices.<br />

With the Security Wizard tool, <strong>Siemens</strong> assists users<br />

in setting the required security level and access<br />

rights. The tool guides users through a range of<br />

menus from which the relevant security features can<br />

be selected with a simple mouse click. This straightforward<br />

configuration not only saves time but also increases<br />

the user’s readiness to consistently apply the<br />

implemented security measures. Furthermore, uninvited<br />

guests are kept at bay.<br />

Manufacturing plants have various machinery and<br />

equipment that are tied together to perform specific<br />

task. These machines or equipment have automation<br />

system which needs to transact data. Communication<br />

over Ethernet have adopted and implemented successfully<br />

in manufacturing environment providing<br />

robust and stable communication platform.<br />

Conventional cabling method may be difficult to<br />

some areas due to constraints in accessibility, distance<br />

and temperature. Using Scalance technologies is an<br />

attractive option when cabling is extremely complex<br />

and time-consuming, or when a high degree of flexibility<br />

is called for, or even when the environment is<br />

highly contaminated. These can significantly reduce<br />

the effort required for maintenance. p<br />

Practical Security Configuration<br />

Data security should not be compromise. However, security<br />

measures often require a degree of expert<br />

knowledge from users.<br />

info<br />

contact<br />

www.siemens.com/simatic-net<br />

zavior.kuladasamy@siemens.com<br />

ideas singapore | 2008


I n d u s t r y<br />

B i o e t h a n o l<br />

p Bioethanol as a replacement for conventional fuel<br />

Clever Alternative<br />

<strong>Siemens</strong> offers a perfectly balanced portfolio that<br />

covers all areas of the ethanol industry based on Totally<br />

Integrated Automation.<br />

Growing energy demand and spiraling oil<br />

prices are putting financial strain on countries<br />

and causing increased demand for fossil<br />

fuel. Energy security has assumed greater significance<br />

than ever as energy consumption, food<br />

production and environmental quality are interconnected.<br />

As a result, many countries throughout the<br />

world see an attractive alternative in ethanol.<br />

A large number of measuring tasks have to be carried<br />

out in a manufacturing plant for bioethanol –<br />

starting with the receipt of raw materials and up to<br />

the delivery of the finished product. Selection of the<br />

correct instrumentation is very important for the efficiency<br />

of the complete plant. In addition to the technical<br />

specifications, the instruments must be safely<br />

integrated into the process automation. Reliability,<br />

long service life, and simple operation are also important.<br />

And in an emergency, a fast and trouble-free<br />

supply of spare parts must be guaranteed.<br />

Million liters) of ethanol. Corn is used as the primary<br />

feedstock. The project was realization from<br />

January 2003 to September 2003 with <strong>Siemens</strong><br />

China “SIAS”, Shanghai provided the project management<br />

services. The system was implemented<br />

by Vogelbusch as the contractor.<br />

The unique combination of TIA used throughout<br />

the plant includes the distributed control system<br />

Simatic PCS 7, a highly distributed 8000 I/O system<br />

with HART, PDM and optical network, eight redundant<br />

controllers, nine Operator Stations implemented with<br />

Chinese characters, and an MES based on OPC.<br />

<strong>Siemens</strong>, a partner for bioethanol<br />

<strong>Siemens</strong> has recognized the challenge and offers a<br />

perfectly balanced portfolio that covers all areas of the<br />

ethanol industry. Using Totally Integrated Automation<br />

(TIA) - all encompassing of a unique vast of products<br />

and systems portfolio, <strong>Siemens</strong> provides solutions for<br />

the complete ethanol process from receiving of raw<br />

materials to storage of the finished product.<br />

Jilin Fuel Ethanol plant in China<br />

Following a first boom in Brazil in the seventies, the<br />

tremendous increase in the price of petroleum and<br />

the recent demand for energy has finally turned ethanol<br />

into a global issue. In the USA alone, more than<br />

30 installations are being built every year and similar<br />

figures are being constructed in Brazil. In Europe, a<br />

traditional stronghold for biodiesel, planning is underway<br />

for a large number of ethanol plants. In Southeast<br />

Asia, the first installations have already commenced<br />

operations, including the largest plant in the<br />

world, located in Jilin, China.<br />

The largest ethanol plant in the world, Jilin Fuel<br />

Ethanol Co Ltd in China, was implemented with<br />

<strong>Siemens</strong> distributed control system PCS7. The current<br />

capacity is 200 Million gallon per year (750<br />

Optimizing the complete workflow with<br />

Totally Integrated Automation<br />

<strong>Siemens</strong> is the only single vendor that can provide a<br />

complete line of products and automation systems<br />

throughout an ethanol plant including all auxiliary<br />

systems. One set of engineering tools provides process<br />

automation from the field level to the control<br />

level through the enterprise management level including<br />

superior system diagnostics and asset management<br />

functionality. Reduced life cycle costs,<br />

shortened times to market and improved production<br />

efficiency can be easily achieved.<br />

Besides greater independence from fuel oil, which<br />

is becoming increasingly expensive, there are further<br />

arguments that speak clearly in favor of ethanol, namely<br />

reduction of greenhouse gases taking into consideration<br />

the entire CO2 cycle and reduction of toxic<br />

emissions when burning sulfur-free ethanol. Biofuels<br />

are also less toxic than conventional ones. p<br />

info<br />

contact<br />

www.siemens.com/biofuel<br />

adnan.rahman@siemens.com<br />

BED<br />

<strong>Siemens</strong> AG<br />

ideas singapore | 2008


Source: F. O. Lichts (2004)<br />

80,000<br />

70,000<br />

60,000<br />

50,000<br />

40,000<br />

Production 2005<br />

Asia<br />

9 %<br />

EU<br />

11 %<br />

Latin<br />

America<br />

42 %<br />

North<br />

America<br />

37 %<br />

Latin America<br />

North America<br />

EU<br />

Asia<br />

9.8 % / a<br />

Market Growth<br />

30,000<br />

20,000<br />

10,000<br />

0<br />

‘90 ‘91 ‘92 ‘93 ‘94 ‘95 ‘96 ‘97 ‘98 ‘99 ‘00 ‘01 ‘02 ‘03 ‘04 ‘05 ‘06 ‘07 ‘08 ‘09 ‘10 ‘11 ‘12<br />

Major growth / year (05–12):<br />

Peru (67.4 %), Columbia (21.4 %), EU (26.9 %), India (20.4 %), Brazil (6.5 %), USA (6.9 %)<br />

Bioethanol production from cornstarch and sugar is helping to fuel explosive growth in the worldwide market for<br />

green energy resources, topping 9.8 percent in Latin America, the US, Asia, and parts of Europe.<br />

G r e e n f u e l f r o m s t a r c h : t h e e t h a n o l p r o c e s s<br />

Starch e.g. Cassava<br />

Starch e.g. Corn<br />

Pretreatment<br />

Milling<br />

Mashing<br />

Water<br />

Enzymes<br />

Liquefaction,<br />

Saccharifaction<br />

Fermentation<br />

CO 2<br />

Distillation<br />

Decantation<br />

Thin<br />

Stillage<br />

Dehydration<br />

DGS<br />

Evaporation<br />

Gasoline<br />

Denaturizing<br />

Drying<br />

Syrup<br />

Fuel Ethanol<br />

DDGS<br />

DGS: Distillers Grains with Solubles<br />

DDGS: Distillers Dried Grains with Solubles<br />

ideas singapore | 2008


I n d u s t r y<br />

P h o t o v o l t a i c<br />

p The Photovoltaic (PV) Value Chain<br />

The Power<br />

of the Sun<br />

The fast growing photovoltaic<br />

market offers opportunities for silicon<br />

producers and their suppliers.<br />

vides value added opportunities for the manufactures<br />

and market sizes are growing at a very fast<br />

pace due to the rising oil price, environmental concerns<br />

and incentives given by some governments to<br />

adopt green energy.<br />

Solutions for the entire value chain<br />

Total value chain represents approximately Euro<br />

10 billion worth of market value in 2006 and projected<br />

figure of Euro 50 billion by 2010 as shown in<br />

Table 1.<br />

In view of the demands, many projects had been<br />

announced recently for various stages of productions<br />

such as Sitronics Samsung, Renewable Energy<br />

Corporation (REC) and NorSun in Singapore alone.<br />

<strong>Siemens</strong>: First in silicon<br />

info www.siemens.de/xxxxxx<br />

Poly silicon is the feedstock for photovoltaic The production process for Poly silicon was originally<br />

contact xxxxxx.xxxxx@siemens.com<br />

and microelectronics industry. However purity<br />

level of the silicon needed for photovol-<br />

“<strong>Siemens</strong> C process”. It has been refined over the<br />

established by <strong>Siemens</strong> in the 50s and it is still called<br />

taic is 7 to 8 N and for microelectronics is 9 to 11 N years for production performance by others and the<br />

(the N indicates the numbers of 9s behind the dot, method is widely used by leading manufacturers. p<br />

e.g. 8N means 99.99999999%).<br />

PV value chain consists of five major production info www.siemens.com/semiconductor<br />

stages as illustrated below starting from Poly silicon<br />

to solar modules. Each production stage<br />

contact woonfu.choo@siemens.com<br />

pro-<br />

Poly<br />

Silicon<br />

Mono Ingots<br />

Multi Ingots<br />

Wafers<br />

Solar Cells<br />

Solar<br />

Modules<br />

Current market size<br />

2006 (Billion Euro)<br />

Projected market size in<br />

2010 (Billion Euro)<br />

Growth rate<br />

market size<br />

Poly silicon 0.8 3.7 463%<br />

Ingots and wafers 1.6 6.8 425%<br />

Solar cells 3.1 13.3 429%<br />

Solar Modules 4.8 20.8 433%<br />

Total market size 10.3 44.6 433%<br />

info choo.woonfu@siemens.com<br />

Table 1: Market size and Projected Growth rate for each stage in year 2010<br />

BED<br />

10 ideas singapore | 2008


I n d u s t r y<br />

P h a r m a<br />

p Pharmaceutical Industry<br />

Compliance Made Easy<br />

Integrated solutions for production operations enhance quality<br />

and visibility and facilitate compliance with CFR Part 11.<br />

There is an increased awareness in the pharmaceutical<br />

industry to be more innovative in<br />

achieving operational efficiency. One such<br />

area is improving workflow and driving for paperless<br />

production operations or realistically speaking a less<br />

paper operation. By going electronic with production<br />

operations, we can improve the quality of the production<br />

records kept and therefore the overall documentation<br />

management and operational efficiency.<br />

Not forgetting that it also contributes to the green<br />

environment image. Moving in this direction shall<br />

require the automated computer systems to comply<br />

with FDA 21 CFR part 11, popularly referred to as<br />

part 11. Correspondingly, the validation process will<br />

also have to take part 11 into consideration. The automated<br />

system architecture can have a huge time<br />

impact on the validation process as a direct result of<br />

human activities involving documentation, procedural<br />

safeguards, checks, etc.<br />

No more automation islands<br />

To illustrate this, imagine a plant operated by “islands<br />

of automation” like the figure shown below (figure<br />

1) with handhelds and mobile programming<br />

devices, each with its own part 11 acceptable system<br />

from different vendors. Not only is this concept difficult<br />

for the part 11 compliance, it doesn’t offer a central<br />

user management, no central archiving and the<br />

effort for change will be high. The validation process<br />

would be quite a challenge.<br />

In contrast, the concept in figure 2 offers a central<br />

user management, central archiving, central engineering<br />

and central services for access control, audit<br />

trail, archiving, etc. By far, this would be an easier<br />

system to validate for part 11 compliance. p<br />

info<br />

contact<br />

www.siemens.com/ pharma<br />

eugene.yeo@siemens.com<br />

peraor<br />

aion<br />

peraor<br />

aion<br />

Figure 1 - Automation<br />

Islands: Standalone<br />

solutions without<br />

intercommunication<br />

ndsria erne<br />

ndsria erne<br />

rograing<br />

eie<br />

rograing<br />

eie<br />

ros<br />

00<br />

ros<br />

00<br />

anded irans irans ipar 2<br />

00<br />

anded irans irans ipar 2<br />

00<br />

ndsria erne<br />

peraor<br />

aion<br />

enra<br />

ngineering<br />

aion<br />

peraor<br />

aion<br />

Figure 2 - Integrated<br />

Architecture: Central<br />

User Management,<br />

archiving,<br />

engineering and<br />

overall audit trail<br />

ros<br />

00<br />

ros<br />

00<br />

irans irans ipar 2<br />

00<br />

irans irans ipar 2<br />

00<br />

02<br />

ideas singapore | 2008 11


RP ru ob dr ui k c t s U nSt ie mr ro uc bo rd i ek<br />

p Simocode intelligent motor management system<br />

Promoting<br />

Energy<br />

Efficiency<br />

With easy integration to PCS 7, the Simocode intelligent motor<br />

management system enables dynamic monitoring of motor performance<br />

and the opportunity to enhance energy efficiency in the plant.<br />

Energy consumption is the second largest operating<br />

expense in a process plant, after raw<br />

materials. And studies have shown that more<br />

than sixty percent of that energy is used to operate<br />

motors. Hence, optimizing motor energy consumption<br />

is a logical starting point in any energy cost reduction<br />

initiative.<br />

In the traditional process plant, it has not been economical<br />

to hardwire all of the operating data from<br />

individual motors back to the process controller,<br />

which makes it almost impossible to determine the<br />

energy consumption for different parts of the process.<br />

This information gap prevents plant operators<br />

M o t o r m a n a g e m e n t s y s t e m S i m o c o d e p r o<br />

Simocode pro (Sirius Motor Management and Control Devices) is the<br />

flexible, modular motor management system for constant speed motors.<br />

By means of a Profibus DP interface it can easily be linked to a higher-level<br />

automation system. Simocode pro implements all motor protection and<br />

control functions, provides operational, diagnostic and statistical data and<br />

organizes the communication between automation system and motor<br />

feeder. In addition, Simocode meets all the requirements for future-proof<br />

power management. Simocode pro is divided into two device series with<br />

different levels of functions:<br />

3 Simocode pro C (Compact): the compact motor management<br />

system for direct on-line starters and reversing starters<br />

3 Simocode pro V (Variable): the variable motor<br />

management system with an even greater range of functions<br />

including voltageand power monitoring<br />

The system also includes software tools for plant configuration,<br />

device parameterization, diagnostics and plant documentation.<br />

from scheduling partial shutdowns to improve energy<br />

efficiency or from taking advantage of the various<br />

incentives that electric utilities offer to balance<br />

demand.<br />

But today’s new class of DCS, exemplified by the<br />

<strong>Siemens</strong> PCS 7, not only provides regulatory control<br />

of processes, but can integrate high speed devices to<br />

enable dynamic monitoring of motor performance<br />

and, hence, much more sophisticated management<br />

of energy consumption.<br />

Simocode spells smart<br />

Simocode is an intelligent motor management system<br />

that can be added to the MCC motor bucket to<br />

make it “smart”. Hardwired circuitry running to the<br />

various motors across the plant is replaced with just<br />

one fieldbus cable and the compact tool provides a<br />

high level of protection, monitoring and control. For<br />

example, the control circuit can be “rewired” via a<br />

mouse click, and eliminating conventional relays saves<br />

space and reduces wiring expenditures.<br />

In particular, with Simocode, a high degree of detail<br />

on the status and performance of each motor component<br />

is provided, including motor current, direction,<br />

phase and overload status. This information can be<br />

sent up to the PCS 7 via a single Profibus DP cable.<br />

Having access to comprehensive data on motor activity<br />

in the process plant provides a number of benefits:<br />

Productivity improvement – engineers can modify<br />

operating parameters, analyze performance,<br />

and reset faults of an individual MCC bucket directly<br />

from the control room; downtime minimization – an<br />

unusual condition such as excessive current draw<br />

can be reported in the DCS, allowing operators to<br />

12 ideas singapore | 2008


T h e b e n e f i t s<br />

a t a g l a n c e<br />

<br />

■ Profibus DP<br />

■ Ethernet<br />

S<br />

S<br />

S-00<br />

DPPA Link<br />

3<br />

3<br />

3<br />

3<br />

3<br />

3<br />

3<br />

3<br />

Higher operating management<br />

and process quality<br />

Lower costs for planning,<br />

assembly and maintenance<br />

Multifunctional electronic full<br />

motor protection<br />

Detailed operating, service<br />

and diagnostic data<br />

Open communication via<br />

Profibus DP<br />

Safety disabling of drives<br />

thanks to emergency stop<br />

system monitoring<br />

Certified according to<br />

ATEX standards<br />

Compatible with previous<br />

Simocode-DP system<br />

ET 200M<br />

SIPAT D<br />

SIMOCODE<br />

■ Profibus PA<br />

take quick corrective action; energy management –<br />

power consumption of different parts of the plant<br />

can be collected within the DCS, allowing plants to<br />

create a strategy that optimizes both energy usage<br />

and production output.<br />

New and updated<br />

And now, the latest release of the Simocode pro motor<br />

management system features a number of new<br />

components, accessories, functions, plus an update<br />

of the parameterization software.<br />

The operator panel with display provides for indication<br />

of current measured values, diagnostic data and<br />

status information directly at the control cabinet. Selecting<br />

predefined profiles, the user can determine the<br />

values to display during normal operation. As for functions,<br />

two new logic blocks can do arithmetic operations<br />

and adjust, calculate and convert analog values<br />

such as temperature, allowing measured values to be<br />

transferred to the DCS in predefined units. An addition<br />

to the statistical data provided by Simocode is “motor<br />

power consumption” (in kWh), which allows users to<br />

quantify power consumption of motor feeders.<br />

An update of the Simocode ES parameterization software<br />

provides multilingual online help and trend indication<br />

of the current curve shape (of up to five<br />

measured values). These new functions can be applied<br />

via a service pack for previously installed versions<br />

of Simocode ES. <br />

p<br />

info<br />

contact<br />

www.siemens.com/simocode<br />

wahseng.liew@siemens.com<br />

ideas singapore | 2008 13


P r o d u c t s<br />

R o b i c o n<br />

p The right medium-voltage AC drives for every application<br />

Perfect Harmony<br />

<strong>Siemens</strong> has the largest installed base of the world’s best<br />

selling medium voltage AC drives, the Perfect Harmony.<br />

Pictures: <strong>Siemens</strong> AG<br />

<strong>Siemens</strong> drives serve all segments of the market,<br />

as <strong>Siemens</strong> is the only company that offers<br />

drives from 300 to 160,000 HP (225 to 120,000<br />

kW). These world‘s best selling medium-voltage AC<br />

drives are designed to help keep maintenance and<br />

operating costs low; production outputs high; and<br />

maintain energy-efficient processes without compromising<br />

environment safety.<br />

Designed for Maximum Versatility,<br />

Efficiency and Reliability<br />

Being the world‘s best selling medium voltage AC<br />

drives, the patented, integrated design of the Perfect<br />

Harmony drive ensures a level of reliability, efficiency<br />

and versatility that is unmatched in the power<br />

controls industry. The Perfect Harmony is designed<br />

to withstand failures that would overwhelm conventional<br />

drive systems.<br />

tions around the world. From water treatment to<br />

power generation to oil and gas production, <strong>Siemens</strong><br />

can provide a custom-engineered Perfect Harmony<br />

drive to maximize process results.<br />

Setting the Standard in Power Conversion<br />

Since its introduction in 1994, the Perfect Harmony<br />

drive has revolutionized power conversion and continues<br />

to set industry standards for reliability and innovation.<br />

However, advances are made without “reinventing<br />

the wheel” like other drive manufacturers.<br />

<strong>Siemens</strong> has maintained the Perfect Harmony’s core<br />

topology and continue to advance its capability, ensuring<br />

life-cycle product support. The Perfect Harmony<br />

of today represents an evolution founded on experience<br />

garnered from a huge installation base. p<br />

Proven Solutions for Every Industry<br />

The most successful medium voltage drive ever built,<br />

the Perfect Harmony is used in thousands of applica-<br />

info<br />

contact<br />

www.siemens.com/drives<br />

doreen.lim@siemens.com<br />

14 ideas singapore | 2008


C l e a n P o w e r I n p u t<br />

The Robicon Perfect Harmony drive meets the most stringent<br />

harmonic requirements for voltage and current distortion.<br />

3 Protects other on-line equipment from harmonic<br />

disturbance (computers, telephones, lighting ballast)<br />

3 Prevents “cross-talk” with other sensitive control and<br />

variable frequency drives<br />

3 Avoids costly harmonic filters and associated<br />

resonance problems<br />

P o w e r Q u a l i t y O u t p u t<br />

3<br />

3<br />

3<br />

No common mode motor insulation stress<br />

- Perfect Harmony includes an isolation transformer<br />

integral in common mode dissipation<br />

- Motor does not require 10 to 13 kV insulation<br />

Perfect Harmony includes an isolation transformer<br />

integral in common mode dissipation<br />

Motor does not require 10 to 13 kV insulation<br />

3<br />

3<br />

3<br />

3<br />

3<br />

3<br />

Drive is compatible with both new and existing 1.0<br />

service factor induction or synchronous motors from any<br />

manufacturer without any special design considerations<br />

No significant VFD induced torques pulsations –<br />

even at low speeds<br />

No need for expensive flexible couplings<br />

No additional VFD induced motor heating<br />

No cable length restrictions<br />

Allows standard motor insulation – decreasing the<br />

motor insulation requirements to less than an acrossthe-line<br />

start motor<br />

T y p i c a l a p p l i c a t i o n s<br />

3<br />

3<br />

3<br />

3<br />

3<br />

Retrofit<br />

Power generation - can ride through voltage<br />

dips or power outages<br />

Water/Wastewater - provides high output voltage<br />

at low power<br />

Oil & Gas - Small footprint, high availability<br />

Pulp/Paper - provides high output voltage at low power<br />

T e c h n i c a l S p e c i f i c a t i o n s<br />

General<br />

Power semiconductors<br />

Line-side converter<br />

Motor-side converter<br />

Closed-loop control<br />

Drive quadrants<br />

Potential separation:<br />

Power section<br />

Open- and closed-loop<br />

control<br />

Permissible humidity<br />

rating<br />

Noise level<br />

Efficiency<br />

(standard version)<br />

Regulation<br />

compliances<br />

Paint finish<br />

IGBTs; diodes<br />

18- to 36-pulse diode rectifier<br />

(standard)<br />

Multi-level converter (PWM) with<br />

IGBT power modules<br />

Sensorless closed-loop control,<br />

fully digital with signal processor<br />

Driving: 2 directions of rotation<br />

(2 quadrant), 4 quadrant option<br />

Fiber-optic cable<br />

Relative air humidity < 95% noncondensing<br />

Approx. 75 dB (A)<br />

96% at the rated operating point<br />

including transformer<br />

IEEE, ANSI, NEMA, UL, CSA, CE<br />

ANSI 61 Gray<br />

Degree of protection Acc. to DIN VDE 0470,<br />

IEC 60529, EN 60529<br />

- Standard IP31 (air-cooling) IP52 (watercooling)<br />

NEMA 1 (air-cooling)<br />

NEMA 12 (water-cooling)<br />

- Optional IP42 (air-cooling)<br />

Cooling Type<br />

Air-cooled<br />

Forced-air cooling with<br />

integrated fans<br />

Permissible ambient and cooling, medium temperature<br />

- In operation 0ºC to + 40ºC: 100% load capability<br />

+40ºC to 50ºC: current derating<br />

- During storage -25ºC to +55ºC<br />

- During transport -25ºC to +70ºC<br />

Water-cooled Deionized water with integrated<br />

water-to-water heat exchanger<br />

Permissible ambient temperature<br />

- In operation +0ºC to + 40ºC<br />

- During storage -25ºC to + 55ºC<br />

(without deionized water)<br />

- During transport -25ºC to + 70ºC<br />

(without deionized water)<br />

Permissible cooling medium temperature (raw water)<br />

- Intake +5ºC to 35ºC<br />

- Outlet Max. +40ºC<br />

Supply Data<br />

Standard<br />

Special option<br />

Control voltage<br />

2.3 to 15 kV<br />

< 2.3 and > 12 kV<br />

1 Ph, 120 VAC or integrated<br />

to auxiliary supply<br />

ideas singapore | 2008 15


T r a i n i n g<br />

S i t r a i n<br />

p Sitrain – Training for Automation & Industrial Solutions<br />

Best in Class<br />

BED/<strong>Siemens</strong> AG<br />

With its Sitrain program of training courses, <strong>Siemens</strong> offers a<br />

broad range of trainings to establish, build and refine knowledge<br />

on automation products, systems and solutions.<br />

The Sitrain Training Center in Singapore has<br />

been known for its reputation in South East<br />

Asia for its methodical approach in teaching<br />

its industrial automation programs. Together with<br />

Sitrain Germany, they conceptualize and developed a<br />

wide range of courses that will help each participant<br />

in ensuring advanced technical capabilities.<br />

Customized and on-site classes are also possible in<br />

some cases when a plant requires a more modified<br />

approach to enhance the skills of their technical personnel.<br />

All trainers were trained and certified by the<br />

<strong>Siemens</strong> Sitrain Learning Academy in Germany and<br />

have didactic and real industrial experience. p<br />

Classes for every purpose<br />

Sitrain offers basic and advance courses for users of<br />

Simatic PLCs, RFID and Profibus, PCS 7 and WinCC.<br />

info<br />

contact<br />

www.siemens.com.sg/ad<br />

adtraining.sg@siemens.com<br />

16 ideas singapore | 2008


Course Description Pre-requisite Course<br />

duration<br />

Simatic PLC<br />

Calendar<br />

Year 2008<br />

Simatic Step-by-Step<br />

Simatic S7 Programming 2<br />

Simatic Redundancy<br />

System<br />

Simatic S5<br />

Simatic TI505 Maintenance<br />

and Programming<br />

Simatic S7-200<br />

Simatic HMI Panels/ WinCC<br />

Flexible<br />

Provides a good foundation in Simatic Step7 software environment and skills to<br />

handle and maintain Simatic S7-300/400 PLC.<br />

Directed at personnel engaged in project engineering tasks who will learn to<br />

structure and create advanced S7 programs in order to work efficiently with S7.<br />

Overview of <strong>Siemens</strong> fault-tolerant system (Redundancy System); participants learn<br />

how to set up and operate S7-400H Hardware Redundancy system.<br />

Provides participants with necessary skills to use Simatic Step5 software to program<br />

and troubleshoot Simatic S5 PLC system.<br />

Entry-level course that covers the tasks necessary to support the design, modification,<br />

start-up and maintenance of a typical Simatic 505 PLC system. Software is<br />

TISOFT.<br />

Introduction to the S7 product family and Simatic S7-200 system review. Concentration<br />

on STEP7 Micro/WIN software, program structuring and instruction set.<br />

Simatic HMI<br />

Performing of a complete system configuration (graphics design, system integration<br />

etc.) Providing skills with the user management tool including security, access,<br />

alarms and messaging.<br />

Background in<br />

Automation<br />

3 days 7-9 May<br />

4-6 Jun<br />

Simatic Step-by-Step 5 days 12-16 May<br />

9-13 Jun<br />

Simatic Step-by-Step 3 days 25-27 Jun<br />

Background in<br />

Automation<br />

Background in<br />

Automation<br />

General Computer<br />

Knowledge<br />

General Computer<br />

Knowledge<br />

Simatic WinCC Foundation course to provide participants with concepts of WinCC SCADA software. General Computer<br />

Knowledge<br />

Simatic S7 Communications<br />

Simatic NET<br />

Foundation course to provide participants with an understanding of networking<br />

and communication concept in Simatic S7 systems.<br />

5 days 26-30 May<br />

3 days 25-27Jun<br />

1 day Upon<br />

request<br />

2 days 16-17 Jun<br />

3 days 21-23 May<br />

18-20 Jun<br />

Simatic Step-by-Step 3 days Upon<br />

request<br />

Certified Profibus Installer Upgrade skills in the installation and testing of Profibus networks. None 1 day 25 Jun<br />

Certified Profibus DP<br />

Engineer<br />

Certified Profibus PA<br />

Module<br />

Profibus Maintenance and<br />

Troubleshooting<br />

Simatic PCS7 System<br />

Engineering<br />

Simatic PCS7 Batch<br />

Simatic PCS7 Process<br />

Safety<br />

RFID (Radio Frequency<br />

Identification)<br />

Micromaster MM4 Drive<br />

Masterdrives Service and<br />

Commissioning<br />

Sinamics S120 Service and<br />

Commissioning<br />

Sinumeric 840D/ 810D<br />

Start up and Service<br />

Simocode pro Engineering<br />

and Commissioning<br />

Worldwide recognized training program that covers the technology, design and<br />

operation of Profibus DP network.<br />

Fully concentrated on Profibus PA. Only accessible for people who passed the<br />

Standard Profibus Engineer Course.<br />

Provides knowledge about cabling techniques, shielding, grounding and Profibus<br />

components. Participants will be capable to maintain, strategically localize, analyze<br />

and solve problems in Profibus installation.<br />

Simatic PCS7<br />

Defining a typical project and planning the system architecture. The participants<br />

build, test and debug a simple PCS7 process system.<br />

Review of a typical batch process model to understand process elements and<br />

terminology including security, system administration and batch control techniques.<br />

Introduction of unique features and benefits of the <strong>Siemens</strong> Instrumented System<br />

(S7-400F/FH) including the programming tool Safety Matrix.<br />

RFID (Radio Frequency Identification)<br />

The course is designed for all Auto-ID professionals, RF engineers, system integrators<br />

and users who need to gain critical skills to install, maintain or troubleshoot<br />

RFID-based systems.<br />

Drives/ Motion Control<br />

Provides basic technical knowledge for start-up and maintenance of Micromaster<br />

440.<br />

The course is designed for Service and Commissioning personnel to configure the<br />

Masterdrive VC (Vector Control).<br />

Provides the technical knowledge to startup, parameterization, drive optimization<br />

and troubleshooting. Skilful use of Starter commissioning tool.<br />

SINUMERIC CNC<br />

The course is designed for service personnel and configuration specialists responsible<br />

for NC/PLC configuration. Configuration of machine control and in depth<br />

knowledge about “first commissioning”.<br />

Motor Protection & Control<br />

Provides knowledge of Siimocode pro system functions and the linkage via Profibus<br />

network.<br />

None 3,5 days 26-29 May<br />

Certified Profibus<br />

Engineer (CPE)<br />

1,5 days 29-30 May<br />

None 2 days 2-3 Jun<br />

Background in<br />

Automation<br />

Simatic PCS7 System<br />

Engineering<br />

Simatic PCS7 System<br />

Engineering<br />

General Computer<br />

Knowledge<br />

5 days 26-30 May<br />

23-27Jun<br />

5 days Upon<br />

request<br />

3 days Upon<br />

request<br />

4 days Upon<br />

request<br />

None 2 days Upon<br />

request<br />

Basic knowledge<br />

in Drives<br />

Basic knowledge<br />

in Drives<br />

Basic knowledge in<br />

CNC<br />

Knowledge of switchgear<br />

and control gear<br />

4 days Upon<br />

request<br />

5 days Upon<br />

request<br />

5 days Upon<br />

request<br />

2 days Upon<br />

request<br />

SITRAIN Helpdesk : +65 6490 6988 Email: adtraining.sg@siemens.com<br />

ideas singapore | 2008 17


P r o d u c t s<br />

M o b i l e P a n e l<br />

<strong>Siemens</strong> AG<br />

p First wireless machine control unit with safety functions<br />

HMI goes <strong>Wireless</strong><br />

<strong>Siemens</strong> presents the Simatic Mobile Panel 277F IWLAN, its first wireless HMI device with<br />

safety. The Simatic Mobile Panel 277F IWLAN has two enabling buttons and an emergency<br />

stop button. The safety functions have been tested and certified according to SIL3.<br />

The Mobile Panel 277F IWLAN has a 7.5 inch<br />

TFT touch display and 18 LED membrane-type<br />

keys. Its six megabytes of memory can be supplemented<br />

with an additional memory card for archive<br />

and recipe data that can be inserted into the<br />

multi-media combination card slot. Interfaces for<br />

connecting the panel to Profinet as well as a USB interface<br />

accessible from outside are also standard features.<br />

Engineering support<br />

When configuring the device, the user is supported<br />

by the WinCC flexible 2007 engineering software to<br />

define “effective ranges” in which the machine can<br />

be controlled by the operator. A transponder limits<br />

the effective ranges in which the device can be identified<br />

locally. This ensures fail-safe operator control<br />

and clear assignment of the appropriate operating<br />

screens and operator authorizations anywhere in the<br />

plant. The transponder can also be used to define<br />

zones in which certain functions are configured,<br />

such as automatic on-screen display or operator authorizations<br />

for particular persons when they enter<br />

the zone.<br />

Designed for industry<br />

With degree of protection IP 65 and a drop height of<br />

1.20 meters, the device is especially suitable for use<br />

in rough industrial environments. The battery can be<br />

changed without interrupting operation so that work<br />

can continue without interference. The device is also<br />

available without safety functions. p<br />

info<br />

contact<br />

www.siemens.com/hmi<br />

colin.quek@siemens.com<br />

18 ideas singapore | 2008


P r o d u c t s<br />

T e l e S e r v i c e<br />

p Simatic TeleService: Remote maintenance via modem<br />

Covering the Distance<br />

With Simatic TeleService, remote servicing of Simatic S7 Automation<br />

Systems (AS) or Human Machine Interface (HMI) devices is possible<br />

using the programming device or Personal Computer (PC) over a fixed<br />

line or wireless network.<br />

With the help of Simatic TeleService, the<br />

connection to the automation components<br />

is extended over the telephone<br />

network to the programming device or PC. The functions<br />

to be performed, such as programming, are<br />

completed using the same tools and functionality as<br />

if the job is done locally. The user has access to the familiar<br />

functions of STEP 7 and the Engineering Tools,<br />

comparable to a local connection.<br />

TeleService Adapter II is supporting Bus connections<br />

to Multipoint Interface (MPI), Profibus DP up to<br />

12Mbit/s, Point-to-Point Interface (PPI) and TeleSer-<br />

T S A d a p t e r a n d B u s C o n n e c t i o n s<br />

vice Adapter IE to Industrial Ethernet<br />

(IE) and Profinet.<br />

Simatic TeleService extends the bus<br />

interface via the telephone network to<br />

access remote CPUs (S7- 200, -300, -<br />

400, C7, WinAC) with STEP7, ProTool,<br />

and all Simatic programming tools.<br />

Therefore no PG/PC is required on-site<br />

at the plant.<br />

The TS Adapter IE supports also remote<br />

maintenance of Simatic HMI operator<br />

panels via WinCC flexible with<br />

Sm@rtService or an Internet Browser<br />

installed on the PC/PG.<br />

Parameterization and secured access<br />

<strong>Siemens</strong> AG<br />

The Simatic TeleService<br />

adapter module<br />

Adapter Bus<br />

Connection<br />

TeleService Adapter II TeleServce Adapter IE<br />

Analog ISDN Analog ISDN<br />

MPI = =<br />

Profibus = =<br />

PPI = =<br />

PROFINET = =<br />

Industrial<br />

Ethernet<br />

= =<br />

S i m a t i c T e l e S e r v i c e<br />

Simatic TeleService consists of integrated components<br />

3 TeleService Adapter II / IE<br />

3 TeleService Software V6.1 (stand-alone software)<br />

3 Function blocks (FBs) for remote maintenance, remote<br />

coupling, alarm using text messages(SMS), by e-mail or fax<br />

The connection to the automation systems is established<br />

using existing communication networks:<br />

3 Analog telephone network<br />

3 ISDN<br />

3 Mobile telephone network<br />

TeleService software V6.1 is used for the local parameterization<br />

of the Adapters. The TS Adapter IE can<br />

also be parameterized over a Remote Link or Internet<br />

Browser.<br />

Access is possible only via dial-in. The TS Adapter<br />

IE comes with a pre-configured firewall. By default<br />

the firewall only permits Simatic services. The required<br />

services, e.g. Sm@rt-Access, Sm@rt Service,<br />

can be enabled via the integrated Web interface of<br />

the Adapter.<br />

Cost-effective anytime anywhere access<br />

Simatic TeleService offers a low-cost, easy to handle<br />

application resulting to a shorter service time, less<br />

maintenance and operational costs (less travel expenses,<br />

lower on-call/onsite requirements, less configuration<br />

hassles).<br />

Remote access through Simatic TeleService enables<br />

the user to access and perform maintenance for<br />

Simatic PLCs, HMI and remote coupling from a central<br />

service center effecting an “anytime, anywhere”<br />

access to plants and machines. <br />

p<br />

info<br />

contact<br />

www.siemens.com/simatic/industriesoftware<br />

christian.kopplin@siemens.com<br />

ideas singapore | 2008 19


P r o d u c t s<br />

G a s E m i s s i o n m o n i t o r i n g<br />

p Solution for the gas emission monitoring<br />

Unique and Adapted<br />

Over the last thirty years, <strong>Siemens</strong> has built a strong and diversified<br />

process analytics portfolio. Famous brand in their field such as<br />

Applied Automation (Process Gas Chromatography) or Altoptronics<br />

(In situ Laser spectroscopy) have been well integrated within <strong>Siemens</strong>.<br />

source<br />

otating copper<br />

Sampe gas inet<br />

Sampe ce<br />

Sampe gas outet<br />

easuring signa<br />

etector ces<br />

icroo sensor<br />

or measurement<br />

20 ideas singapore | 2008


Strengthened by the high quality and reliability<br />

of its products, <strong>Siemens</strong> has chosen to<br />

propose the best and most suitable technology<br />

for each application instead of having a multicomponents<br />

system with a global average result.<br />

All <strong>Siemens</strong> analyzers are compliant with the latest<br />

regulations in Europe, Asia and US (TUV, QAL1...etc).<br />

Furthermore, in order to bring a complete solution<br />

to its customer, <strong>Siemens</strong> is able to propose the<br />

system integration (sampling and conditioning system,<br />

shelter), maintenance and service contract<br />

through its own local or regional office and partners<br />

network.<br />

Non Dispersive Infra-Red (NDIR) Analyzer<br />

Since all gases absorb infrared light energy of various<br />

wavelengths, multiple gas mixtures, even with<br />

very complicated absorption spectra, can be accurately<br />

quantified using this technique. <strong>Siemens</strong> developed<br />

an original and efficient design by using double<br />

or triple layer detectors filled with the measuring<br />

component. One broad bandwidth IR source is used<br />

for all components and the selection is realized inside<br />

the detector with no moving part.<br />

The Ultramat 23, by using this specific technique,<br />

allows to measure up to three IR components simultaneously<br />

with the option of an additional electrochemical<br />

cell for O2 measurement. Measured components<br />

are CO, NO(x), SO2, CO2 and O2.<br />

For emission monitoring in large combustion plant<br />

or incineration plant, the Ultramat 23 is the benchmark<br />

solution.<br />

Its main advantages are the use of cleanable sample<br />

cell, of no moving part and the possibility to perform<br />

a calibration with ambient air by using the so<br />

called “AUTOCAL”. These key factors make the Ultramat<br />

23 to have the lowest cost of ownership on the<br />

market.<br />

In-situ Laser spectroscopy<br />

The basic principle of the diode laser absorption<br />

spectroscopy is the use of a laser beam crossing a<br />

stack. One of the characteristics of the laser is its monochromatic<br />

feature and therefore emits only one<br />

specific wavelength resulting in a low interferences<br />

with other gases.<br />

The laser beam being absorbed by the specific gas<br />

molecules reaches the receiver with a lower intensity.<br />

The Intensity absorbed by the molecule is then directly<br />

proportional to the concentration of this molecule<br />

in the gas volume. The LDS 6 is a single (or dual)<br />

gas analyzer, which can simultaneously measure at 3<br />

locations. From the central unit to the sensors, there<br />

The LDS 6 in-situ laser spectrometer<br />

is a robust optical fiber which can lengthen up to<br />

1000m. An important difference with any other in<br />

situ technology is the use of the second derivative<br />

calculation of the signal which allows to be independent<br />

of the transmission condition as opacity of the<br />

stack, and water droplet.<br />

Due to the very low concentration of HF and HCL to<br />

be measured for the emission monitoring and their<br />

high reactivity with their environment, the in situ Laser<br />

LDS6 is the perfect solution. An extractive system,<br />

because of the sampling line, will cause the loss<br />

of these components. Therefore, the high selectivity<br />

of the laser LDS6 and its high sensitivity allows<br />

measurement of the HF, HCL and H2O.<br />

The last important feature to remember is its quasi<br />

inexistent maintenance due to the absence of consumable,<br />

moving part and the permanent self calibration<br />

by using a build-in reference gas cell.<br />

A new WTE plant in Singapore<br />

The future waste-to-energy plant and Singapore’s<br />

fifth, is expected to be running in operations in early<br />

2009. <strong>Siemens</strong> will provide the equipment - Ultramat<br />

and LDS 6, for the continuous emission monitoring<br />

system. When completed, the plant will be able<br />

to treat 800 tones of solid waste a day to generate<br />

more than 20MW of energy. <br />

p<br />

info<br />

contact<br />

www.siemens.com/processanalytics<br />

frederic.thielland@siemens.com<br />

Pictures: <strong>Siemens</strong> AG<br />

ideas singapore | 2008 21


T e c h n o l o g y<br />

1958 1979 1996 2002<br />

Hard-wired programs First programming devices<br />

Totally Integrated Automation<br />

Manufacturing Execution<br />

Systems<br />

p Simatic– 50 years of proven engineering leadership<br />

Automation conquers the World<br />

It began in 1956 when a team of experts developed a “<strong>Siemens</strong> automation system”. In 1958, Simatic<br />

was registered as a trademark and has since become one of the most successful automation systems<br />

in the world.<br />

At the Paris machine tool fair in 1959, <strong>Siemens</strong><br />

proudly presented the first generation of its<br />

“Building-Block System for Solid-State Controls”:<br />

the Simatic G. Switching elements in that era’s<br />

conventional electromechanical systems were relays<br />

and contactors. But in the Simatic G, transistors performed<br />

these functions. Their advantage was that<br />

they were smaller and not subject to wear and tear.<br />

Positive response early on<br />

A factor that helped Simatic gain ground was the positive<br />

response to the arc control system developed in<br />

the early 1960s. <strong>Siemens</strong> equipped many transformer<br />

substations with this system, because these facilities<br />

often suffered short circuits caused by arcs resulting<br />

from operator errors in using the switchgear, or from<br />

voltage surges due to lightning. Arc extinction systems<br />

had to convert an arc into a harmless short circuit<br />

in a matter of milliseconds, which Simatic G could<br />

do because of its fast switching times.<br />

A new era<br />

The era of programmable logic controls (PLCs) began<br />

in the early 1970s. Their functions were not determined<br />

by hardware connections but by the software.<br />

The S5 module, performed automation,<br />

programming and documentation tasks. Subsequently,<br />

the first bus systems were introduced, a<br />

prerequisite for integrating multiple individual controls<br />

into a single, powerful data network. During the<br />

1990s, these advances enabled Simatic to develop<br />

into the core of a process control and management<br />

system that handles all automation tasks from the signal<br />

level to the control console.<br />

Though on many occ asions Simatic is still equated<br />

with programmable controls, that association has<br />

long been incorrect, explains Hermann Richter, product<br />

manager for Simatic PCS 7: “Simatic stands for<br />

Totally Integrated Automation, and consequently for<br />

a new way of implementing automation tasks.” A<br />

Simatic platform, Richter explains, makes end-to-end<br />

automation feasible. “The advantage is that this will<br />

virtually eliminate costly system incompatibilities<br />

and discontinuities,” explains Richter.<br />

Platform for Control Systems<br />

A prerequisite for such integration is uniform data<br />

networks that connect all levels of automation, much<br />

like a nervous system. Equally crucial is to structure<br />

the system landscape according to hierarchical and,<br />

as far as possible, autonomous levels. The advantage<br />

is that if a fault occurs, only the function of the affected<br />

process segment is lost; the rest of the system<br />

continues to operate, though with limitations. This<br />

approach also makes it possible to expand the system<br />

step by step. “The trend is clearly in the direction of<br />

open systems architecture,” Richter says. He adds<br />

that this is necessary to protect the customer’s investment.<br />

“Such a system shouldn’t be scrapped<br />

early; it should continue to serve the customer’s<br />

needs.” <br />

p<br />

contact<br />

dieter.broeckl@siemens.com<br />

22 ideas singapore | 2008


I n B r i e f<br />

<strong>Siemens</strong> establish partnership with Excel Marco<br />

Certified Solution Partner<br />

In photo (L-R): JJ Hetzel, <strong>Siemens</strong> AG Partner<br />

Management Program; David Ong, Managing<br />

Director Excel Marco; Dieter Broeckl, <strong>Siemens</strong><br />

Pte. Ltd. Industrial Automation<br />

<strong>Siemens</strong> AG<br />

<strong>Siemens</strong> is proud to announce the formation of partnership<br />

with Excel Marco (Industrial Systems) as the certified solution<br />

automation partner in Process Control System Simatic PCS 7<br />

and PCS 7 Safety specialist. <strong>Siemens</strong> and Excel Marco jointly<br />

provides complete automation solutions for Process Safety to<br />

the offshore FPSO (Floating Production Storage Off-loading),<br />

Oil & Gas Production Platform, Jack-up Drilling Rigs, Onshore<br />

Refinery and Petrochemical plants in the Asia Pacific region,<br />

Middle East and the South Americas. Excel Marco offers a wide<br />

range of engineering services, from DCS/PLC systems design,<br />

logic programming, control panel fabrication, testing to full<br />

turn-key systems integration. <br />

p<br />

contact: dieter.broeckl@siemens.com<br />

<strong>Siemens</strong> remains to be the PLC market leader<br />

True Customer Understanding<br />

<strong>Siemens</strong> bagged the Frost & Sullivan Market Leadership Award for three consecutive<br />

years now pronouncing <strong>Siemens</strong> true understanding and anticipation<br />

to the customer requirements; superiority in product quality; global customer<br />

service and outstanding overall product value delivery.<br />

The Frost & Sullivan Market Leadership Award is presented to the companies<br />

in South East Asia which shows excellence in areas of the market leadership<br />

process, including the identification of market challenges, drivers and<br />

restraints as well as strategy development and methods of addressing these<br />

market dynamics.<br />

p<br />

contact: dieter.broeckl@siemens.com<br />

<strong>Siemens</strong> AG<br />

<strong>Siemens</strong> celebrates 100 years in Singapore<br />

A Century of <strong>Siemens</strong><br />

Taking part in the cake cutting ceremony. From left: Professor<br />

Cham Tao Soon, Chairman, Singapore Symphony Orchestra; Dr.<br />

Klaus Wucherer, Executive Advisor to the CEO, <strong>Siemens</strong> AG; His<br />

Excellancy SR Nathan, President of the Republic of Singapore;<br />

Mr. Hans-Dieter Bott, Country Manager, <strong>Siemens</strong> Singapore; Dr.<br />

Beh Swan Gin, Assistant Managing Director, Economic<br />

Development Board<br />

Since 1908 <strong>Siemens</strong> has been continuously setting the<br />

pace in the technological and economical growth in<br />

Singapore, thus making the company one of the longest<br />

surviving foreign companies ever founded locally.<br />

It was initially established as a technical bureau sales<br />

office to <strong>Siemens</strong> Brothers Dynamo Works, a London<br />

based company.<br />

Over the years, <strong>Siemens</strong> innovations have left its<br />

mark on almost every aspect of the Singaporean life.<br />

It built over one-third of the country’s power plants;<br />

automated SingPosts’ latest postal automation systems<br />

and Changi Airport’s air traffic management<br />

systems and supplied more than 19 train sets to the<br />

country’s MRT transport system.<br />

This years theme, “Setting the Pace” means <strong>Siemens</strong><br />

has and will continuously set the pace for technology<br />

and innovation in building, empowering, moving, connecting,<br />

protecting, enhancing, developing and caring<br />

for the Singaporeans and in the island’s economy.<br />

“<strong>Siemens</strong> is proud to have played a major role in<br />

setting the pace in growth, development a nd technologies<br />

in Singapore, by answering many of the<br />

nation’s toughest questions in energy, industry and<br />

healthcare,” says Mr. Hans-Dieter Bott, Country Manager<br />

of the <strong>Siemens</strong> Group of Companies in Singapore.<br />

“We remain committed to setting the pace for<br />

now and into the future.”<br />

p<br />

contact: nadine.dietrich@siemens.com<br />

<strong>Siemens</strong> AG<br />

ideas singapore | 2008 23


D i a l o g u e<br />

info<br />

Do you want to find out more about<br />

automation and drive engineering from<br />

<strong>Siemens</strong> Automation and Drives? Then visit<br />

our online information platform on the<br />

Internet:<br />

www.siemens.com/<br />

automation/newscenter<br />

online<br />

The current issue of ideas international<br />

can be downloaded as a PDF file from our<br />

website at<br />

www.siemens.com.sg/read-ideas<br />

The electronic archive also gives you<br />

access to past issues. Please e-mail us your<br />

comments and suggestions for improving<br />

ideas. This feedback will then be included<br />

in the further conception of ideas<br />

international.<br />

Contact:<br />

princess.nuevo-caraan@siemens.com<br />

seminars<br />

Process Analytics Solutions<br />

Certification Seminar<br />

Seminar 1:<br />

Process Gas Chromatographs - Reduce cycle<br />

times at the highest level of performance<br />

with the lowest possible costs<br />

Date: April 11, 2008 9AM - 2PM<br />

Seminar 2:<br />

O2 Measurement - Right Technology for the<br />

Right Application<br />

Date: July 04, 2008 9AM - 2PM<br />

Seminar 3:<br />

Continuous Emission Monitoring Systems in<br />

accordance to EN 14181 Standards<br />

Date: September 26, 2008 9AM - 2PM<br />

Seminar 4:<br />

Insitu Laser Spectroscopy - A new way to<br />

optimize your process and improve your<br />

safety measurement<br />

Date: December 05, 2008 9AM - 2PM<br />

To request more information about the<br />

seminar, please email us at<br />

princess.nuevo-caraan@siemens.com<br />

ideas singapore 4-2008<br />

Editorial Board<br />

Christian Kopplin<br />

Dieter Broeckl<br />

Frederic Thielland<br />

Hartmut Klocker<br />

Liew Wah Seng<br />

Mabel Chin<br />

Marie Princess Nuevo Caraan<br />

Zavior Kulandasamy<br />

Technical Writers<br />

Adnan Abdul Rahman<br />

Choo Woon Fu<br />

Colin Quek<br />

Darman Putra<br />

Doreen Lim<br />

Eugene Yeo<br />

Jorey Guzman<br />

Volker Schul<br />

News Writer<br />

Nadine Dietrich<br />

Publisher<br />

<strong>Siemens</strong> Pte. Ltd.<br />

60 MacPherson Road<br />

Singapore 348615<br />

Concept<br />

Marie Princess Nuevo Caraan,<br />

Christian Leifels<br />

Regional Support and Coordination<br />

Benedikta Verlinde, Bianca Krach<br />

Publishing House<br />

Publicis KommunikationsAgentur GmbH,<br />

GWA<br />

Corporate Publishing<br />

P.O. Box 3240, D-91050 Erlangen, Germany<br />

Telephone +49 (0) 91 31/91 92-527<br />

Telefax +49 (0) 91 31/91 92-596<br />

publishing-magazines@publicis-erlangen.de<br />

Editorial staff:<br />

Kerstin Purucker<br />

Layout:<br />

Stefanie Eger, Jürgen Streitenberger,<br />

Roland Karl<br />

Copy editor:<br />

Daisy Kraus<br />

Ideas Singapore is published twice a year<br />

Title: <strong>Siemens</strong> AG<br />

Circulation: 2,000<br />

©2008 by <strong>Siemens</strong> Aktiengesellschaft<br />

Munich and Berlin<br />

All rights reserved by the publisher.<br />

The following products are registered trademarks<br />

of <strong>Siemens</strong> AG<br />

SIMATIC, SCALANCE,TOTALLY INTEGRATED<br />

AUTOMATION, SIMOCODE, PCS 7, ROBICON,<br />

SITRAIN, WINCC, SIMATIC PANEL PC,<br />

SINEMA, SIMATIC TELESERVICE, STEP 7<br />

If trademarks, technical solutions or similar<br />

products are not included in the list, it does<br />

not imply that they are not protected. The<br />

information provided in this magazine contains<br />

merely general descriptions or characteristics<br />

of performance which, in case of<br />

actual use, do not always apply as described<br />

or which may change as a result of further<br />

development of the products. An obligation<br />

to provide the respective characteristics<br />

shall only exist if expressly agreed upon in<br />

the term of contract.<br />

Printed in Singapore

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