Process News8th Edition June 2 2001

I N F O S , N E W S A N D T R E N D S F R O M T H E W O R L D O F P R O C E S S A U T O M A T I O N

CCononttenentsts

Dear readers

In this issue, we have focused on our op-erations in Asia. The booming markets ofthis region, with growth which is notice-ably higher than that of other markets,have not merely become a recent targetof our interest. On the contrary, Siemenshas a history with countries in Asia, suchas China, which stretches back morethan 100 years. The structures and themutual trust which have developed fromthis are more important than the basisfor a successful business relationship.And the Siemens Automation & Drivesbusiness area, with its approximately5,000 employees in manufacturing,sales, service and engineering, is one ofthe most successful in Asia. The above-average growth in the chemicals, petro-chemicals, pharmaceuticals, foodstuffsand luxury foods sectors as well as thenecessary improvement of infrastructuremeasures requires partners with sector-specific skills. This is why Siemens isdevoting itself in Asia to strengtheningthe process industry market segment.We see the training and promotion ofour local employees through targetedknowledge management as one of ourmost important duties as these employ-ees are a crucial link to our customers.

Your editorial team

To be continuedRoche in China once more puts its trust in Simatic PCS 7 and a strong engineering team in Vitamin B6 production

Following its plants for themanufacture of vitamin A, vitaminE and citric acid, Roche set up byfar the largest vitamin B6

producing plant in Asia in Pudong,China. The partly manualautomation aimed at by Rochewas achieved by a highly moderndistributed automation concept.The Simatic PCS 7 already usedwith great success in earlierprojects and the cooperation withthe Siemens engineering teamwhich has proven effective formany years was the guarantee forsuccess once again.

R oche is one of the foreigninvestors who has been veryactive on the Chinese market

for many years. The Roche NewAsiatic (Shanghai) Vitamins Ltd.

Company founded in 1996 is a jointventure of two major pharmaceuti-cal companies, Hoffmann-La Roche,one of the most innovative manufac-turers of pharmaceuticals and theworld’s leading producer of vitamins– and Shanghai New Asiatic Phar-maceuticals, Ltd., a very successfulChinese company. This project is thesixth’s joint venture that Roche hasfounded in China.

Roche New Asiatic’s latest projectis an ultra-modern plant for produc-ing vitamin B6 in Gong Lu Town inPudong, China. With an annual ca-pacity of around 1,000 tons of vita-min B6, the plant is one of the largestin the world and by far the biggest ofits kind in Asia. The vitamin B6 madethere is destined mainly for use as afeed additive in the agricultural in-dustry (see the insert “Innovationsfor more than 100 years”).

Continuing a successfulpartnership

Roche New Asiatic has placed theautomation of the plant in the handsof a partner who has already provenits competence in earlier projects.Siemens Industrial Automation Shang-hai, Ltd. (SIAS) was already entrust-ed with the automation of the vi-tamin A, vitamin E and citric acidproduction plants which Roche hasset up over recent years. The goodexperience that Roche had had dur-ing past projects with local Siemensexperts and especially with the teamfrom SIAS and the Simatic PCS 7process control system were amongthe crucial factors for continuing thisproven partnership for the new vita-min B6 plant.

In mid-1999, during the prelimi-nary design phase, Markus Driess,project manager at Roche New Asiatic,called the SIAS engineers into theteam. Siemens was awarded the con-tract to provide the entire controland field technology in mid-Novem-ber 1999.

The SIAS team’s competence wasan important factor for the project’ssuccess especially at the very begin-ning of the phase, as Klaus Gräser,responsible for international au-tomation concepts at the Roche vita-min division headquarter, empha-sizes. “The team around Lin Hongand Jay Peng from SIAS has imple-mented all our guidelines in a veryshort time. Lin Hong and Jay Pengliterally went to their limits duringthe project – I have been really veryimpressed by their great commit-ment.”

Individual, distributedautomation solution

The production of vitamin B6 isbased on a complex chemical processwith several synthesis stages. The

Roche and Siemens teams workedtogether very closely in order to meet the strict requirements of thisprocess and to satisfy the Roche’sspecifications. Roche demanded aprocess automation that was to be assimple as possible and at the sametime tailored to the conditions onsite. The operators should be en-couraged to take over the responsi-bility for the process. This led to amodern, highly distributed solution.A central control station and roomfor switching cabinets was practi-cally no longer required: both theprocess visualization and operationand the entire I/O level – distributedover the five new production build-ings – was installed directly on site inthe Ex area.

(Continued on page 2)

F o c u s : A s i aChina:

B 3/4 Strategy, service, support and applications

Southeast Asia:

B 5/6 Strategy and applicationsfrom Malaysia, Taiwan, Indonesia and the Philippines

Products:

B 7/8 Simatic PCS 7with new functionality

New total sulfur analyzer

Simocode-DP: Used in all sectors of process industry

Sitrans T3K-PA: Now with Profibus Profil 3.0 conformity

Service and support: New information system on the Internet

Applications:

B 9 Tikkurila: Paint production with Profibus-DP andBatch flexible

Didier: Simatic S7 in the glass industry

From around the globe:

B 10 Success stories, headlines,trade fairs, Net news

2

Siemens also supported Roche inthe Installation, Operation and Per-formance Qualification (IQ, OQ andPQ) of the plant and simultanuouslyconducted an intensive training ofRoche employees. The courses for en-gineering and operating personnelcovered the whole scope of thesystem, from PCS 7 system courses,through operator instruction right upto maintenance and service courses.

The new plant was officiallyhanded over to production in Octo-ber 2000. The quality of the productsatisfies the strictest conditions andRoche New Asiatic is more thanpleased with the way the project washandled and the performance of thenew plant. Thanks to intensive train-ing, all 220 employees in vitamin B6

production were optimally preparedfor handling the new system and theexcellent cooperation of all partici-pants was a guarantee for smoothperformance during the project.

Team competence was decisive

Markus Driess also emphasized theimportance of the good teamworkwhen he praised the performance ofthe entire SIAS team and especiallythe project manager Lin Hong in afinal letter of approval. “The cooper-ation with the Siemens team and es-pecially the untiring support of theexperts at SIAS were the decisive fac-tors for the project’s successful com-pletion. I am sure that we will con-tinue this excellent cooperation onfuture projects.”

Urs Huber, Taishan GeneralManager of Roche Vitamin Ltd., is

The new automation solution isbased on the Simatic PCS 7 processcontrol system. A total of 32 distrib-uted Simatic ET 200M I/O devicescollect the 1700 signals of the fieldlevel. The ET 200M stations arelinked to the automation systemsthrough the Profibus-DP.

A total of 13 positive-pressure ex-plosion proof cabinets are installedin the Ex area, 3 interface cabinetsfor the Motor Control Center(MCC) in the switching room andtwo automation controller cabinetsin the control room make theautomation system on site complete.

Twelve operator stations allowthe operators to monitor and oper-ate the process safely on site. TheIndustrial Ethernet system bus withtwo high-performance star couplersguarantees system-wide communi-cation. The engineer can access allcomponents of the process controlsystem through the central engineer-ing station.

The engineering contract includ-ed the complete cabling, cabinetengineering and system configura-tion in addition to the hardwareplanning. Siemens was also responsi-ble for the Factory and SystemAcceptance Test (FAT and SAT) andthe commissioning of the plant.

Tailor-made software

The implemented automation con-cept for the vitamin B6 plant is alsoreflected in the user software writtenby experienced Siemens experts.Easy operation of the system for theoperating personnel has been the

main focus throughout all develop-ment stages. The functionality of theuser software essentially covers theindividual control levels such as pHvalue control, cascade and ratio con-trol as well as modules for the weigh-ing systems, complex control andinterlocking functions. Importantsignals are integrated as back-uploop controllers to maintain criticalfunctions even in the case of a CPUfailure.

The SIAS team on site had inten-sive contact with the specialists inthe development departments atSiemens Karlsruhe during projectrealization and the critical phases ofcommissioning. This kept themcontinuously informed of the cur-rent status of component deliveriesat all times. The regional and world-wide coordination of all Siemensteams involved in this project washandled by the Siemens office inBasle which is also responsible forRoche account management on theSiemens side.

In accordance with even thestrictest requirements

The plant meets internal companyspecifications as well as the require-ments of the national standards andthe regulations of the Good Manu-facturing Practice (GMP). In addi-tion, an extensive safety concept hasbeen developed which is dividedinto four safety levels and preventsthe spread of fire. A Roche-specificemergency shutdown concept isalso part of the extensive safetyfunctions as well.

greatly impressed by the perfor-mance of the Siemens’ staff. “Thesoftware developed by SIAS particu-larly convinced our experts of theSiemens team’s competence. We hadtherefore not a single doubt that thePCS 7 system would work perfectly

from day one of production. Fromthis point of view everything speaksin favor of a further cooperationwith Siemens Shanghai.” C

Lin Hong, SIAS Shanghai,

Cornelia Dürrfeld, Editor

Process News 2/2001

About 6 years ago, Siemens Auto-mation and Drives and the Chinesecompany SAIC founded the jointventure Siemens Industrial Au-tomation Shanghai Ltd. (SIAS) andin the year 2000 Siemens took overabout 90 percent of the shares. SIASis the Siemens Automation andDrives solution provider for Chinaand the leading specialist in thefield of production and process au-tomation.

The SIAS Chemical & Pharma-ceutical Group is made up of themost experienced engineers andspecialists at SIAS and has been in-volved especially in the engineeringof solutions for process automa-tion for about three years. Togetherwith the other divisions at SIAS,

German-Chinese fusion of competencethe Chemical & PharmaceuticalGroup offers a complete package ofengineering solutions with the opti-mum strategy from the initial phasesof project consulting and plant de-sign right through to service andsupport during operation for allphases of the plant life. The focus isplaced on applications in the chemi-cal and pharmaceutical industries,but SIAS is also active successfullywith numerous projects in otherbranches of the process industry, es-pecially in the field of environmentalengineering.

Satisfied customers

Although still a relatively youngcompany, SIAS is already able toboast a considerable number of

satisfied customers. Such well-known names as ATO, BASF,Bayer Unilever as well as leadingChinese companies such as SPC,YPC and Yizheng Chemical Fiberhave entrusted SIAS with the au-tomation of their plants – withgreat success.

SIAS will cooperate even moreclosely with the regional Siemensbranches in China in the next year,proving its engineering know-howtogether with Siemens in new pro-jects in the petrochemical, oil andgas industries. Siemens and theemployees at SIAS will thereforehave many opportunities in thenear future to mutually reap thebenefits of the experience and com-petence of both parties.

More than 100 years ago, the Swiss

entrepreneur Fritz Hoffmann-La

Roche recognized the importance

of the industrial production of

standard drugs and founded the

company F. Hoffmann-La Roche &

Co in 1896. Hoffmann-La Roche

soon opened the first subsidiaries in

Germany, Italy, France, the USA,

UK and Russia and laid the founda-

tions for the international success

story of the pharmaceutical compa-

ny. Today, Hoffmann-La Roche is

represented on all continents and

employs a grand total of more than

67,000 people in its Pharmaceuti-

cals, Diagnostics and Vitamins &

Fine Chemicals divisions. Roche is

the worldwide leader in the field of

vitamin synthesis.

Big in China

In May 1994 Roche founded the

first of what have now become six

joint ventures in China. These joint

ventures concentrate on the pro-

duction of vitamins and additives

for the pharmaceutical, food and

beverage and agricultural indus-

tries. In the plants of its joint ven-

tures Roche produces vitamin A,

vitamin E and citric acid.

Innovation for more than 100 yearsVitamins are indispensable sub-

stances for the human and animal

metabolism which play a central

role in almost all processes of an

organism, for example as active

centers of enzymes. Since humans

and animals cannot produce most

vitamins themselves, these sub-

stances must be ingested with their

food.

This also applies for the vitamin

B6, which carries the chemical

name pyridoxine. It is a crucial part

of the protein metabolism and

ensures normal growth in humans

and animals. Like most B-vitamins,

it is very sensitive to light and heat

so that humans may frequently

exhibit deficiencies when insuffi-

cient fresh food is available. This

deficiency can be compensated by

synthetic vitamins.

The new vitamin B6 plant which

went into production in Pudong

this year will not only ensure the

supply of this important substance

to the Chinese market for the food

and feed industry but will also sup-

ply the world market. This further

underlines Hoffmann-La Roche’s

leading position in this important

business field.

F o c u s : A s i a

SIAS: Siemens Joint-Venture

Roche briefly speaking

Lin Hong and all the others involved in the SIAS

project are happy about the successful project

established with Roche

Last October the new vitamin B6

plant was officially inaugurated

To be continued(Continued from page 1)

Shanghai

Urumqui

Beijing

Shanghai and SFAE (Siemens Facto-ry Automation Engineering) inBeijing, are key elements of ourservice offer. Over 2000 queries amonth, of which 75 percent are dealtwith in less than two hours, are proofof the high skills level of our staff.Using state-of-the-art service soft-ware tools, each query is trackeduntil it has been settled to the satis-faction of the customer. That satis-faction is regularly reviewed, becauseit is our absolute top priority.

In the process industry, in whichmany installations have to runround-the-clock for years on end,reliable availability of spares is vital.Two spares stores in Beijing andShanghai, covering the full Siemensautomation range, quickly deliverspares to customers in need. Repairs,too, are carried out on-site in China.

A total of eight training centersnow provide not only continuousand professional training of Siemensstaff, but also offer training coursesfor customers’ own technical spe-cialists. And of course all coursesare conducted in Chinese, with allrelated documents and manualsalso printed in Chinese; and whencustomers receive visits from aSiemens service engineer, they canbe sure he will speak their language,because all service personnel areChinese.

Ready to answer any questions

With this special service packageSiemens is ideally equipped to servethe Chinese market, whether visitinga customer in Shanghai or dealingwith a query from Urumqi. C

Jürgen Köhler, Wang Ping, Siemens Beijing

3

But commercial success is not justabout good products.

Siegfried Schmidt: Quite right. Thatis why we are continuously enhanc-ing our service and support facilitiesin collaboration with our joint ven-ture partners. Our service network isgrowing all the time, and we areworking hard to make sure we are at our customers’ side even morequickly and efficiently than ever. Asan example, we are currently in theprocess of setting up a project teamin Nanjing, where BASF is building anew joint venture location togetherwith SINOPEC. In that project weare gaining especially from the engi-neering resources of our joint ven-ture operation, Siemens IndustrialAutomation Ltd., Shanghai (SIAS),which has many years’ experience inthe field of process automation.

Is this success a German or a Chineseone?

Siegfried Schmidt: It’s definitely acombination of the two. Our mainfocus is on developing the skills ofour local staff. We are running a spe-cial Leadership Program to promotethe training of up-and-coming Chi-nese management staff, because theyare the ones who can best judge thespecific needs of the Chinese market.With their openness to new tech-nologies, their thirst for knowledgeand speed of thought and action,and of course their awareness of theChinese mentality, they are the deci-sive factor in A&D’s success in thisbusiness.

In view of that, it is no coinci-dence that the Chinese characterscontained in the logo of the Automa-tion and Drives division representthe word “Together”. And it is ourdeclared aim to ensure our work fol-lows that motto in all respects. C

Siegfried Schmidt was interviewed

by Cornelia Dürrfeld, Editor

Automation concept provided uswith a solid foundation on which tobuild our position as the marketleader in production automation inChina.

And where do the new challenges lie,in your view?

Siegfried Schmidt: Definitely inprocess automation, which currentlyoffers enormous potential for growthin China. Modernization of industri-al resources and environmental pro-tection are challenges for which theChinese Government needs reliable

suppliers, including inthe automation field.With over 200 water andsewage treatment pro-jects successfully com-pleted, Siemens togeth-er with its joint venturepartners has alreadydelivered plenty of evi-dence of its high level ofcompetency and spe-cialist skills.

With the acquisitionof Milltronics and Moore,

Siemens has given a major boost toits competencies in process automa-tion in this part of the world too. Weare able to show proof of our com-petitiveness in numerous applica-tions in all fields of process auto-mation, such as in petrochemicals,chemicals, pharmaceuticals, glass andwafer fab. Our Simatic PCS 7 processcontrol system comes with a wholerange of outstanding references frommajor customers such as SINOPEC,BASF, Roche and Nestlé.

Part of this successful automa-tion strategy is integrated commu-nication based on Profibus, Indus-trial Ethernet, AS-Interface andEIB. In partnership with the re-sponsible organizations, we are cur-rently working on the introductionof Profibus as the national industrystandard.

In itself an everyday situation: a malfunction is reported in thecontrol system of an installation.The fault cannot be localized evenby the diagnostic functions. A member of staff calls themanufacturer’s hotline.

B ut in this particular case, thecompany in need of help islocated in Urumqi in North

Western China, several hours’ flyingtime from the major cities of Beijingor Shanghai.

In order to respond rapidly and beat its customer’s side even in the mostpopulous country in the world, cov-ering a surface area the size of thewhole of Europe, Siemens has devel-oped a number of highly specializedservice solutions. The increasing in-dustrialization in China, accompa-nied by steadily rising demand for au-tomation solutions, requires Siemensto deliver top class service and sup-port performance.

From the Service Hotline

The Active Service Concept includesthe creation of a detailed action planpackage to respond to any malfunc-tions in major projects. The packagecomprises pre-assembled modulescovering every conceivable eventual-ity and offering solutions or rapidmeans of finding solutions. Beingprepared for malfunctions is still the best form of preventive care forcustomers and suppliers alike.Customers can be sure Siemens willprovide them with optimum sup-port even in critical phases.

A Service Hotline (+86 10 64731919)and the 24-hour service provided byour joint venture operations, SIAS in

China is not a market like anyother. The enormous geographicalspread of this vast country, andits booming industry, demandhighly efficient and customer-oriented automation solutions.We spoke to Siegfried Schmidt,head of the Automation and Drivesdivision of Siemens Ltd. China,about the strategies which havealready made Siemens so success-ful in China today and about howSiemens intends to help buildingthe markets of tomorrow.

Mr. Schmidt, how do you assess the currentsituation of Siemens inChina? Has the launchinto this major marketbeen a success?

Siegfried Schmidt: Actu-ally the ”launch” phasehas been over for quitesome time. Siemens haslong been a respectedcompany in China, andhas established itself as areliable and competent partner toChinese industry. The Automation& Drives Group now employsapproximately 2000 people at 20locations and operates a total of ninejoint ventures in China. In the pastyear we generated sales of 166 mil-lion Euro, 46 percent up on the yearbefore. And the prospects for 2001are even brighter.

How do you explain this great success that Siemens has had with itsautomation products and solutions in China?

Siegfried Schmidt: In China greatvalue is placed on partnership withthe customer. Consequently, we re-organized ourselves to change from a primarily product-oriented struc-ture to a customer-oriented one.Furthermore, our Totally Integrated

Always at theCustomer’s Side

Service and Support in China

Process News 2/2001

Building the FutureTogether

With customer orientation and specialist skills, Siemens is conquering the Chinese markets

F o c u s : A s i a

These three automation

experts of tomorrow fully

agree: Profibus and

Simatic PCS 7 are future-

oriented systems for China

“Process auto-mation in China

still bears anenormouspotential

for growth”

plant’s automation. Siemens In-dustrial Automation Ltd. Shanghai(SIAS) was awarded the contract toimplement the automation system.

The SIAS Team was responsiblefor the entire hardware configura-tion and commissioning and heldextensive training courses in order tofamiliarize the water supply plantpersonnel with the new automationsystem. SIAS is also responsible forthe after-sales service of the automa-tion system.

Redundant and highly available

Redundant, high-availability SimaticS7-400H controllers and an opticProfibus ring ensure maximum sys-tem availability. A total of 27 SimaticET 200M units record the signals inthe plant and transfer them to the

controllers via a Profibus. A re-dundant Simatic WinCC ProcessMimic Display ensures that theoperating personnel are able tomonitor all the key processes at alltimes.

The water supply plant inShaoxing is the first in the entireregion of Eastern China to befitted with the redundant, high-availability Simatic S7-400H con-trollers and an optic Profibusring. In the future, other plants in

this sector will also benefit from theadvantages of this technology. C

Yang Xiening, Shanghai

The days when profitability andenvironmental protection in theprocess manufacturing industryappeared to be incompatible havelong gone. At the Wujing ChemicalPlant, Siemens industrial automa-tion technology, comprising aSimatic PCS 7 Process Control Sys-tem, Profibus-PA and fieldequipment, is controlling the facil-ities for recycling carbonmonoxide as part of the aceticacid manufacturing process. Inthis way, it is making a contribu-tion towards lowering productioncosts and simultaneouslyreducing emission levels.

Along with other substances,the Wujing Chemical Plant inShanghai produces around

100,000 tons of acetic acid everyyear. This process requires largeamounts of carbon monoxide. How-ever, only a certain percentage of thecarbon monoxide can be exploitedduring the reaction process. Thewaste gas was previously burned off.

In order to make better use of thecarbon monoxide gas and at thesame time to reduce the waste gasvolumes, a new plant was to recyclethe post-process carbon monoxidefrom the depleted gas flow and reuseit in the production process. Sincethe quantity of the carbon monoxiderequired in the manufacture of aceticacid represented a considerable costfactor, this solution will also im-prove the plant’s profitability.

In the face of fierce competition

The new plant was automated usingthe Simatic PCS 7 Process ControlSystem and Siemens field equip-ment. However, before Siemens In-dustrial Automation Ltd. Shanghai(SIAS) was awarded the contract, thePCS 7 had to beat off fierce competi-tion. The decision to choose theprocess control system was madeprimarily on two reasons: first of all,the complete openness of the PCS 7system was a very convincing argu-ment. Secondly, the control room is more than 300 meters away fromthe plant, consequently the operatorwanted a rugged and low-cost fieldbus system.

The automated solution for theacetic acid plant includes an au-tomation system which is connect-ed to the operator and engineeringstation via Profibus. Two SimaticET 200M devices collect the fieldsignals and transfer them to the au-tomation system via the Profibus-DP. The intrinsically safe field busProfibus-PA was also used. SeveralProfibus-DP/PA links and couplersconnect the Profibus-DP networkto the Profibus-PA field bus viawhich the field devices are incor-porated within the process controlsystem. This involves a total of 42Sitrans P pressure transmitters, 25Sipart PS2 electro-pneumatic posi-tioners and 5 Sitrans TK tempera-ture transmitters to ensure that theprocess can operate precisely ac-cording to specifications.

Expertise of the SIAS Team

The SIAS Project Team performedthe entire hardware and softwareconfiguration for the process controlsystem, carrying out comprehensiveand extensive function tests as wellas the Factory Acceptance Test. Inaddition, the SIAS Team also pro-vided local support for the com-missioning, carried out the loop

checks and undertook the task ofsetting the perimeters for all com-ponents. The plant operator was of course also given continuoussupport by SIAS in starting-up thesystems.

“The carbon monoxide recyclingfulfilled our expectations in everyrespect. We now have considerablyless exhaust gas to dispose of than inthe past and, in addition, can pro-duce the acetic acid at significantlylower cost. In this context, the au-tomation concept using SimaticPCS 7 and Profibus-DP/PA not onlyensures optimum process controlbut was also in itself an excellentlow-cost solution. Thanks to the use

Since the beginning of this year a new water supply plant has been securing the water supply to the city of Shaoxing, with apopulation of several million, inthe province of Zhejiang, China.Simatic automation technologyensures that the inhabitants of thecity have a supply of clean wateravailable at all times.

W ater has always been asubject of very specialimportance in Shaoxing.

The Dayu Mausoleum in Shaoxing is after all a reminder of the firstChinese emperor Dayu who is seenas one of the pioneers of water sup-ply in China. Dayu was not only the founder of the Xia Dynasty but in the third millennium BC was alsothe driving force behind the floodcontrol along theYangtze.

Since the be-ginning of this yeara new water sup-ply plant has beenensuring that the4.3 million inhabi-tants of Shaoxinghave an adequatesupply of water atall times. The plant treats approxi-mately 400,000 cubic meters of watera day. After carrying out extensivecomparisons the operator of theplant chose a Simatic solution for the

4 Process News 2/2001

of this system we have been able to achieve cost savings of some 25percent.”

More than just satisfied

The plant has now been operatingwithout any problems since June2000 and all those involved are morethan just satisfied with the project.

The new automation system at theWujing Chemical Plant demon-strates once again that the engineer-ing expertise of the SIAS Team andthat the open and powerful SimaticPCS 7 Process Control System cancope with any challenge. C

Ying-Hao Lin, Shanghai

F o c u s : A s i a

Water is lifeSimatic secures the water supply for Shaoxing city

Making optimum use of resourcesThe perfect automation solution for chemical plant in China

ever, almost all thecountries have onething in common –enormous growth.This requires a well-developed in-frastructure and ef-

fective utilities for thebooming cities.

The Siemens Centerof Competence (CoC)

in Singapore have made itits business to offer a range

of services, which take intoaccount the different condi-

tions in each country. For morethan a year now, they have been

supporting the regional Siemens of-fices during the planning, engineer-ing and implementation of projects.The recent acquisition of MooreProducts and Milltronics providedthe CoC with additional engineeringpersonnell as well as extending theproduct range. In addition, since theacquisition of Applied Automation,process analysis system business forall countries in the Asian-Pacific re-gion (with the exception of Pakistan,India and Korea) has been carried outfrom the Regional Headquarter(RHQ). The RHQ encompasses allthe skills from engineering and sys-tem manufacture of complete analyz-er houses for hazardous areas to af-ter-sales service. The specific de-mands of the analyzer business re-quire expert know-how. Siemens hasconcentrated this know-how in theRHQ in Singapore. From here, Cus-tomers are also supported with theirdeliveries in other regions of theworld via the leading EPCs.

Convincing references

The RHQ and the CoC have proventheir expertise in numerous projects.Three complete analyzer houses werebuilt for the new natural gas produc-tion plant on Luzon Island, Philip-pines. Eight analyzer cabinetsequipped with a total of 12 gas chro-matographs are being delivered for aliquid gas plant in Bontang, Indone-sia. Over forty PCS 7 projects have

The roots of Merck KgaA,Germany, reach back into the17th Century. From the humblebeginnings of a pharmacy,Merck now is a leading globalmanufacturer of high qualitypharmaceutical, laboratory andchemical products.

M erck operates in forty-eight countries and theiractivities are successfully

conducted by one hundred andninety six companies of the MerckGroup.

One of the many requirements ofthe semi-conductor industry is spe-cialty electronic chemicals. Thesechemicals are used in the process ofwafer manufacture including clean-ing and etching. Sulphuric Acid(H2SO4) is used in the cleaningprocess, the critical parameter how-ever is that this acid has to be ultrapure (<100ppt impurities).

In 2000 Merck built an ultra pureH2SO4 plant in Kemaman on theeast coast of the Malaysian Peninsu-lar. Mr. Rolf Hafner, OperationsManager, Merck Singapore, ex-

5Process News 2/2001

been successfully executed in the re-gion covered by the CoC, these havecovered a wide range of applicationsand processes including Polyethyl-ene, Mango Processing, Wafer Fab,Wax Storage, Ultra Pure SulfuricAcid and Airport Terminal Controls.One of the first successes of the yearsaw Siemens Taiwan win a project toprovide the PCS 7 control system fora waste incineration plant, this is oneof many Taiwan is planning to buildin the years ahead and puts SiemensTaiwan in a strong position for con-tinued success in this area.

A comprehensive training pro-gramme enables the Regional Head-quarter and both CoCs to create theprerequisite for effective onsite sup-port of their customers in the in-dividual countries. At the trainingcenters, courses are held for bothSiemens customers and employees.

Expertise for customers

Keiren Lake, General Manager of theCoC , sees the challenges of the futureprimarily as a continuing to promoteSiemens` skills and expertise on theAsian market. "Our Totally Integrat-ed Automation” concept allows us tooffer differentiated solutions versusour competitors. This combined withour experience in all importantprocess automation sectors enablesus to offer best value for our cus-tomers. I am convinced that by work-ing closely with our customers to findbest fit solutions for their applica-tions and by offering Totally Inte-grated Automation packages Siemensin Asia will be a major contributor toindustries developing new facilities inthe region. C

David Favell and Terence Hong,

Siemens Singapore

plained, that the location was chosenbecause of its proximity to an estab-lished sulphuric acid facility, ownedby Malaysia’s largest producer, SeeSen Chemicals.

The plant has a design capacity of10,000 tonnes to meet the expectedmarket demand in SE Asia up to2008.

The majority of ultra pure H2SO4

manufactured at Kemaman is des-tined for the large semi-conductorcompanies in Singapore. The prod-uct is transported by road in speciallydesigned ISO containers to the Merck

transfer and filling facility in Tuas,Singapore. In clean room conditionsthe product is transferred to smallercontainers for distribution.

Merck engaged Siemens Malaysia,with support from the CoC in Singa-pore, to engineer, supply, test, installand commission the Control Sys-tems, Instrumentation, VSD’s andMCC’s. This was actually the firstTIA project in Malaysia.

Plant wide Profibus-DP and -PAwas used for communication be-tween the PCS 7 controllers, VSD’s,local panels and field instrumenta-

tion. Although a relatively smallsystem, consisting of approximately50 instruments and a 250 I/O DCS,the project provided many chal-lenges, including working to a verytight time schedule.

Mr. Rolf Hafner commented“that a fast-track and high-tech pro-ject like that, with a realisation timeof less than 12 months, was only pos-sible due to the professional work ofSiemens and their excellent prod-ucts.” C

David Favell, Siemens Singapore

In the heart of expanding marketsStrategies for the countries of south-east Asia

Ultra PureMERCK Ultra Pure Sulphuric Acid Plant, Kemaman, Malaysia

F o c u s : A s i a

Now they know their

way around: in the

training center the

course participants

learn everything about

Simatic PCS 7 and

Totally Integreated

AutomationMany people see countries such asThailand, Australia and Malaysiaprimarily as favored holidaydestinations. However, thefabulous scenery of the Pacificand Indian Ocean areas is also thesetting for a booming economicregion. Siemens is supporting thegrowth of industries of this regionby providing powerful productsand well thought out processautomation solutions. Siemens inSingapore accomodates theCenter of Competence for processautomation systems andinstrumentation providingservices and support to eight AsiaPacific countries and the RegionalHeadquarters for the processanalyser group covering NorthAsia, SE Asia and Australia.

S outh-east Asia is not just a re-gion of impressive geographi-cal and climatic diversity. The

individual countries differ in theireconomic infrastructure. Oil & Gasfacilities, chemical manufacturingand state-of-the-art wafer fab plantsare just some of the diverse range ofindustries based in this region.

Diverse Challenges

Some countries in South-east Asia orthe metropolis of Singapore, the basefor many petrochemical, chemical,pharmaceutical and high tech indus-tries, are among the most importanteconomic regions in the world. Koreais the home to some of the largestconstruction contractors in the re-gion as well as large petrochemicalcomplexes and ship building facili-ties. While much of the Philippinesindustry is linked to agriculture theSE Asia/Pacific countries of Malaysia,Thailand, Indonesia and Australiahave diverse range of industries in-cluding chemicals, mining & mineralprocessing, oil and gas productionand downstream processing. How-

As part of the ”Malampaya DeepWater Gas to Power” projectdriven by Shell PhilippinesExploration B.V., a new gasproduction plant is being built in the Philippines, equipped bySiemens with the latest processanalyzer components.

T he new onshore gas plant,being constructed by ShellPhilippines on Luzon Island,

delivers the natural gas, which isextracted offshore, to the gas powerstations of the “Malampaya DeepWater Gas to Power” project forpower generation. In the process, thesulfur has to be extracted from thedried natural gas because the hydro-gen sulfide it contains causes corro-sion in pipelines and turbines.

The sulfur extraction plant has tosupply some 14 million cubic metersof sweetened, dry gas perday. The latest process an-alyzer technology fromSiemens ensures that theoperator has the processfirmly under control. Twopumping processes oper-ating in parallel and oneredundant design automa-tion concept ensure maxi-mum availability and con-sistency of the pumping volume inorder to guarantee the supply to theconnected power stations.

Tested – and passed fit

The contract to act as general con-tractor for the construction of theplant was awarded to the FosterWheeler Corporation. Foster Wheel-er was looking for a reliable partnerfor the process analytic part of theplant and – after carrying out de-tailed testing – finally chose Siemens.

The entire analytic system ishoused in three stainless steel con-

tainers. Four PGC 302 gas chromato-graphs monitor the quality of thenatural gas. In addition to Ultramat6, Siemens Sipan conductivity trans-

mitters and analytic equip-ment are used to measurethe dissolved oxygen.

The PGC 302 gas chro-matograph is used not onlyfor quality control but is al-so a reliable instrument forensuring a smooth produc-tion process, particularly incritical areas such as here inthe natural gas processing.

Safety first

In order to test the plant’s function-ality, a factory acceptance test wascarried out by Foster Wheeler, ShellPhilippines, Shell Singapore andShell Holland, which was focused onoperational safety and reliability.The plant passed the test without ahitch, enabling it to be deliveredquickly. Commissioning is plannedfor the end of April 2001. C

Andy Lee, Siemens Singapore

One of the world’s largest gas lique-faction plants is located in Bontang,Indonesia. Since it was commis-sioned into operation in 1977 over227 million tons of gas have beensupplied from here to Japan, Koreaand Taiwan. Siemens – as it hasalready done in previous projects –qualified as a supplier for the ana-lytic components needed for theimminent upgrading of the plant.

6 Process News 2/2001

L ast year, in order to increasethe productivity of the entireplant, the gas plant operator,

PT Badak NGL Co., decided to up-date four trains, which were nowmore than 15 years old. This projectis part of the reliability enhancementprogram, which is intended to elimi-nate the weaknesses in the plant andwhere possible to avoid these in ad-vance in order to facilitate a continu-

In the best traditionSiemens as a partner in the modernization of one of the world’s largest

gas liquefaction plants in Indonesia

High-tech at full speed

Process analyzer system from Siemens for gas productionin the Philippines

F o c u s : A s i a

ous increase in the plant’s efficiencyand reliability.

Proven cooperation

The Chiyoda Corporation was ap-pointed main contractor for thisproject. Chiyoda chose Siemens as apartner for fitting analytical compo-nents – not only because there wasalready a proven track record of co-operation between the two compa-nies during previous projects, allbeing carried through to successfulconclusion. Consequently it can al-most be said that this cooperation is“based on tradition”.

Eight analyzer shelters, each withtwelve gas chromatographs from theAdvance Maxum series and fourinfrared analyzers, form part of theequipment supplied. There are con-sequently now 12 AAI AdvanceOptichrom process gas chromato-graphs from previous deliveriestogether with the 12 new AdvanceMaxum units.

Here again, Chiyoda was so satis-fied with Siemens as their partner thatthe good tradition of cooperation willundoubtedly be continued. C

Andy Lee, Siemens Singapore

High tech in a fantastic environment:

analytic technology made by Siemens

applied in a gas liquefaction plant in

Bontang

One of the analytic containers

on its way to the plant

ACER Display Technologies isworld leader in the manufactureof Thin Film Transistor (TFT) andstate-of-the-art Plasma DisplayPanels (PDP). Applications forthese displays range fromnotebook PC’s to television sets.

I n 1999 Siemens Taiwan wasawarded a project, by leadingclean room technology company

M+W Zander, to provide a fully in-tegrated control system to the newACER Display Eagle Project in LungTan Taiwan.

Siemens were responsible forengineering, integration, configura-tion, supply, testing and commis-

sioning the entire Facilities Manage-ment Control System (FMCS) andProcess Skid Package Control Sys-tems from OEM’s.

A modern production plant ofTFT LCD’s today would be incon-ceivable without the use of the latestautomation systems that ensureabsolute constant clean room con-ditions.

In addition to references, localpresence and local expertise, a cru-cial factor in the selection of PCS 7was the Siemens “Totally IntegratedFab” concept, which facilitates gen-eral and standard automation of theentire project with a uniform user

interface and gen-eral engineering.The owner (ADT)saw this as an op-portunity to re-duce its overallcosts (Total Costof Ownership).

The common philosophy be-tween ACER and Siemens engi-neering personnel was to develophomogenous automation of allsub-systems, ensuring commonhardware and common user inter-face. Fast track configuration was

Consistent ConditionsACER Display Eagle Project, Long Tan, Taiwan

achieved using Siemens standardlibraries and CFC’s.

The 17750 I/O system is made up of twelve AS417H redundant con-trollers, six AS416 controllers, twoAS414 controllers, eight servers andseven multi clients. Interfaces topackaged equipment and third partyPLC manufacturers were implement-ed by Siemens engineers.

All clients and servers communi-cate over a Fast Ethernet 100 MHzFiber Optic ring. This also applies toserver controller communications.Siemens preferred field bus Profibusis installed throughout the plant.Web servers are installed for intranetand internet communication using@aGlance software.

PCS 7 performs the vital job ofensuring consistent continuous clean

room conditions – 24 hours per day365 days per year.

The clean room conditions aresubject to extremely high demandsin terms of temperature (maintaintemperature within ±0.5 °C of a setparameter) pressure, humidity andcleanliness. Fluctuations to these pa-rameters can result in a shutdown ofthe machine with the consequence ofdamaged product and lost produc-tion.

For more information regardingthis project or Siemens Process Au-tomation Taiwan capabilities con-tact Siemens Ltd, Taipei.hk.wang@ siemens.com.tw C

David Favell, Siemens Singapore

Hk Wang, Taipei

For the production

of TFT LCD’s ACER

uses Simatic PCS 7

technology

When it was launched, the Simatic PCS 7 process control sys-tem was initially designed for usein smaller and medium sizedplants. Scalable expansion andfunctional additions have alsoextended the range of applica-tions to cover larger and verylarge plants. The version V5.1which has now been released has set another milestone.

Scalability expanded

The scalability of the new version ofthe Simatic PCS 7 process controlsystem has been expanded in bothdirections. In the lower segment thePCS 7 Starter Package is a full valuestarter system – ideal for smallerplants, for technical colleges or train-ing. Attractively priced, the systemoffers the full PCS 7 functionality; itis only the number of PLT positionsthat is limited to approx. 160. Subse-quent expansion to cover the entirebill of quantities for larger plants can

be done without causing an inter-ruption to the system. In the uppersegment, control can be providedeven for very large plants with up to18,000 PLT positions with a furtherexpansion of the bill of quantities forthe operator stations and the so-called multi-client/server architec-ture.

Extra engineering performance

A number of functional expansionshave been introduced to enable theproject planning for large plants tobe structured on a more efficient ba-sis. A few examples: when automati-cally creating component symbolsfrom the technological hierarchy, asymbol is automatically created foreach engineering element (con-troller, motor, valve, …) in the cor-responding control panel of thescreen hierarchy. The user then onlyneeds to place these symbols on thescreen – the system automatically es-tablishes all the necessary links withthe process.

The Import/Export Assistant, theTool in the PCS 7 tool chain thatprovides for particularly efficientvolume engineering – now also pro-vides support for the general plan-ning of circuits as used typically forlocking mechanisms. The GraphicObject Update Wizard providesfunctions which can be used forexporting, importing or updatingdynamic user objects from controlscreens, whilst maintaining the cir-cuit with the assigned process values.There is however also the facility foraltering the dynamic informationexported to an Excel table, then re-importing it and consequently veryeasily creating control screens forother part systems. This deliversconsiderable potential for savings,particularly in systems with regularlyoccurring structures.

The Faceplate Designer gives theuser a tool with which he can createhis own faceplates quickly and sim-ply. These are created using standardmethods, with support from assis-tants and libraries and require noprogramming.

The online control optimizationtool Siepid has also been integrated

into the engi-neering systemand with whosehelp PID con-trollers can beoptimized andthe calculatedcontrol parame-ters directly in-corporated intothe engineeringdata storage.

SafetyIntegrated

There are a num-ber of key tech-nological inno-vations on theautomation lev-el. The scaleableperformance ofAS 414 F/FH and

AS 417 F/FH controllers, a library ofTÜV-certified faceplates as well ascorresponding fail-safe I/O assem-blies, enable fail-safe or fail-safe andhigh availability systems to be assem-bled. In this context, safety require-ments under SIL3, AK6 as well asCat. 4 can be met using just one con-troller. The special feature of this pio-neering concept is that fail-safe andstandard assemblies can be driven onthe same Profibus-DP string, the asso-ciated functions will run on the samecontroller and be processed using thesame project planning tool. Thanks tothis homogeneous integration of thefail-safe technology in Simatic PCS 7,engineering and testing costs will belowered, the costs of maintenance andspare parts reduced. C

Roland Wieser, Karlsruhe

In view of the need to reduce thesulfur content in fossil fuels, moreaccurate analysis processes arerequired for their production. The total sulfur content analyzerfrom Siemens ensures thatproduct quality is maintained and environmental protectionregulations adhered to.

Fuels used in internal combus-tion engines contain varioussulfur components which are

converted into sulfur dioxide duringthe combustion process. The mil-lions of tons of SO2 released everyyear into the atmosphere in this wayyear pollute the environment in theform of smog or acid rain and alsohave a detrimental effect on theservice life and function of exhaustcatalytic converters. The urgent needfor the introduction of low sulfurfuels is also a prerequisite for the useof new exhaust cleaning systems suchas the Denox catalytic converter orNOx filtering, as well as for the devel-opment of fuel-efficient power units.

Stricter requirements

In order to reduce total sulfur emis-sion levels, increasingly more strin-gent regulations on the sulfur con-tent of fossil fuels are being passed,particularly in the industrializedcountries. One such example inEurope is the vehicle oil programwhich is being used to promote areduction in the sulfur content ofpetrol and diesel fuel from over 1000ppm in 1995 to less than 50 ppm bythe year 2003. In the USA, federalregulations, which are defined in theClean Air Act of 1990, require areduction in the sulfur content downto 30 ppm by 2005. A further reduc-tion in the maximum limit to below10 ppm is expected to be announcedfor the period after 2005. One of theprerequisites for the manufacture ofsuch low sulfur fuels are analyticalprocesses which provide reliable in-formation on the product qualityand the adherence to environmentalprotection regulations.

Trials carried out at SiemensChromatography Global at its Karls-ruhe and Bartlesville, Oklahomasites, showed that traditional analysissolutions reach the limit of their

capabilities within this low concen-tration range. That is what promptedthe development of a total sulfurlevel analyzer in Karlsruhe, with itsunique vaporization system provid-ing for the reliable detection of sulfurconcentration levels down to lessthan 1 ppm.

Vaporized sample

The total sulfur content of a fuel isderived from a number of unidenti-fied sulfur components that possessvarious chemical properties andwhose concentration levels in some

cases lie within the ppb range. A con-tinuous flow of the fuel to be tested isfirst sprayed as a fine mist for theanalysis and then suddenly vapor-ized in a heated tube. This vaporizedsample is fully burned off in a hydro-gen-air flame, with all hydrocarbonsbeing converted into carbon dioxideand water in the process and all sul-fur elements into sulfur dioxide.This much more basic mixture canbe separated by chromatograph withthe help of the patented, valvelessseparation column switching andrecorded using a sulfur-selective de-tector. Despite the high complexityof the sample the total sulfur levelanalyzer delivers the precise sulfurcontent of the test medium everythree minutes.

This enables Siemens to offer therefinery industry an important ana-lytical tool for the purpose of ensur-ing product quality and compliancewith environmental regulations. C

Ulrich K. Goekeler, Houston

Klaus Grimm, Karlsruhe

Process News 2/2001

Smaller, larger, more efficient and

more reliableNew version of Simatic PCS 7

Sulfur sensorsNew total sulfur content analyzer

Simply everything under control:

with the new Simatic PCS 7

version 5.1 more processes can

be controlled more conveniently

The Simocode-DP 3UF5 motorprotection and control device withconnectivity is used around theworld in all sectors of the processindustry. It offers functions forcomprehensive motor protectionand for system monitoring. Theintegrated control softwarereplaces costly hardwaresolutions for the control circuitand covers all typical motorapplications (direct starters,reversing drives, star-deltastarters, etc.). Simocode-DPfacilitates detailed motor andsystem diagnosis and simplifieddata exchange with theautomation system via theintegrated Profibus-DP interface.

T he optimized price-performancesystem combines standardpre-programmed functions

with freely parameterizable elementssuch as timers, meters and logical op-erations, so that each customer-spe-cific instance is represented by a mo-tor branch circuit.

Using the Simocode-DP objectmanager software, the device can becompletely integrated in the SimaticS7 Step 7 data management system.

All Simocode-DP functions as wellas diagnostic information can beeasily integrated into the PCS 7process control system via function-al modules and faceplates. FromMarch 2001, these drivers also sup-port the Y-Link for the redundantcoupling of one-channel slaves to thehigh-availability Simatic S7-400 H.Simocode-DP is also integrated into

Simatic PDM via a separate devicedescription, the software for univer-sal and cross-manufacturer parame-terization, commissioning, mainte-nance and diagnosis of connectivefield devices.

Reliable separation

Simocode-DP is increasingly becom-ing a standard within the chemical in-

S ervice and support for prod-ucts or systems is often re-quired quickly, because it is

important to get production up andrunning again as soon as possible.The motto here is “time is money”.But what do you do if questions comeup during commissioning or when a

fault occurs, when nothing more canbe done without an answer? There isan information pool available forsuch cases which can be accessedaround the clock from anywhere inthe world. It provides answers to asmany questions as possible. Siemens’aim is to build a very comprehensive

8 Process News 2/2001

New optionsMotor protection and control device Simocode-DP with ‘reliable separation’

Always at your serviceNew Internet information system for service and support questions

CertifiedSitrans T3K-PA temperature transmitter for Profil 3.0

dustry for the protection and controlof motor and load branch circuits. Inthis sector, particular value is placedupon the high availability of the sys-

tem, i.e. it should be possible to workon power circuits in the IT measur-ing, control and regulation technol-ogy systems, while the plant contin-ues to operate, without special pre-cautions against hazardous shockcurrent.

When compared with similar prod-ucts, Simocode-DP is the only devicewhich is able to provide the ‘reliableseparation’ function in accordancewith DIN VDE 0100/0106/0160 asstandard. Even if a ‘serious’ error oc-curs (e.g. detached soldered joints,undone screws, break of a phase par-tition), a voltage overspill from thepower circuits of higher voltage (e.g.230 V) to power circuits with func-tional extra-low voltage (25 V AC or60 V DC) will be prevented. In orderto achieve reliable separation, allthese power circuits must be insulat-ed from each other by doubled airand leakage paths. C

Karin Thiel, Erlangen

information service on the Internetfor all automation and drive technol-ogy products which answers ques-tions on the subject of service andsupport. Manuals can be downloadedand FAQs read on many products.All the available information on aparticular subject can be located us-ing a knowledge manager. There willbe telephone numbers for the servicecenters in each country or the centralhelpline number as well as informa-tion on replacement parts availabilityand much, much more. Also of greatinterest is the forum, where manyquestions can be both asked and an-swered by users. Sniff out the answersto your questions at: http://www.ad.siemens.de/support

Even if there is no informationavailable on the product you want, itwill be worth your while returningfrom time to time as the site is stillunder construction. C

Achim Heim, Karlsruhe

T he new Sitrans T3K-PA uni-versal temperature transmitterhas received its Profibus Profil

3.0 conformity certificate. Amongthe special features of the new profileis the fact that a transmitter can beconfigured in such a way that it isinterchangeable with every tempe-rature transmitter which conformswith Profil 3.0, and that without re-configuring.

Further standardized status infor-mation leads to increased safety ofplant operation for the plant opera-tor. In addition, the parameterizationof the process devices is precisely de-termined via the acyclical services inProfil 3.0.

With a current input of only 11 mA, the hardware side of the

Sitrans T3K-PA places low load onthe system as a whole. Even if a defectoccurs, maximum power consump-tion at the temperature sensor head isrestricted to 14 mA. This means thatin the case of a fault, only the defec-tive measuring point will fail, not theentire Profibus-PA phase.

The Sitrans T3K-PA micro-processor provides the Profibus-PAwith the signals measured by the var-ious sensors and status of the mea-surement quality. Data such as sen-sor type, limit values or for examplethe behavior when the transmitterfails can be programmed in theSitrans T3K-PA. C

Georg Nafz, Karlsruhe

De facto standard for

the protection and

control of motor and

load branch circuits:

Simocode-DP with a

Profibus-DP interface

Here are the answers to

all questions: service

and support by Siemens

Suppliers and fitters for the glassindustry also rely on Siemensautomation technology. Animpregnation and annealingsystem with state-of-the-artSimatic technology was installedat Didier.

A s a turnkey supplier for allfireproof requirements, Di-dier has been involved with

the glass industry for more than acentury. Didier manufactures prod-ucts used in the installation of glassfurnaces and their associated units,such as regenerators, recuperators,distributors or exhaust gas channels.Last year, an impregnation and an-nealing system for the fireproof ma-terials was modernized at the Markt-redwitz site. This project involvedupgrading the control room and allthe automation technology as well as the low-voltage distribution andcabling of all system parts.

Didier decided to use the Simatic S7automation system with the Profi-bus-DP bus systems and IndustrialEthernet. The system was able to

When Tikkurila Paints Oy, a major paint manufacturer inFinland, overhauled itsmanufacturing systems, it wasn’tdone with a coat of paint. TheFinnish company has equippeditself for the future with a newautomation concept based onthe Profibus-DP distributed fieldbus system with the SimaticPCS 7 process control system andBatch flexible.

T he Monicolor paint factory inVantaa-Tikkurila to the northof Helsinki was using an auto-

mated control system, part of whichhad been in service for almost aquarter of a century. As part of itsplant modernization, a distributedfield bus system with decentralizedperipherals for the mixing systemswas to be installed in the factory (an-nual turnover of approx. 30 millionliters base paint). By doing this, thepaints manufacturer aimed to makeconsiderable savings on installation,operation and maintenance, and alsoto reduce space requirements by re-

prove its flexibility with the integra-tion and coupling of external compo-nents, such as the control technologyor the individual closed-loop con-trollers. The annealing furnace 2, thetransport system and the preheaterswere also integrated as customer sys-tem parts.

The system is centrally operatedand monitored by the control system,comprising a server and two clients.The data management is carried outby the server which is prepared fordata exchange with the primary officenetwork (vertical integration). Theonsite operation, e.g. manual andcorrective inputs of the individualsystem parts is via OP27, and there isalso an option for remote mainte-nance via modem.

In the system, which has been run-ning smoothly since October, theprocess data for each product cycle isrecorded and stored in a database forquality assurance. The most impor-tant information is added to theproduct label. C

Horst-Reiner Herold, Bayreuth

9Process News 2/2001

Finnish paintsPaint production given a guaranteed future with Profibus-DP and Batch flexible

FireproofSimatic S7 controls impregnation and annealing system

moving the need for switching cabi-nets and cable harnesses.

Guaranteed future with Profibus

Tikkurila believed Ethernet andProfibus-DP was the best solution forguaranteeing the company’s future.Simatic PCS 7 with WinCC andBatch flexible was used for theprocess control system. The automa-tion level comprises two Simatic S7-417 controllers, from which sevenProfibus-DP phases begin.

These seven Profibus-DP phasestake over communication at the fieldlevel. There are approximately 800valves in the plant which are almostexclusively pneumatic valves. A fur-ther 400 motors and approx. 200 lev-el meters produce around 2500 I/Osincluding checkback measurements.Depending on the type of the signalto be recorded, these I/Os are opti-mally recorded with the differentSimatic peripherals. Around 110slaves are installed at the field level,primarily Simatic ET 200S, 200M,200X as well as Masterdrives for theagitators. DP/AS interface link mod-ules link the Profibus network with

sensors based on actuatorsensor interfaces. As most ofthe peripheral modules hadan IP 68 protection rating,the peripherals could be in-stalled directly in the sys-tem, thereby removing theneed for switching cabinets.

Around 50 per cent ofthe factory floor is in a haz-ardous zone, as paint pro-duction involves highlyflammable solvents whichmay form explosive mix-tures with air. The pneu-matic ducting for the con-trol of valves in the haz-ardous area is controlled bySimatic ET 200X peripher-als installed in the non-haz-ardous area.

All the modifications had to be completed withina very short window inNovember and December1999. All critical points dur-

ing the modification were met ontime without great difficulty. Aftercomprehensive tests in December1999, the plant returned to normaloperation in January 2000.

More flexible with Batch flexible

As the paints are produced in batch-es in the plant, Tikkurila chose Batchflexible because it was specially de-signed for discontinuous processesand clearly simplifies recipe creationand alteration. The chemist can easi-ly represent a recipe graphically with-out any programming knowledgeand save it in the recipe database.Recipe alterations can even be madewhile a batch is running.

Jorma Pöyry, automation engi-neer at Tikkurila, has a very positiveoutlook: “We were looking for clearand reliable recipe automation at areasonable price. We found what wewere looking for in the SiemensSimatic PCS 7 process control systemwith Batch flexible.” C

Mika Saila, Helsinki

Not only the Didier products are

absolutely fireproof. You may also rely

on the Simatic S7 controller in every

delicate situation

P r o c e s s N e w sPublisher

Siemens AG,Automation and Drive Technology

Responsible for contentAnton S. Huber

EditorCornelia Dürrfeld, Siemens AG A&D AS PAS

Östliche Rheinbrückenstr. 50, D-76187 KarlsruheTel: +49 (0) 7 21 5 95-25 91,Fax: +49 (0) 7 21 5 95-63 70

e-mail: cornelia.duerrfeld@khe.siemens.de

Editorial committeeDavid Favell, Dr. Michael Gilluck, Achim Heim,

Walter Huber, Michael Lang, Harald Mag, Hartmut Oesten, Manfred Schirner, Bernd Renner

Publishing housePublicis MCD, Werbeagentur GmbH

Head of periodicalsWolfgang Meyer

CoordinationSylvia Schwope

Artwork and layoutHerbert Haida, Jürgen Streitenberger

PhotosHoffmann – La Roche (1, 2), Wujing Chemical Plant (4),

Acer Display Technologies (6), Vividia (7), Wolff (7), Tikkurila Oy/

J. Rahkonen (9), Didier (9)

ISSN 1430 2292

© 2001 at Siemens AGAll rights reserved by the publisher. No part of this documentmay be reproduced without prior written permission from the

editor. Process News is printed on 100% recycled paper.

ET 200, INDUSTRIAL EHTERNET, instabus EIB, PROFIBUS-DP/PA, SIEPID, SIMATIC, SIMOVERT,

SIPAN, SIPART, SITRANS, STEP 7, ULTRMAT, TOTALLY INTEGRATED AUTOMATION,

are registered trademarks of Siemens AG.

If trademarks, technical solutions or similar are not included inthe list, it does not imply that they are not included.

F R O M A R O U N D T H E W O R L D

G ood news for everyone inter-ested in Simatic PDM soft-ware and who wants to use

it: The software package is now avail-able as a multimedia CD. SimaticPDM can be used to parameterizefield devices via Profibus-PA andHART over a uniform interface andconnect them withthe Simatic PCS 7process control sys-tem.

The CD, which isavailable in Germanand English, beginswith a short intro-ductory film. Theuser is then present-ed with 12 differenthighlights of SimaticPDM, for which explanatory text andpictures can be called up. To make iteasier for users to navigate the CD,graphical instructions backed upwith brief audio segments are also

Multimedia

available. These explain the integra-tion of the devices with Simatic PDMboth in the stand-alone version andthe integrated version.

The CD also contains files on in-stalling a complete Simatic PDMVersion 5.0.2+SP1 in a total of fivelanguages (German, English, French,

Italian and Span-ish), which theuser may test freeof charge for 60days. Naturallythere is also anopportunity toobtain a full li-cense for thisversion of SimaticPDM.

The SimaticPDM Multimedia CD can be orderedusing this number E20001-W0050-P710. C

Georg Nafz, Karlsruhe

W ith the most powerful pow-er station in Singapore,Power Seraya Ltd. supplies

the chemical and petrochemical plantsin the largest industrial district on Ju-rong Island with electrical energy.

As general contractor, SiemensPower Generation took over respon-sibility for the last expansion of theplant. As subcontractor for all thesupply generators and the analytics,Samsung Korea awarded the orderfor the supply of the analyzers for thefeed-water treatment to Siemens. Intotal, two complete analyzer cabinets

Major contract in Singapore

were delivered, each containing 40Sipan 34 conductivity devices, 14Sipan 34 devices for determining pHlevels and four Sipan 34 devices forthe monitoring of the dissolved oxy-gen in the boiler feed water. The sys-tem components are being built inSiemens’ analyzer system plant inSingapore.

This project has enabled the sys-tem plant to promote itself as a skilledand reliable partner for other projectsin this region. C

Bernd Renner, Karlsruhe

V ictrex PLC in Lancashire isone of the leading manufac-turers of high-performance

plastics, which are used as chemicallyinert and lightweight materials inmany areas. Two new lines for theproduction of polyaryletherketone,for sale under the trade name PEEK,are using the Simatic PCS 7 processcontrol system for their automationtechnology.

In addition to the excellentprice/performance ratio, the greatflexibility and the opportunity for auniversal automation solution withTotally Integrated Automation, were

High-tech polymer production

the key factors in the decision tochoose PCS 7. The PCS 7 also made itpossible to automate both continu-ous and batch sections of the process.

During commissioning of thesystem, Siemens organized compre-hensive training for the Victrex em-ployees. This did not just enable theemployees to learn about their newduties, but they are now also in aposition to adapt the system tochanging conditions – and this givesthem more control over the entireprocess. C

Marc Chung, Manchester

Process News 2/2001

Siemens AG, Process Automation and Instrumentation, Östliche Rheinbrückenstr. 50, D-76187 Karlsruhe, Germany

Order No. E80001-V381-A72-X-7600004900 RPE12 0501 32.Printed in Germany

Subject to change without prior noticeSiemens Aktiengesellschaft

Cargill Rotterdam chooses Simatic PCS 7N

• Stop Press

+ + + Siemens takes over the

Altoptronic company in

Göteborg/Sweden, one of

the leading suppliers of laser

spectrometry with application

focus on combustion

processes, environmental

technology and metallurgy.

The acquisition is part of

Siemens’ growth strategy in

process analytics. + + +

+ + + Siemens receives orders

for today’s largest wafer plant

in China. SMIC, Shanghai, is

currently building 20,000

square meters of different

types of clean rooms. M+W

Zander is to engineer the

clean room facilities. Siemens

received orders for the clean

room automation package

(HW and application

engineering) based on the

Siemens “Totally Integrated

Fab” concept and for the

electrical as well as

automation installation

package. + + +

A fter a detailed decision-mak-ing phase, Cargill Rotterdamhas chosen Simatic PCS 7 for

the modernization of its automationsystem.

The Siemens automation solutionfor the fine chemicals works com-prises 25 AS systems, four OS servers

and seven OC clients and an ES oper-ator station. Compex will be used fora number of MES (Management Ex-ecution System) tasks. The batch sys-tem bases on Compex proCX. C

Peter Venhovens, The Hague

INTEL 23.–25.5. Milan, Italy

International Exhibition for Electronics, Electrical Technology, Lighting and Household Appliances Components

INTERKAMA 24.–28.9. Düsseldorf, Germany

Solutions for Automation in Production and Business Processes

ELEKTROTECHNIEK 1.–5.10. Utrecht, The Netherlands

Expert show for Electric Engineering

SPS/IPC/DRIVES 27.–29.11. Nuremberg, Germany

Electric Automation Technology – Systems & Components, International Exhibition and Conference

FAIR PREVIEW

M PA REGELE, a Siemenssolution provider fromLandsberg, equipped a new

Südstärke GmbH plant for the extrac-tion of potato protein with the PCS 7process control system. The new pro-duction site in Schrobenhausen wasconfigured and commissioned withinseven months – a very short time peri-od for this plant.

“The fact that this was possible wasdue both to the convincing skills ofthe MPA REGELE project team andto the excellent structuring and goodhandling of PCS 7,” explained An-dreas Kotte, project manager at MPAREGELE. In particular, the Engineer-ing Tools and the integrated simula-

tion options considerably simplifiedthe configuration of the automationsystems.

The universal data managementand the excellent diagnostic capabili-ties of PCS 7 were very important toSüdstärke GmbH. And the clear andcomprehensible process visualizationinterface provides more comfortwhen operating the new plant.

The extraction of protein has beenrunning very smoothly for a goodyear now. This is the best proof forMPA REGELE and Südstärke thatchoosing PCS 7 was definitely theright decision. C

Sigmund Reinbold, Munich

As quick as a flash

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Net News:Here are a few interesting www.siemens.dewebsites dealing with the www.pcs7.desubjects covered in this www.siemens.de/automationedition of Process News: www.fielddevices.de

www.processanalytics.com

China http://w4.siemens.de/chinaSingapore http://www.siemens.com.sgTaiwan http://www.siemens.com.twIndonesien http://www.siemens.co.idPhilippinen http://www.siemens.com.phMalaysia http://www.siemens.com.myFinland http://www.tikkurila.fi/

tikkurila_com/index.html

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