Industrial product aerogel

process news Systems and Solutions for the Process Industry s 1st edition April 2|2003 Innovations in process analytics Schering-Plough and Siemens team up for production retrofit First of its Kind: Industrial Aerogel Production CONTENT 10 Feature article: Aerogels are exceptionally good insulators and can be used for building translucent roofs – like the one shown in this picture In Frankfurt, Cabot produces Aerogels on an industrial scale in a first-of-its-kind plant EDITORIAL Using a new process control system, Cytec was able to drastically improve product quality in their Mobile plant 14 Siemens offers a dedicated drives and motors portfolio that covers a wide range of applications in the process industry Life Science A Winning Team Siemens Ireland is a reliable partner in upgrading Schering-Plough's multi purpose facility NEWS Significant reference project at Jilin Fuel Ethanol in China 20 Boosting Performance in Indonesian Gas Pipeline Chemical Industry Economic Innovation Migration project from Teleperm M to PCS at Wacker procen Calomat awarded prize by research center Lloyd’s Register Approves Products for Marine Applications CASE STUDIES Chemical Industry Comprehensive Solution Siemens installs analysis systems at Dow Stade 24 Chemical Industry Premiere in Egypt Simatic PCS in CMC production Aerogels First of its Kind Production by Cabot 10 21 25 Chemical Industry A Database for Production Batch Done Right Integrated process control and data management system at Akzo Nobel in Singapore Cytec Industries increased output with Batch Manager ACHEMA NEWS Specialty Chemicals 12 Process Analytics Total Analytics Solutions Innovations in process analytics at Achema Cover, source: Focus, Peter Menzel Highly insulating aerogel process news 2/2003 EDITORIAL Dear readers, 18 20 In their pilot plant, Wacker Polymer Systems is relying on Simatic PCS for controlling product development processes 16 Level Monitoring A New Level Siemens introduces remote monitoring concept via Internet and new monitoring devices 18 Drive Technology The Safer Side Drive solutions for the chemical industry ess news 19 Process Control Technology Even More PCS Simatic PCS further expands its scope of functions TECHNOLOGY 22 Process Control ”We Too Can Learn From Siemens” Comparison of fieldbus and control systems at Infraserv Höchst TRENDS 26 Service and Support the rigorous requirements of the chemical and pharmaceutical industries demand partners with an extensive knowledge of customer processes and the necessary technical know-how With expertise in both process technology and automation engineering, Siemens offers a unique blend of competencies to meet these requirements Industry solutions from Siemens range from single individual solutions to standard solutions for machine and plant building, systems integrators, and manufacturers of chemical and pharmaceutical products Naturally, the knowledge we acquire about our customers’ requirements is continuously employed in the development of new products Siemens has therefore chosen the motto “Better together – from process development to operation” for its presentation of products, systems, and solutions at this year’s Achema fair, which will be held May 19–24, 2003, in Frankfurt, Germany You will find a variety of new products in the fields of level monitoring technology, process analytics, and drive technology at the booth In the focus, of course, is our Simatic PCS process control system with its new functions With our Totally Integrated Automation platform we have furthered the horizontal integration of production plants, and with the Simatic IT Framework we are now accelerating the vertical integration and enabling close cooperation between planning and production Greater productivity, shorter time-to-market, better quality, higher plant availability, and better asset management – we understand what the process industry needs The Industry Suites from Siemens show the whole range of products, systems, services, and know-how that we offer, along with the ways in which we support our customers throughout the life cycle of a plant Visit us at our booth in hall 10.2 and see our new products, systems and solutions for yourselves Time is Money Services for operation, maintenance, and modernization 27 DIALOGUE process news 2/2003 Hans Georg Kumpfmüller President of Process Instrumentation and Analytics Division NEWS Significant reference project at Jilin Fuel Ethanol in China W ith a convincing concept, Siemens was able to beat off fierce competition and persuade a key customer in China to automate with the Simatic PCS process control system The Jilin Fuel Ethanol Co Ltd., a subsidiary of the China National Petroleum Corporation, is equipping a new plant with the Siemens process control system The plant, which produces ethanol from corn, has a capacity of about 600,000 tons of ethanol per year It was not only the smooth integration of the safety technology, the great openness of the system, and the excellent price/performance ratio of the concept but also the good groundwork of the Siemens project team that tipped the balance in favor of the PCS The entire system, which includes a total of 9,000 I/O points, is controlled from two PCS control rooms Eight high-availability PCS automation systems and a redundant optical industrial Ethernet ring form the reliable backbone of the control system, Boosting Performance in Indonesian Gas Pipeline gas booster station, including SCADA extensions, emergency shutdown and fire & gas detection systems The system comprises a total of 1200 I/O points ■ which is also equipped with a realtime-capable production monitoring system In addition, a redundant OS server, seven OS multi-clients, and two single OS stations are installed in Jilin The engineering and commissioning will be performed by Siemens Industrial Automation Ltd in Shanghai ■ The new Gas Booster Station will improve gas transmission through PGN’s pipeline I ndonesia is known as one of the biggest gas suppliers in the world The 540-Kilometer long Gas Transmission Pipeline in Sumatera Island, owned by Indonesia State Gas Company (PGN), was constructed in early 1996 to transmit the gas from Jambi area to Duri There PT Caltex Pacific Indonesia utilizes the gas as the fuel to generate steam for their Duri Steam Flood project PGN sees increasing gas demand in the future required by Caltex; that is why they are building a new Gas Booster station to increase the transmission pressure in the pipeline Siemens will supply and install the entire control system technology for the new process news 2/2003 Calomat awarded prize by research center T he IRSID Institute in Metz, Lorraine, is the premier European research center in the field of iron and steel IRSID recently conducted an assessment of various thermal conductivity gas analyzers for hydrogen measurement in this industry At the end of the six-month test phase, the Calomat analyzer emerged with the best results of all the instruments in the comparison The analyzer demonstrates good linearity and long-term stability, excellent reproducibility of measured values, and very The Calomat is exceptionally well suited for the iron and steel industry, as the IRSID research center confirms short response times It shows very low influence of the measuring gas flow in the range of 40 to 90 liters per hour and insensitivity to fluctuating ambient temperatures The Calomat also exhibits no hysteresis effects and is exceptionally easy to handle The conclusions of the testers: Calomat is absolutely appropriate for industrial applications and is ideally suited for measurements on blast furnaces in the steel industry, for monitoring coke oven gas, and for heat-treatment ovens ■ Lloyd’s Register Approves Products for Marine Applications L loyd’s Register of Shipping has issued approval certificates for Siemens ultrasonic level monitoring systems This approval meets customer requirements for use in marine, offshore, heavy industrial, chemical and petrochemical tank storage applications as outlined in Lloyd’s environmental categories ENV1, ENV2, ENV3, and ENV5 Approved products include Echomax XRS and XPS transducers, as well as AiRanger XPL, DPL Plus, and SPL electronic monitors These products have been tested and meet the requirements of the Lloyd’s Register Approval System process news 2/2003 In addition, the Siemens facility in Breda, The Netherlands, has received a Bureau Veritas Marine Project Approval that complements its existing ISO 9001 registration from the Bureau Veritas Quality International B.V This recognizes the quality system of this location to coordinate marine and related projects Other Siemens products that have the Lloyd’s Register certificate include Sitrans LC 500 and Sitrans LC 300 level monitoring instruments; Pointek CLS 100, 200 and 300 point level devices; Sitrans LR 300 radar; Sitrans P pressure transmitter and Sipart PS positioners ■ Siemens level monitoring devices are now approved for use in marine applications like this FPSO vessel (Floating Production, Storage, Offloading) CASE STUDY Aerogels Process expertise and automation technology – a perfect match in Cabot’s new aerogel production step toward industrial production, erecting a semi-works plant with a capacity of about 1,000 tons per year First of its Kind Simultaneous engineering and process development The new aerogel plant of Cabot Nanogel is the first of its kind using an innovative, cost-effective production process on an industrial scale Siemens Axiva not only developed the process but also took over responsibility as general planner for the engineering, procurement and construction of the new semi-works plant at the Industriepark Hoechst Industrial Complex in Frankfurt, Germany Siemens Axiva did the engineering for all civil work, mechanical equipment, piping and also the total electrical, instrumentation and automation (EI&A) of the plant C abot Corporation’s acquisition of the Aerogel Research Division of Aventis Research & Technologies in 1998 was an important milestone in the expansion of their nanogel division The U.S company secured the rights to a patented method for the manufacture of aerogels on an industrial scale Cabot also used a pilot plant where the process had already been tested on a laboratory scale and where first samples had been produced The Siemens Axiva team, at that time still part of Hoechst AG, had developed the method starting with its initial conception in the early 1990s, and Cabot wanted to take advantage of this know-how Siemens Axiva therefore continued to develop the process after 1998 – which recommended them as a competent partner for further developing the process all the way to fullscale industrial production But before industrial production, the existing process had to be optimized on a technical laboratory scale and adapted to the requirements of the potential market Applying integrated process development (IPD), Siemens Axiva can support such projects with a wide range of services Cabot also benefited enormously from this integrated solution during the decisive phase of process development Starting with demands that Cabot made on the product, Siemens Axiva first produced samples in the pilot plant that Cabot evaluated and made partially available to potential aerogel customers for test purposes These results were then fed back into process development and used for the further development of the process and of new optimized product samples After the first promising studies, Cabot then decided to pursue the next Official efforts to build the semi-works plant on the Hoechst Industrial Park began with the signing of the contract on January 30, 2001 In this project, Siemens Axiva was able to demonstrate its traditional expertise in the development, conception and building of so-called “first of its kind” plants Siemens Axiva optimized the actual process further during the plant’s engineering and erection This of course also had effects on the engineering process and construction already underway at the site At the same time Siemens Axiva had to scale up the process from pilot scale to that of the semi-works plant and also had to convert from batch to continuous operation As a general contractor, Siemens Axiva was responsible for all units in this process news 2/2003 project – from civil work to mechanical equipment, piping to EI&A To save time, Cabot chose to reactivate an old, shut-down plant and building on the Industriepark Hoechst Industrial Complex instead of constructing a grass roots plant Siemens Axiva worked closely with Cabot’s project leader, Eldor Classen, during engineering of the semi-works plant to realize and erect the plant as fast as possible The Siemens Axiva project team, headed by Herbert Eidkum, put in a total of about 60,000 hours for the engineering and supervision of all activities In the first few months, the team gutted the building on the Hoechst Industrial Park and prepared it for the installation of the new equipment Then they installed the hardware – masonry and concrete, steel works, mechanical equipment, piping, and EI&A equipment – and configured and installed the entire DCS Tough competition for every purchase order For this project, Cabot and Siemens Axiva followed an open book procedure for the total investment: Siemens Axiva placed all purchase orders, but Cabot reserved the right on every order to examine the bids and Siemens Axiva’s recommendations and made the final decision on the contract award As a result of the collaboration, Siemens was able to convince Cabot of the value of its products and solutions for several subprojects For instance, Cabot chose the Siemens Simatic PCS process control system for the very first time Siemens was also able to get the orders for low-voltage switchgear including the variable frequency drives as well as the entire building technology, including the access control systems Construction of the plant required among other things installation of about 250 pieces of new mechanical equipment, miles of pipes, and installation and integration in the control system of about 100 drives and 1,000 sensors and actuators Foto: Focus, Peter Menzel A thin block of aerogel is deflecting the heat of a blowtorch process news 2/2003 CASE STUDY Aerogels Siemens Axiva The Automation and Drives (A&D) Division of Siemens has acquired Siemens Axiva to strengthen its process engineering expertise for the process industry especially with respect to chemical and pharmaceutical processes Moreover the Siemens Axiva know-how will improve the customer benefit of A&D products, systems and services and make Siemens more attractive for customers in these industries The portfolio encompasses services from integrated technology and process development to so-called first-of-its-kind plants These plants require specific expertise in developing a suitable production process for laboratory substance and up-scaling of the process for production A new drying process makes industry-scale production of aerogels feasible The Siemens team configured the DCS in two stages to save valuable time First all instrumentation loops were configured and were installed at site with the complete hardware by the first handover date, so that loop checks could take place in the plant Then they implemented the basic and batch functions and the complete system software was loaded and updated just before mechanical completion and final handover of the total plant to Cabot Siemens Axiva made a major contribution to all stages of the project – from process development right to construction – and is rightly very proud of the new plant Moreover, Siemens was able to prove once again that close networking of know-how in process technology and in engineering and plant construction at Siemens Axiva with Siemens automation and solution concepts is an enormous time and cost advantage Tight schedules met The right way Good cooperation between all involved teams guaranteed that an ambitious schedule of just 15 months up to mechanical completion could be met – although parallel ongoing process development and resulting improvements were simultaneously integrated in work on site Despite all this, Siemens Axiva handed over the completed plant at the end of April 2002 – one week earlier than planned The plant’s fast and problem-free completion greatly impressed Torsten Lahrs of Cabot: “Because process development, plant construction, and configuration of the control system all came from the same source, so to speak, communication between the teams involved was exemplary And the immense know-how of the engineering staff on site and in process development enabled us to complete the proj- ect, with all its challenges, successfully.” After mechanical completion and handover of the plant in April 2002, the first “real” aerogel was produced at the semiworks Plant in Frankfurt in September 2002 Cabot’s goal now is to gather experience with the semi-works plant and to further optimize the process In the meantime, Cabot is planning a large-scale plant with a capacity of 10,000 tons a year – and after successful commissioning of the semi-works plant, Siemens Axiva has a good chance of winning this contract ■ Dr Jürgen Hess (Key Account Cabot), Siemens Axiva Frankfurt E-Mail: hess@siemens.com process news 2/2003 Cabot The secret of aerogels is locked inside: a porosity of 95 percent and a medium pore size of about 10 nanometers make aerogels supreme insulators Industrial production of aerogel: Translucent revolution Aerogels can consist of practically any metal oxide or mixtures of metal oxides, polymers, carbon, or various other materials At Cabot in Frankfurt, silica is used as the framework Aerogels belong to the family of nanoporous solids – an aerogel’s typical pore size is about 10 nanometers and these pores make up about 95 percent of the material volume This basic data indicates what to expect from aerogels: They have extraordinarily good sound and heat insulation properties (about six times better that polystyrene foam) and can therefore be used as insulating material One area of application is as insulation for engine compartments and vehicle doors in automobiles, and they have various uses in the building industry Because aerogels are translucent – meaning that they allow passage of some light – they open up totally new architectural possibilities It is conceivable, for example, to fill insulating windows with aerogels to create translucent facades while providing very good heat insulation Although aerogels were described as early as 1935, they could not be manufactured on an industrial scale until Siemens Axiva developed a manufacturing process This was mainly due to the fact that aerogels had to be dried under supercritical conditions It was not until Siemens Axiva’s development of the new process, which allowed aerogels to be manufactured with conventional drying processes, that the road was clear for industrial production To improve the mechanical properties of the aerogels, Siemens Axiva also developed a special forming process to produce monodisperse and spherical aerogels With the help of computeraided simulation tools, Siemens Axiva managed to develop a special patented mixing nozzle, which can create silica gel particles with a narrow distribution of particle sizes, extremely good flow properties, and a very high resistance to abrasion Big (not only) in black: Cabot is ready to conquer new markets Black is still the Cabot Corporation’s favorite color That’s because industrial carbon black, which is used as a coloring and filling material, has been the U.S company’s most important product for more than 100 years The other two main business fields of the Cabot Corporation are the production of performance materials, such as tantalum and cesium, and fumed metal oxides, especially silica and aluminum oxide However, Cabot is relying more and more on specialty process news 2/2003 chemicals and spin-off products that have developed from the main business, including ink for printers and nanogels The first product of the company’s nanogels division is aerogel, which Cabot will produce in Frankfurt Cabot has ambitious goals for the future The company not only wants to consolidate and expand its main area of business – where the emphasis is mainly on the optimization of production and improvement of product properties – but also to continue developing specialty chemicals and spin-off products to open up and exploit new market opportunities To achieve these goals the company is relying less on acquisitions than on expanding its own know-how, as Kenneth Burnes, Cabot’s president and CEO, stresses: “We work hard to improve our operations and to develop our technologies for new market opportunities – successfully.” 10 CASE STUDY Specialty Chemicals Cytec Industries increased output with Batch Manager Batch Done Right Combining S88.01 standards with a diverse team of industry experts allowed Cytec Industries’ Mobile plant to achieve its expectations of increasing production while using their existing equipment Only two days after modernization was completed, the plant was delivering 40 percent more product at higher qualities at lower handling, stocking and off site disposal costs Better process control helps Cytec in tuning production and their products to their customers’ needs C ytec, a specialty chemicals and materials technology company, serves markets that include aerospace, plastics, industrial coatings, mining, and water treatment The company posted sales in 2001 of $1.4 billion Commitment to the customer, superior technology and operational excellence is paving the way for Cytec Industries to achieve aggressive growth targets, amidst the backdrop of a global economic slump The company’s significant water treating sales volume growth was supported by control modernization and expansion at plants in Bradford, England, and Mobile, Alabama, USA As a result of the work described in this article, the Mobile plant is now the largest producer worldwide of emulsion polyacrylamides These products are used predominantly in the water treatment and mining industries S-88.01 standards make expansion affordable Cytec’s goal was to increase the facility’s output utilizing mostly existing equipment by maximizing process efficiencies and reducing waste Adherence to the S88.01 standard for batch recipe management would be a critical part of this new venture The Instrumentation, Systems & Automation Society’s (ISA) S88.01 Batch Control Standard was drafted to define standards and recommended practices for the design and specification of batch control systems as used in the process control industries The standard defines a consistent data structure for batch control language to simplify programming, configuration, and communication between various system components within a control system’s architecture Cytec’ implemented the S88.01 standard by employing Siemens’ ProcessSuite Batch Manager Installed by expanding the existing APACS+ system, the graphical process news 2/2003 14 CASE STUDY Life Science Siemens Ireland is a reliable partner in upgrading Schering-Plough's multi purpose facility A Winning Team Since Schering-Plough decided to upgrade the control system in their primary production unit in Avondale, Ireland, Siemens and ScheringPlough have been working closely together at improving plant performance and ensuring FDA compliance Multiple projects have already been executed, including a new water-for-production unit and the upgrade of an existing SCADA system Moreover, Siemens is constantly supporting Schering-Plough in the validation and documentation process The expert knowledge Siemens team ensures the long-term performance of all improvements and has become an important success factor for the modernization projects at the Avondale site S chering-Plough is a worldwide research based pharmaceutical company At their production site in Avondale, over 400 fulltime employees are manufacturing active pharmaceutical ingredients Their production facility in Avondale is made up of manufacturing cells ranging from a small pilot facility to large bulk production Standardization ensures smooth upgrades Schering-Plough decided at an early stage to standardize on control equipment from Siemens and have reaped the benefit of a well defined upgrade strategy ever since All production facilities are now equipped with technology based on Simatic and the Totally Integrated Automation concept from Siemens For several years, Schering-Plough has cooperated closely with Siemens in upgrading and improving several units in Avondale “We have between four and eight people constantly on site, doing minor modifications and supporting Schering-Plough in the validation and documentation aspects of their processes”, says Eamonn Nally, Siemens manager Simatic PCS Operator Stations controlling bulk production process news 2/2003 15 at the Avondale site “What is special on this site is that it is not a one-time commitment for a single project, but a long-term partnership where both Siemens and Schering-Plough can benefit enormously from sharing their expertise.” Protecting investments while using modern technology One recent project for Siemens and Schering-Plough was the system upgrade for the large bulk Production Cell P5 Commissioning of P5 was first completed in 1994 with a base control layer of TI controllers and a SCADA system of Tistar When Schering-Plough decided to upgrade this system in 1998, a fundamental review of control strategy was carried out on site After extensive research, ScheringPlough chose Simatic PCS Operator Stations as the new system front-end According to Karl Lawler, Systems Engineer at Schering-Plough, “Siemens offered a well defined upgrade strategy from Tistar to PCS That way, we were able to protect our initial investment in PLC code Moreover, this proved to us that Siemens was committed to long term support of both its client base and automation platforms – and so we were investing in technology for the future.” The upgrade strategy was to install the new front-end in parallel with the existing Tistar system and to fully validate the new PCS front end with reference to the operational system This also had the advantage that plant operators had the opportunity to become very familiar with the new system before switch over No loss in production during changeover During the entire change-over no loss of production occurred, due to the extensive up front planning by the Siemens Project Team led by David Mahon “We designed the new system having the requirements of the changeover in mind from day one This meant that we had a very high degree of confidence that no production time would be lost on changeover.” In the meantime, other projects have been completed A new water-for-production system was installed with controllers from the Simatic S7-400 range, and Siemens also replaced the site boiler control system with a new Simatic S7-400H controller In order to ensure future compliance with the most stringent regulations from the Food and Drug Administration (FDA), Schering-Plough have begun a fundamental review of the control and validation strategy for the entire site This involves carrying out a critical analysis of all systems with a view to harmonizing data handling in terms of storage, interface and security The in-depth knowledge of the on site Siemens engineering team of all the manufacturing cells in Avondale means that their input into the process is critical to the long term success of the initiative Once complete the Avondale site will be well positioned for growth in the future ■ Owen Bonner, Dublin E-Mail: owen.bonner@siemens.com process news 2/2003 Simatic PCS and Batch flexible at Schering-Plough in Singapore A new production line at Schering-Plough in Singapore uses only the latest technology for packing a highly effective drug for treating hepatitis C The active ingredient and the solvent are packed in a dualchamber cartridge system VETTER in Ravensburg suplied the entire processing equipment of the new fully automated production plant in Singapore More than 25 years of experience with complex aseptic production processes in close cooperation with the pharmaceutical industry recommended the company and their partners for this project The Simatic PCS process control system comfortably and reliably controls the production of the solution that will later be packaged in the dual-chamber cartridges V-LK® VETTER put the job of automating this plant in the hands of the ssg starkstrom systeme GmbH in Freiburg The heart of the production line is the compounding system where the active ingredient is prepared The visualization and automation system must be able to process several batches simultaneously and to document the production process The batch processes for manufacturing the dissolved active ingredient can be controlled comfortably with Batch flexible, allowing for processing complex tasks flexibly with alternating control routines The project was started in August 2001 and preliminary commissioning was completed in December 2001 in Germany The plant went into operation in Singapore in May 2002 and was handed over to the operators at the end of 2002 Both VETTER and Schering-Plough benefited especially from the experience of the ssg team who made completing the project in such a short time possible while still meeting the customer’s requirements for plant availability and productivity 16 ACHEMA NEWS Level Monitoring Siemens introduces remote monitoring concept via Internet and new monitoring devices A New Level The Achema, held every two years in Frankfurt/Main, Germany, is one of the most important and biggest fair for the chemical and petrochemical industry Siemens will present several new solutions and services – especially for continuous level monitoring The Internet based Levelwatch.com service for monitoring distributed or remote silos and tanks and two new monitoring devices will be among the highlights of this year’s presentation at the Achema W ith Levelwatch.com users can access bulk material levels at anytime, from anywhere, using the Internet By logging into a secure, customized web site, it is possible to view level data and respond to changing raw material supplies It is ideal for monitoring remote storage silos, bins and tanks holding virtually any bulk material, including grain, petroleum, specialty chemicals, plastic pellets, aggregates, cement, pulp, and many other bulk solids or liquids At the remote site, reliable instruments from Siemens take the level readings A Levelwatch.com unit connects this field data via landline, wireless modem, or satellite to a secure web site that is staffed continuously The system monitors level status, tracks trends, and sends alarms directly to designated personnel by any combination of phone, fax, pager, or e-mail Multiple benefits This information can be used for business decisions and help to streamline business supply chains Vendors of raw materials can use Levelwatch.com to provide a val- ue-added inventory management service, building a business partnership with clients beyond that of a regular supplier By monitoring customers’ material levels, they can anticipate demand and optimize delivery schedules Manufacturers who rely on timely deliveries can use it to ensure the supply of raw materials for continuous production, without running out process news 2/2003 17 or requiring emergency deliveries Remote level monitoring reduces costs and saves staff time traveling to remote sites A broad variety of Siemens level monitoring devices are fully compatible with Levelwatch.com – just like the two new capacitance technology devices for monitoring levels in conductive or non-conductive materials that will be introduced at the Achema fair High accuracy at a reasonable price The new Sitrans LC 300 is a cost-effective instrument for level measurement in high accuracy applications such as the processing of food and beverages, pharmaceuticals, detergents and pet food It performs in liquids, bulk solids and slurries, including viscous media, even in challenging environments involving vapor and dust Sitrans LC 300 combines high accuracy and reliability with low maintenance and ease of installation The unique inversefrequency approach to capacitance technology provides high resolution and longterm stability The patented Active-Shield technology protects the measurement from the effects of moisture, vapors, foam, temperature or pressure variations, and material build-up Its advanced electronics provide for simple calibration and its integrated local display make on-site installation and set-up easy The 2-wire transmitter complies with Namur NE 43 for current signaling process news 2/2003 Modular construction features a full range of NPT, BSPT, and JIS connections and DIN and ANSI flanges, as well as corrosion-resistant PFA and 316L stainless steel wetted parts, to suit virtually any application Mastering demanding tasks: Sitrans LC 500 The new Sitrans LC 500 is a high performance field instrument that provides reliable continuous level and interface measurement, even in the critical conditions often found in the chemical and hydrocarbon processing industries It has been designed for extreme conditions characteristic of high-pressure coalescers, fractional distillation columns, catalytic crackers, glycol regenerators, heater treaters, gas and oil tankers, F.P.S.O ships and LNG processing plants The smart, 2-wire transmitter has HART® communications for remote commissioning and inspection Its advanced electronics provide for one-step calibration and local display for easy on-site installation and set-up One-point calibration makes setup possible without shutting down the production process Full-function diagnostics comply with NAMUR NE 43 for both local and remote diagnostics, showing all the relevant variables at the same instant The patented Active-Shield technology protects the measurement from the ef- fects of moisture, vapors, foam, material build-up, and temperature or pressure variations The unique probe design has a high integrity seal, which allows for reliable use in high pressure/high temperature conditions as well as in high pressure/low temperature conditions The PFA probe-insulating sleeve is chemically resistant This special insulated probe design prevents “cold flow of plastic” often associated with competitors’ devices, ensuring stable measurement without the need for frequent re-calibration The instrument is effective in temperatures from -200 to 400 degrees Celsius (-328 to 752 degrees Fahrenheit) and pressures from full vacuum to 525 bar (7665 psi) Sitrans LC 500 is approved for hazardous conditions, and has Lloyd’s Register approval for use in marine applications Sitrans LC 500 offers an auxiliary output and a solid state switch, enabling the instrument to perform the additional function of a level controller when these are connected to a relay that activates a pump Modular construction features a full range of probe options and process connections, as well as customized configurations, to suit virtually any application ■ Janet Wile, Peterborough E-Mail: janet.wile@siemens.com 18 ACHEMA NEWS Drive Technology Drive solutions for the chemical industry The Safer Side Nothing works in the process industry without electromechanical drives The desire for cost-effective, reliable, and above all comprehensive drive solutions is a prime concern Siemens Automation and Drives offers drive solutions that are adapted to the special requirements of the chemical industry as well as solutions for distributed drive technology In addition to a full range of low-voltage motors, frequency converters meeting NAMUR standards and offering PFIV protection are available S iemens low-voltage drives cover the power range from 0.06 to 1,000 Kilowatt Economy motors of efficiency class EFF1 and EFF2, gear motors, explosion-proof motors, motors meeting NEMA specifications, combustion motors, and industry- and customer-specific motors are available depending on requirements The potentially explosive and dangerous areas of the chemical industry in particular demand the use of specially protected drives The explosion-proof motors from Siemens are protected from both gas and dust explosions The full EEx motor range includes a complete cast-iron series in the versions • “increased safety” – EEx e II T1–T3 • explosion-proof enclosure – EEx de IIC T1–T4 • non-sparking – EEx nA, Ex nA • dust explosion proof for Zone 21 and 22 • optional VIK version All explosion-proof Siemens motors have been tested and certified by the Federal Physical-Technical Institute (PTB) or by Deutsche Montan Technologie GmbH (DMT, a renowned technology service provider in the fields of raw materials, safety, and infrastructure) Frequency converters The chemical industry offers many areas of application for converters: pumps and fans, mixer drives in connection with offset shaft gearboxes, agitators in potentially explosive areas, extruders with high torque requirements, or foil processing machines requiring the synchronized running of several drives The Micromaster frequency converters combine maximum technical sophistication with functional versatility and are designed to meet the special requirements of the chemical industry The Micromaster 440, for example, is designed especially for those applications that demand greater dynamic response than normal The vector control ensures a uniformly high drive quality even in the case of sudden load changes In combination with the torque control and the encoder module, synchronized multimotor applications can also be controlled easily With LC output filters, motors in explosion hazardous areas can be operated from up to 300 meters away The class A limit values (according to EN 55011) are also satisfied with unshielded lines up to a distance of 200 meters, and all important protection and overload functions are integrated as standard equipment All devices in the Micromaster series meet the requirements of the EU Low Voltage Directive as well as having the CE mark and UL and CUL certification All Siemens standard drives with the Profibus option are also integrated into Totally Integrated Automation (TIA) TIA’s use of uniform communication, identical configuration, and common data storage results in a savings potential of up to 30 percent Even more powerful Siemens naturally also offers drive solutions that have a higher power range (more than 10 Megawatt) and are well ■ suited for process applications Erwin Buchert, Nuremberg E-Mail: erwin.buchert@siemens.com process news 2/2003 19 ACHEMA NEWS Process Control Technology Simatic PCS further expands its scope of functions Even More PCS In the current Simatic PCS Version 6.0, Siemens has already considerably extended the scope of functions of the process control system, increased the scalability, further enhanced vertical integration, and thoroughly improved the engineering and batch system In the automation sector, however, standing still is synonymous with moving backward, so new developments are always continuing in various directions A new route control system for PCS is currently being implemented Moreover, new features for Simatic Batch and Simatic PDM are being developed and integrated into PCS PCS – Training for success Sitrain is the training partner for Simatic PCS and offers courses for engineers, systems integrators, and planning, operating, and service personnel Implementation and training on the process automation of a plant, right up to the operator level, is done virtually, using examples and exercises Further information about the range of courses is available at: www.siemens.de/sitrain U ntil now there has been no optimum solution for automation with PCS for the plants with complex and extensive tank farms because apart from the tank automation aspect, material transport automation is a key task PCS had no standardized solution for this Siemens has previously used this function only in connection with the Braumat control system Now that experience has been transferred to the independent software package Route Control Systems (RCS), which can be used in various industries and is totally integrated into PCS RCS is designed for manual and automatic control of up to 300 material transports The routes can be configured very easily to considerably simplify engineering and implementation In addition, RCS offers simple, standardized control of the process elements capable of diagnostics process news 2/2003 so that additional information can be displayed or provided in the event of a fault Keyword: PCS Steady improvement Not long ago, the PCS Batch system was drastically improved and now additional enhancements are under way A standardized API interface makes integration into the World of IT easy That way, error sources for the user are eliminated and the system becomes even more robust Moreover, the system now offers interfaces for the integration of S5, Teleperm and third party controllers Features for attributing equipment-independent recipes to sub-plants were also enhanced Simatic PDM is the central tool for engineering, programming and commissioning of intelligent process devices It will have more features and will be further integrated into PCS engineering in the fu- ture Device-specific parameters, for example, are now integrated into the new Process Object display mode of PCS Modifications can be made directly in this mode PDM will also become part of PCS Audit Trail so that parameter modifications of devices can be monitored Additional improvements for PDM that are currently in the planning phase include integration into the Simatic Logon Service and extended diagnostic features ■ Alberto Pelegri, Karlsruhe E-Mail: pcs7.sss@siemens.com CASE STUDY Chemical Industry Migration project from Teleperm M to PCS at Wacker Economic Innovation Wacker Polymer Systems (WPS) is one of the world’s leading manufacturers of redispersible powders and vinyl-acetate-ethylene dispersions The company, located in Burghausen, has updated its automation technology and converted the polymerization pilot plant from Teleperm M to Simatic PCS The migration of the plant was completed without any problems and Wacker is already considering follow-up projects with Simatic PCS W PS emerged from a Joint Venture of Wacker Chemie GmbH, Burghausen and Air Products and Chemicals Inc in Allentown, Pennsylvania The polymers that are produced at two sites in Calvert City, USA and the company headquarters in Burghausen are applied mainly in the building, adhesives and textile industries but also as important ingredients in paints and varnishes The heart of the company is the polymerization pilot plant where all product lines of WPS are developed This central plant is equipped with all the latest technology – and the automation technology must meet the highest demands For this reason one sub-plant was already converted from Teleperm M (TPM) to PCS in a pilot project in 1996 Siemens was responsible for supplying the hardware and the software engineering for this project Since the polymerization pilot plant was still being used, the conversion had to be done quickly Only very short shutdown phases could be used for the migration work – a great challenge for the executing engineers Thanks to perfect preparation and planning and extensive testing of the user software in ad- Great potential for the future The results are absolutely convincing in Wacker’s opinion, “With its high availability PCS7 is exactly the right process control system for the requirements in the polymerization center” Ferdinand Baueregger, engineer at Wacker Chemie, praises the new system The flexible and open TIA concept is bound to see the PCS establishing itself in other areas of the plant ■ Migration completed in short time In autumn 2002 Wacker decided to make a clean sweep and completely replace the existing process control systems TPM AS215, AS230 and OS525 with Simatic PCS Siemens was WPS’s first choice for this project because PCS had already brought excellent results in other parts of the plant Besides, Siemens has been offering made-to-measure migration solutions for years and therefore has the necessary know-how to guarantee a troublefree conversion vance the conversion proceeded exactly according to plan The tasks of the old Teleperm M systems were changed over to the new system step by step combining several AS215 on one PCS automation system Simatic ET 200M devices were installed at the now free slots of the Teleperm M controllers The ET 200M communicate with the control system via Profibus The wiring up to the terminal strip could therefore be retained Only the connections from the terminal board to the ET 200M had to be rewired Wacker 20 Ferdinand Baueregger is very satisfied with the smooth migration from Teleperm M to Simatic PCS Alois Brandmaier, Burghausen E-Mail: alois.brandmaier@siemens.com process news 2/2003 21 CASE STUDY Chemical Industry Siemens installs analysis systems at Dow Stade Comprehensive Solution Dow Germany contracted with the Siemens System House in Karlsruhe to outfit a production plant in Stade, Lower Saxony, with analysis systems Siemens not only supplied the equipment but also provided complete installation and commissioning of the systems on site U ltramat and Oxymat analyzers are no strangers to the Dow staff in Stade The analyzers have been in use there for quite some time (as they are in almost all the other locations of this internationally active company), but in the past they have usually been planned, integrated into the production system, and commissioned by Dow itself For this project, however, a bottleneck in resources led the company to search for a suitable external service provider Thanks to extensive experience with the construction and commissioning of analysis systems, Siemens was once again well positioned to win this order On-site work included the installation of measuring systems in the outdoor analysis cabinets as well as completely equipping an analysis house built by the customer Complex media well under control Every analysis system consists of the primary sample conditioner at the removal point, the secondary sample conditioner in the analysis house or cabinet, and the actual analyzer, which includes all the necessary safety-oriented shutdown devices (according to the LOPA study and SIL 61508) To achieve maximum possible availability and production reliability, all analysis systems are redundant “We use the new systems mainly for analyzing gas streams contaminated by solids,” explains Ralf Schade, who is responsible for process analytics at the Stade factory “We have to prevent lines, sample conditioning components, and the analyzer itself from becoming blocked, and we have to have suitable measures ready to clear such blockages quickly if they occur.” Standards for further projects The Siemens analysis systems had already satisfied the detailed specifications of Dow Germany during acceptance testing at the System House in Karlsruhe They were installed on schedule under the direction of a supervisor and were put into operation without any problems “With this first installation,” says Ralf Schade, “Siemens has set a high standard for future projects.” ■ Herbert Rösinger, Karlsruhe E-Mail: herbert.roesinger@siemens.com Dow in Stade is highly satisfied not only with the analyzers from Siemens but also with the performance of the Siemens project team process news 2/2003 TECHNOLOGY Process Control Technology Comparison of fieldbus and control systems at Infraserv Höchst ”We Too Can Learn From Siemens” Infraserv Höchst Technik GmbH & Co KG, in Frankfurt, is the leading maintenance service provider for technical process systems and subsystems in the Rhine/Main region and is a key resource when questions arise during the life cycle of these systems One of the fields of activity of Infraserv Höchst Technik is the EMR Competence Center of the Interessengemeinschaft Regelwerke Technik (IGR) The task of the EMR Competence Center is the preservation and further development of expertise in the field of EMR and automation technology, as well as the organization of work teams and projects The test lab at Infraserv Höchst Technik tests field devices, fieldbus systems, and control systems for the IGR and examines new technologies for their suitability for use in process-technical systems In addition to two complete multivendor systems for the two fieldbus systems, FF (Fieldbus Foundation) and Profibus PA, a complete Simatic PCS setup with integrated fail-safe technology has recently been added to the lab equipment ProcessNews spoke to Manfred Dietz, head of the test laboratory, about his experience with Profibus and PCS Mr Dietz, why exactly is your laboratory interested in the FF and Profibus fieldbus systems? Manfred Dietz: There are basically two fieldbus systems which NAMUR classifies as suitable for process technology, and those are the FF system from the Fieldbus Foundation and Profibus PA That’s why our lab is mainly concerned with these two systems You stress the PA after Profibus Manfred Dietz: That is a very important point In terms of functionality, processtechnical suitability, and so on, you can really only compare Profibus PA and FF because Profibus with Profibus DP and Profidrive have many more features than FF and PA This is obvious just from the fact that every FF system also has an interface to Profibus systems to cover such functions as drive control, for example That’s not possible with FF alone Profibus with DP has the solution for this And which system is better? “all-rounder”; it covers many areas of automation technology, from drive control through low-voltage switchgear up to the process level with Profibus PA In addition, its ”As far as the handling is simpler, so the technician or maintefunctional scope is nance mechanic can find concerned, PCS – his or her way around especially with the the system more quickly However, for us here at integrated safety Höchst there is another technology – is important point in favor certainly unique of Profibus PA Here, future fieldbus technology at present.” will be applied above all in the modernization of which I “only” want to measure and reguold plants Profibus has a clear advantage late, FF is, if you will, the more specialhere because migration and modernizaized system that has more functions to oftion solutions are available for this sysfer in this respect This, of course, means tem; FF lacks this capability that FF is very complex and requires a great deal of specialized technical knowlYour test lab has recently installed a comedge Profibus, in contrast, is more of an plete Simatic PCS system, including inteManfred Dietz: That’s hard to say offhand If I’m looking for a solution with Publicis 22 process news 2/2003 Publicis ©Infraserv Höchst 23 Profibus PA and Simatic PCS7 in the test lab at Infraserv Höchst Technik grated fail-safe technology What is your opinion of this technology? Manfred Dietz: As far as the functional scope is concerned, PCS – especially with the integrated safety technology – is certainly unique at present I know of no other system that offers as many possibilities What does Siemens need to work on to ensure that PCS stays successful in process technology? Manfred Dietz: PCS is a very powerful system – and that power has usually come at the cost of user friendliness And at the field level, with Profibus PA, the system has not yet exploited its full potential, in my opinion We as users would like to see a simple, process-oriented I/O system for Profibus PA with which we can address sensors and actuators in the field There is no solution in sight for this task yet – not for FF either, as it happens All in all, I assess the chances of PCS7 very positively In my opinion, the trend is clearly moving process news 2/2003 The landmark of the Höchst Industry Park is the prominent technical administration building of the former Hoechst AG plant It was built under the direction of architect Peter Behrens between 1920 and 1924 toward integrated safety technology – and here Siemens has a very good solution on offer with the fail-safe and high-availability AS, as well as the integrated fail-safe modules Siemens has been very committed to process automation in recent years As a leading company in the manufacturing industry, Siemens has a lot of catching up to in process automation Where you see Siemens today? Has the company understood the priorities in the process industry? Manfred Dietz: Of course I can’t speak for the whole process industry, but I think that providing our laboratory with the PCS7 system shows that Siemens sees close cooperation with the process industry as very important, and that the company is willing to adapt to our sometimes very special requirements We too can learn from Siemens Sometimes in the process industry one has the tendency to look no further than oneself and one’s own technologies At the same time, however, other industries are coming up with innovations that are extremely interesting for process technology As a market leader in automation technology, Siemens is one of the few companies in Europe that consciously and actively helps to shape future trends We can only benefit when such an innovative company shows a commitment to the process industry Thank you for talking to us Holger Rachut, Karlsruhe E-Mail: holger.rachut@siemens.com CASE STUDY Chemical Industry Simatic PCS in CMC production Premiere in Egypt A company from Cologne, Germany has set up a plant for manufacturing cellulose products from scratch near Cairo This was the first large-scale project with the Simatic PCS process control system for Josef Meissner GmbH & Co., which installed the system Thanks to extensive support from Siemens, the project went exactly according to plan The end customer, Egycel, now benefits from increased process reliability and product quality Egycel 24 The Simatic PCS controls the complex multistage etherification O ver its almost 80-year history, Josef Meissner GmbH & Co in Cologne has become a renowned global partner for the design, engineering, and construction of plants for manufacturing explosives, nitroaromatics, formaldehyde and cellulose derivates, and more recently other cellulose-based products Today Meissner employs a permanent staff of 65 and has installed more than 450 plants for leading companies all over the world The experience gained through these installations was a major reason why the Egyptian manufacturer Egycel decided to place the order for the construction of a new production plant for carboxymethylcellulose (CMC) with Josef Meissner GmbH & Co CMC is a water-soluble cellulose ether used in the building, ceramics, textile, and cosmetics industries, as well as in oil and gas exploration The most important phase in the manufacturing process is the multistage batch process of alkalization and etherification, whereby important product properties can be “set” individually, causing various effects on the subsequent process steps This demands maximum flexibility from the entire system, especially the process control system Flexible, expandable, comfortable The new control system was to be readily expandable, was to allow the rapid implementation of process-technical functions at both the controller and the operator level, and was to offer easy recipe management Meissner soon decided in favor of the Simatic PCS process control system with the Simatic WinCC process visualization system from Siemens and a redundant solution made up of two OS servers and four OS clients Twenty-one distributed I/O stations (primarily ET 200M) transmit process data from approximately one thousand process control elements in the field via Profibus in fiber optic cable technology to the control system’s two Simatic S7-416 controllers In order to complete the first PCS project in the planned period, Siemens was involved from the start and supported the plant builder from the ordering through training and the set-up of the client/server architecture right up to final signal and function testing in Cologne As a result, the entire installation was ready to be commissioned on site in just six weeks Installation in record time The premiere was a huge success for Meissner With the new process control system installed in record time, Egycel, the end customer, is now able to manage diverse processes (with a total of 13,000 WinCC variables) much more easily and more reliably than ever before The various process data can be visualized clearly and a consistently high quality can be eas■ ily documented Reinhard Stader, Cologne E-Mail: reinhard.stader@siemens.com process news 2/2003 25 CASE STUDY Chemical Industry Integrated process control and data management system at Akzo Nobel in Singapore A Database for Production Siemens has recently completed Factory Acceptance Testing for batch process control and production information systems for the Akzo Nobel Surface Chemistry Pte Ltd Quat Plant currently under construction on Jurong Island in Singapore Siemens Singapore has worked closely with Akzo Engineering in the Netherlands and local EPC contractor, SembCorp Engineers & Constructors, to design and build the system A kzo chose Siemens Singapore for this project because of their satisfaction with the PCS system at Akzo’s site in Malaysia At the plant automation level, the PCS process control system is used with a tightly integrated Failsafe/High Availability safety system Adoption of a remote I/O concept with maximum utilization of Intrinsically Safe standard and failsafe I/O cards minimizes system hardware and site installation costs To ensure system reliability and high availability, redundancy has been provided at all levels of the system including field communications, CPU’s, system communications and servers Integrated data management At the operator interface level, redundant servers and an engineering station are also used as operator stations Recipe management and batch control have been implemented with the Batch flexible software All operator stations are also batch clients so that the plant can be operated from any operator station process news 2/2003 At the Plant Information system level, a dedicated server running the MISLight software has been used to collect process data and batch records and to store other external plant data such as material stock levels, material movements and laboratory data This external information is entered via a customized production database user interface built on the Simatic IT platform This application provides numerous customized data entry forms and reports in a fully user access controlled environment The next phase of the project involves installing the Engineering & Operator stations with the CPU cabinet and MIS server in a temporary site office to allow operator training on the actual control system The PCS software has already been configured with in-built plant simulations and dedicated operator screens to control simulated field devices and thus will facilitate the training Final installation and Site Acceptance Testing is scheduled for July ’03 with plant startup in September ’03 Excellent cooperation Akzo’s plant manager Mark Hutchinson is very satisfied with the progress of the project so far “It was a pleasure to work closely with the Siemens team recently during the testing phase of this project We are looking forward to seeing the finished PCS system up and running at our new facility in July managing our fairly complex batch production process, and we anticipate that the production database will be an extremely powerful tool in providing management information and reporting for our plant” ■ Abram Ziegelaar, Singapore E-Mail: abram.ziegelaar@siemens.com ... (Floating Production, Storage, Offloading) CASE STUDY Aerogels Process expertise and automation technology – a perfect match in Cabot’s new aerogel production step toward industrial production,... of aerogels is locked inside: a porosity of 95 percent and a medium pore size of about 10 nanometers make aerogels supreme insulators Industrial production of aerogel: Translucent revolution Aerogels... competent partner for further developing the process all the way to fullscale industrial production But before industrial production, the existing process had to be optimized on a technical laboratory