Siemens MediaService

Siemens 

MediaService 

March 2017 

siemens.com 

Content 

PRODUCTS 

02 For optimum cell growth 

03 From the printer to the skies 

APPLICATION 

05 Filling up on green fuel 

07 Smart air supply 

09 Positioned for future growth 

MediaService 

Industry News 

The March issue of the MediaService 

offers another interesting selection of 

product and application news from 

the world of drives and automation. 

We start with a look at a totally new 

fermenter monitoring solution for the 

pharmaceutical industry which measures 

the oxygen consumption of living 

cell cultures. We then take to the 

skies with 3D-printing technology: 

Siemens supports the production of 

exterior and interior aircraft components 

using additive manufacturing. 

Also featured in this issue: “green refueling” 

is enabled by a Siemens automation 

solution harmonizing different 

system components in Europe’s 

first multi-energy hydrogen-based filling 

station. We also hear how a modern 

drive solution helps save the energy 

used to fire a furnace in the 

casting industry. The modernization 

of two wind blowers for a cupola furnace 

simplifies the engineering process 

required for the manufacture of 

cylinder crank cases, cylinder heads 

and crankshafts for passenger cars 

and commercial vehicles. Finally, we 

read how Siemens PLM software improves 

productivity in the development 

and production of high-grade 

components and systems for efficient 

drive and control technology.

MediaService | March 2017 2 

For optimum cell growth 

Siemens components for precision gas analysis in the pharmaceutical industry 

The physical differential measurement of 

oxygen and carbon dioxide in the supply 

and exhaust air flows enables precise 

control of the fermentation process. 

The modular gas analyzer Siprocess GA700 

from Siemens is used in what is currently a 

unique application in the pharmaceutical industry: 

measuring the oxygen consumption 

of living cell cultures. The measured results 

provide conclusive information about a cell 

culture’s “state of health”. 

Nuremberg, Germany. In the biological 

production of active ingredients, 

the quality and yield of the active substances 

obtained depend to a large 

degree on the correct care of the living 

cell cultures used. Their condition can 

now be precisely determined using a 

new and currently unique method: the 

physical differential measurement of 

oxygen consumption and carbon dioxide 

emissions. To enable this process, 

Siemens supplies the gas analyzer 

Siprocess GA700, a complete solution 

comprising the Ultramat 7 analysis 

module and the Oxymat 7 measuring 

device. Alongside precise analysis results, 

this Siemens solution offers a 

higher degree of process control and 

cost savings of up to 50 percent. 

In the pharmaceutical industry, a distinction 

is drawn between chemical 

and biological production used to 

manufacture active ingredients. Biological 

production is comparatively 

more labor-intensive, as it involves living 

cell cultures which are kept in 

large steel vats known as fermenters, 

where they produce the required active 

ingredient. The quality and efficiency 

of this process depend heavily 

on the right care of the living cell cul- 

tures. Their “state of health” can be 

most efficiently determined by measuring 

their oxygen (O2) consumption 

and carbon dioxide (CO2) emissions. 

This enables the physical 

differential measurement of oxygen 

and carbon dioxide in the supply and 

exhaust air flows. Also part of the 

complete solution surrounding the 

wear-free measurement principle developed 

by Siemens is the preparation 

of samples. This entails the extraction 

and preparation of gases 

before feeding them to the analyzer, 

a process known as “extractive gas 

analytics”. This method of physical 

differential measurement is currently 

unique in fermenter monitoring, and 

will be featured at the Siemens booth 

(D35) in Hall 9 at this year’s Hannover 

Messe from April 24 to 28, 

2017. 

Precise analysis enables operators 

to quickly recognize where optimization 

is required and take the necessary 

action to adjust the fermentation 

process. Process control at this point 

can be performed using a Simatic 

PCS 7 control system together with 

any necessary instrumentation. This 

method offers users the best possi- 

ble control over the process, an improved 

raw material and active ingredient 

yield and also up to 50 percent 

cost savings per fermenter filling. 

Process Gas Analytics 

http://w3.siemens.com/mcms/ 

sensor-systems/en/process-analytics/extractive-continuousprocess-gas-analytics/siprocess-ga700/Pages/Default. 

aspx 

Ultramat 7 


sensor-systems/en/process-analytics/extractive-continuousprocess-gas-analytics/siprocess-ga700/Pages/ 

siprocess-ga700-ultramat-7. 

aspx 

Oxymat 7 


sensor-systems/en/process-analytics/extractive-continuousprocess-gas-analytics/siprocess-ga700/Pages/ 

siprocess-ga700-oxymat-7. 

aspx


From the printer to the skies 

Siemens supports supply of the first 3D-printed aircraft components 

Following on from printing of the monitor shrouds, Strata and Siemens will turn their attention to another joint project: The construction of an 

external aircraft component in metal. 

Siemens and Strata jointly develop MENA 

Region’s first 3D-printed aircraft interior parts 

for Etihad 

Al-Ain/United Arab Emirates. Although 

Siemens has already gathered 

wide experience in the field of 

3D printing, the company recently 

broke new ground in cooperation 

with aircraft component manufacturer 

Strata based in Al-Ain in the United 

Arab Emirates: For the very first 

time, the company is supporting the 

production of exterior and interior 

parts for aircraft using 3D-printing 

technology. This marks the start of a 

partnership with the Mubadala Development 

Company, the UAE’s sovereign 

wealth fund, to help launch 

and develop Industrie 4.0 in the 

Emirates. 

Additive manufacturing, also known 

as 3D printing, is already in use in a 

wide range of industrial sectors. This 

involves building up components additively 

one layer at a time on the 

basis of 3D-design data using plastics, 

metals and other materials. 

Whether burner tips for gas turbines, 

armrests for trams or terminal boxes 

for Germany’s Deutsche Bahn railway 

– Siemens has already gathered 

plenty of experience in this 

technology. Aircraft construction represents 

a new field for Siemens. The 

company supports aircraft component 

manufacturer Strata based in 

Al-Ain in the United Arab Emirates to 

supply elements for use in aircraft 

interiors for the first time: shrouds 

for the wall monitors used by for Etihad 

Airways. To ensure a perfect fit, 

these are manufactured with a 3D 

printer out of plastic powder. The 

monitor shrouds for Etihad are just 

the first step in what promises to be 

a long-term partnership between 

Siemens and UAE’s state-owned investment 

fund, the Mubadala Devel-


opment Company. The aim of this 

close future partnership: To support 

the United Arab Emirates and North 

Africa in the process of introducing Industrie 

4.0 and additive manufacturing 

with a view to creating an additional 

economic mainstay alongside 

oil extraction and tourism. In keeping 

with this vision, the next order with 

Strata is already in the pipeline: After 

printing the monitor shroud, Strata 

and Siemens will work together on 

printing an external aircraft component 

made of metal. Siemens also intends 

to support Strata in building a 

complete 3D-printing facility. 

New ground 

For Siemens, the monitor shroud contract 

posed a whole new set of challenges. 

“Before the shroud can be in- 

stalled, it has to be approved by the 

European Aviation Safety Agency 

EASA,” explains Assem Khalaili, 

Siemens AG’s Head of Industry Customer 

Services Middle East. “There 

isn’t yet a process in place at Siemens 

for this certification. Luckily 

though, we were able to call on our 

colleagues in the Mobility Division 

who have gained comparable experience 

with the certification of parts 

used in railway applications, as 

these also have to comply with the 

highest safety class.” Before the 

monitor shrouds “take to the air”, 

they and the outside component in 

metal will be presented to investors 

and decision-makers at the “Global 

Manufacturing and Industrialization 

Summit Middle East” in March. This 

development marks the official 

“take-off” for additive manufacturing. 

Additive manufacturing 

makes its entry into the 

world of aviation, as 

Siemens supports the 

3D-printing of aircraft 

cabin components for 

Etihad Airways. 

Additive Manufacturing 

http://www.siemens.com/global/ 

en/home/markets/machinebuilding/additive-manufacturing.html 

Service Business Excellence 

Portal 

https://technoweb.siemens.com/ 

web/service-business-excellence-portal/overview-strategy


Filling up on green fuel 

Multi-energy filling station system modules harmonized with Siemens 

Berlin, Germany. Clean Energy Partnership 

(CEP) and additional cooperation 

partners have launched Europe’s 

first ever multi-energy filling station in 

Berlin, which supplies hydrogen produced 

from wind power and solar energy. 

To enable the technology and 

systems contributed by the various 

partners to be integrated into a stan- 

Clean Energy 

Clean Energy Partnership is Europe’s 

biggest demonstration 

project in the field of hydrogen 

mobility. Based on the German 

Transport Energy Strategy, the 

Initiative was launched in the political 

arena by the German Ministry 

of Transport in 2002 in order 

to investigate the system 

compatibility of hydrogen as a 

fuel in the field of mobility. 

dardized operating system, the project 

associates opted to use Simatic 

PCS 7 technology from Siemens. 

This automation solution integrates 

all the system components without 

the need for major changes to the 

automation technologies provided by 

the individual cooperation partners. 

This eliminated the expense which 

would have been involved in implementing 

an overall synchronization 

solution. It allowed the project partners 

to adhere to the tight schedule, 

secure the intellectual property attached 

to the individual parts of the 

installation and ensure round-theclock 

availability. 

“Green” or “clean” energy has long 

since ceased to be a novelty, and its 

availability is improving all the time. 

One reason is completion of the 

H2BER project in Berlin, Europe’s 

first ever hydrogen-based multi-energy 

filling station. The project was 

completed under the auspices of the 

Clean Energy Partnership (CEP) and 

Europe’s first multi-energy filling station in 

Berlin is monitored by the Simatic PCS 7 

process control system, which also integrates 

the components of the different cooperation 

partners.


other cooperation partners. To allow 

the hydrogen to be used across its entire 

cycle – from production through 

electricity and heat generation to its 

use as a fuel – the control systems of 

the individual technology partners 

needed to be integrated into a standardized 

overall system. In concrete 

terms, these systems included a combined 

heat and power plant to provide 

electrical energy and heat for the filling 

station, as well as tank technology 

for the two hydrogen (H2) fuel dispensers 

which will allow passenger 

vehicles and buses with 350 bar and 

700 bar tanks to be filled in the future. 

This harmonization process was made 

possible using the higher-level Simatic 

PCS 7 process control system from 

Siemens, which monitors the integrated 

system and communicates with the 

individual partner modules which supply 

hydrogen produced from solar and 

wind power. 

Everything under a single umbrella 

The software technology Open OS, 

part of the Simatic PCS 7, is an open 

solution which homogenizes heterogeneous 

system landscapes by connecting 

third-party components such 

as CodeSys, Wago, Freelance and 

also Simatic S7-1500. For the H2BER 

project, this eliminated the need for 

an overall synchronization concept. 

All the partners were keen to protect 

their intellectual property in the form 

of patents, trademarks and copyrights. 

Open OS guarantees the requisite 

degree of protection. The data 

required for signal processing is received 

from subordinate or ancillary 

system components, and is then collated 

by the system in a central measuring 

station. Individual components 

such as programmable logic controllers 

(PLCs), third-party controllers 

from other manufacturers, or readyto-install 

package units can be integrated 

using WinCC communication 

channels or OPC. This allows OPEN 

OS to create a PCS-7-compatible 

map of the system requiring integration, 

with the result that the plant op- 

erator works on a standardized visualization 

level. “All the partners 

involved worked in close cooperation 

right from the start of the project 

to agree which information is relevant 

and how we could forward 

which signals,” explains Wolfgang 

Kraus, Project Engineer at McPhy. 

“For this pilot project, we solved the 

issue by linking the Simatic PCS 7 

process control system via Open OS 

to the third-party and S7-1500 controllers, 

and transmitting the data of 

relevance over standard communication 

channels.” The structure of 

the overall solution comprises an operator 

prompting level with clientserver 

architecture, some aspects of 

which have been configured to be 

redundant in the interests of availability. 

The lower system level features 

an Ethernet ring which is connected 

to all the subordinate 

systems. This is where OPEN OS 

connects the data from third-party 

systems, captures it and makes it 

available in harmonized form on the 

operator prompting level. 

Maximum security and availability 

Another benefit of the Open OS solution 

is that data archiving can be carried 

out fully automatically over the 

system. Long-term archiving takes 

place using the integrated Siemens 

Process Historian Server. Open OS 

also permits archiving to take place 

in the form of XML files, meaning 

that already implemented solutions 

can be simply reproduced. This reduces 

the engineering effort and cost 

input required for future projects, 

such as a second H2 filling station. 

The comprehensive Siemens solution 

ultimately not only allowed the 

tight schedule to be adhered to but 

also ensured the required degree of 

intellectual property protection and 

twenty-four-seven availability of the 

filling station as well as all its systems. 

This was all achieved without 

the need to make major changes to 

the automation technologies used by 

the involved partners. 

McPhy 

McPhy Energy Germany is a 

subsidiary company of the 

French McPhy Energy S.A. 

which was established in 2008. 

The company is specialized in 

the development and manufacturing 

of hydrogen technologies. 

At the H2BER filling station 

MyPhy operates an 

innovative solid-state storage 

system (metal hydrides) with a 

capacity of 100 kilogramms, 

which complements the on-site 

compressed gaseous storage. 

McPhy was the responsible 

project leader for the process 

control system of the integrated 

manufacturer´s system alliance. 

Process Control System 

www.siemens.com/simaticpcs7 

Intelligent Integration of system 

components 


process-control-systems/en/ 

distributed-control-system-simatic-pcs-7/simatic-pcs-7-technologies/open_os/Pages/ 

OPEN-OS.aspx


Smart air supply 

Energy-efficient drive solution for radial blowers in the casting industry 

Neue Halberg-Guss GmbH employs a workforce of just under 3,500 around the world and manufactures high-quality cylinder crank cases 

from different molten metals. 

The Sinamics G120P Cabinet frequency converters 

are specifically optimized for the operation 

of pumps, fans and compressors. 

Saarbrücken, Germany. Neue Halberg-Guss 

GmbH (Halberg) based in 

Saarbrücken produces cast iron 

drive components for the automotive 

industry. A recent retrofit involved upgrading 

two radial blowers on the cupola 

furnace, a shaft furnace used to 

smelt metals. Halberg decided to use 

an Integrated Drive System (IDS) 

from Siemens, which has enabled 

the company to save around ten percent 

in energy costs overall. The 

new solution has allowed Halberg to 

improve not only the availability and 

energy efficiency of the plant, but 

also its engineering and safety. 

The company Neue Halberg-Guss 

GmbH (Halberg) was founded in 

1756, and is based in Saarbrücken. 

It is Europe’s market and technology 

leader in the development and production 

of cylinder crank cases, cylinder 

heads and crank shafts for 

passenger cars and commercial vehicles. 

The company processes 

180,000 tons of iron every year, from 

the smelting stage at temperatures 

of 1,500 degrees Celsius to castings 

used in diesel and petrol engines. 

The nerve center of the plant is the 

18-meter high cupola furnace, whose 

availability directly impacts on the 

whole of the linked production process. 

As part of on-going maintenance 

work on the furnace, two radial 

fans had to be retrofitted, and are 

now equipped with Integrated Drive 

Systems (IDS) from Siemens. “We 

attach a high level of importance to 

our maintenance program, which is 

why we undertake a lot of modernization 

work. In this way, we foster 

and promote availability, efficiency, 

economy and importantly also environmental 

awareness,” explains Halberg’s 

Head of Electrical Maintenance 

Michael Steuer. 

Well integrated overall system 

The blowers each supply up to 

24,000 standard cubic meters of air 

per hour, ensuring an uninterrupted 

smelting process. They are driven by 

Simotics FD motors with a maximum 

output of 325 Kilowatts (kW) and 

Sinamics G120P Cabinet frequency


converters, which together form an 

IES2 energy efficiency class drive 

train in compliance with EN50598-2. 

This allows Halberg to make energy 

cost savings of up to ten percent in 

running operation. This has enabled 

98 percent efficiency to be achieved, 

five percent up compared to the previously 

used fan motors. The frequency 

converters can now also be run in 

energy saving mode, or switched 

off altogether and switched back on 

remotely as required over the Profi- 

Energy communication profile. For 

motor dimensioning and to determine 

which motors would fulfill the required 

performance characteristics, Halberg 

used the Siemens energy saving tool 

SinaSave. On this basis, the decision 

was taken to opt for Sinamics G120P 

Cabinet with 315 kW and the threephase 

induction motor Simotics FD 

High Efficiency with a shaft height of 

315 and 325 kilowatts. This choice enabled 

the company to actually go 

down a step to a smaller motor size. It 

also meant improved values in terms 

of moment of inertia, moveable mass 

and efficiency. Another benefit of Simotics 

FD motors is their smart modular 

system concept which offers outstanding 

flexibility with a wide range of 

possible applications. One of the 

many ventilation options uses internal 

cooling fins which prevent contamination 

by dirt deposits from the ambient 

air during motor standstill periods, 

making them ideal for use in harsh environments 

such as the Halberg 

foundry. 

Simple programming 

Using the Step 7 programming software 

and the integrated commissioning 

tool Starter, motors and converters 

can be ideally coordinated at the 

press of a button, resulting in an improved 

degree of system efficiency. 

Because the frequency converters allow 

the measurement distances of the 

analog pressure sensors from the air 

channels to be fed directly to the relevant 

inputs at the frequency converter, 

a dynamic and independent subsystem 

is created through the integrated 

PID (Proportional Integral Derivative) 

controller. This does not need to be 

programmed in the higher-level programmable 

logic controller (PLC), 

which forwards the energy consumption 

values via the OPC (Open Platform 

Communication) interface, so 

saving valuable computing performance. 

Wide-ranging improvements 

Alongside improving energy efficiency, 

the retrofit has also enabled availability 

to be significantly improved. 

Instead of the two separately operated 

redundant drives used in the past, 

the new motors can be individually 

switched over, with alternating supply 

by converter 1 or 2. Logging operating 

hours according to maintenance 

aspects allows the ideal load distribution 

to be achieved. Against the backdrop 

of improvements in terms of 

availability, engineering and energy 

consumption, Halberg intends to 

make further use of Siemens technology 

for planned modernization projects 

in other areas. 

The wind blowers for the cupola furnace 

were retrofitted using an Integrated Drive 

Solution (IDS) comprising Sinamics G120P 

frequency converters and Simotics FD 

motors. 

Converter 

www.siemens.com/sinamcis 

Integrated Drive Systems 

www.siemens.com/ids 

Motors 

www.siemens.com/simotics


Positioned for future growth 

Component manufacturer improves productivity with Siemens PLM Software 

The Siemens PLM Software solution is customizable to meet customer requirements and can be seamlessly integrated with Liebherr’s existing 

operational data acquisition system. 

Biberach, Germany. Liebherr-Components 

Biberach GmbH (Liebherr) develops 

and manufactures high-quality 

components and systems for high-performance 

drive and control technology. 

For the continuous improvement of its 

quality processes, Liebherr uses IBS 

QMS Software from PLM (product lifecycle 

management) specialist Siemens 

PLM Software. The solution enables 

the company to implement optimal 

transparency and to improve its manufacturing 

productivity. 

Liebherr-Components Biberach 

GmbH (Liebherr) is part of the components 

division of the Liebherr 

Group, which developed the first 

quickly transportable and easily 

erected revolving tower crane over 

six decades ago. Today the company 

manufactures technically sophisticated 

high-performance drive components, 

such as large diameter bearings, 

gearboxes and rope winches, 

as well as electrical machines and 

switchgears. These components are 

used in products such as earthmoving 

machines, wind turbines, mining 

equipment, maritime applications 

and vehicle systems. In order to 

safeguard its reputation for producing 

high-quality products, the company 

always uses IBS QMS Software 

from Siemens PLM Software to monitor 

and document the production 

processes, to achieve transparency 

and to improve manufacturing productivity. 

Choosing a reliable solution 

Comprehensive analysis and evaluation functionality in IBS QMS supports continuous quality 

and productivity improvement. 

Until 2003, Liebherr used a manual 

process for acquiring and evaluating 

quality data. Liebherr then decided to 

introduce an integrated computeraided 

quality (CAQ) and manufacturing 

execution system (MES) solution 

that would elevate process transparency, 

minimize administrative costs, 

increase production and individual 

worker responsibility, include a solution 

for concern and complaint management 

and allow the company to 

integrate a batch tracking system. 

Additionally, the CAQ/MES solution 

needed to be seamlessly integrated 

with Liebherr’s existing operational 

data acquisition (ODA) and enter-


Liebherr manufactures technically sophisticated high-performance drive components, such as large diameter bearings, gearboxes and rope 

winches, as well as electrical machines and switchgear. 

prise resource planning (ERP) systems. 

In November 2003, Liebherr selected 

IBS QMS software from 

Siemens PLM Software. Key decision 

factors included the ability to customize 

the solution to meet customer-specific 

needs and the seamless integration 

with existing ODA and ERP 

systems. 

Eliminating duplication 

In May 2004, Liebherr implemented 

IBS QMS and initiated training 

for approximately 700 employees 

using 100 terminals in the large 

diameter bearings, gearbox and 

crane technology departments. With 

a user-friendly operating interface, 

Liebherr can achieve a high degree 

of integration and eliminate duplicate 

data entry. Production orders are 

sent from the ODA system to IBS 

QMS, triggering respective inspection 

processes. Using touchscreen 

terminals, operators can determine 

which orders are being processed at 

any given machine as well as the 

current manufacturing status of each 

order. Inspection results are acquired 

and reviewed in parallel with production 

processes for further analysis. 

Only after processing all CAQ 

characteristics can the production 

order be closed. 

Certifying results 

The ability to continually monitor 

each component throughout manufacturing 

helps Liebherr identify 

trends early in the process. In addition 

to defect avoidance, the main 

emphasis is on the continuous improvement 

process (CIP) for products 

and procedures. At the request 

of the customer, Liebherr can generate 

individual certificates to substantiate 

processing results. 

Enhancing traceability and 

transparency 

The documentation and allocation of 

batch and serial numbers enable 

identification of individual stages 

throughout the part production process 

and allow Liebherr to track all 

batches. Internal complaints are 

managed with QMS Concern and 

Complaint Management (CCM), 

which allows Liebherr to prioritize the 

processing of once-defective parts 

that have been corrected. By using 

QMS CCM, Liebherr can document 

actions and allocate costs, such as 

rework, increasing transparency and 

enabling the identification and rapid 

elimination of weak points. The comprehensive 

analysis and evaluation 

functionality in IBS QMS supports 

continuous quality and productivity 

improvement. “IBS QMS helps us improve 

process transparency and positions 

Liebherr for future growth,” 

says Jürgen Stuhlmüller, quality assurance 

manager at Liebherr. On 

this recommendation, other Liebherr 

sites have also selected Siemens 

PLM Software as their CAQ/MES solution 

provider. 

PLM Software 

www.siemens.com/plm 

Quality Management 

www.siemens.com/mom/ibsqms


Siemens AG (Berlin and Munich) is a global technology 

powerhouse that has stood for engineering 

excellence, innovation, quality, reliability and internationality 

for more than 165 years. The company 

is active in more than 200 countries, focusing on 

the areas of electrification, automation and digitalization. 

One of the world’s largest producers of energy-efficient, 

resource-saving technologies, 

Siemens is a leading supplier of efficient power generation 

and power transmission solutions and a pioneer 

in infrastructure solutions as well as automation, 

drive and software solutions for industry. The 

company is also a leading provider of medical imaging 

equipment – such as computed tomography 

and magnetic resonance imaging systems – and a 

leader in laboratory diagnostics as well as clinical 

IT. In fiscal 2016, which ended on September 30, 

2016, Siemens generated revenue of €79.6 billion 

and net income of €5.6 billion. At the end of September 

2016, the company had around 351,000 

employees worldwide. Further information is available 

on the Internet at www.siemens.com. 

MediaService: 

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MediaService Digithek: 

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MediaService application reports may be based on 

previously published Siemens technical articles. 

Press Contact: 

Process Industries and Drives 

Stefan Rauscher 

Tel.: +49 (0)911 - 895 7952 

stefan.rauscher@siemens.com 

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Tel.: +49 (0)9131 7 - 26616 

david.petry@siemens.com 

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Tel.: +49 (0)211 - 6916 1003 

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