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Flexible, comprehensive and customized. Automation solutions for the Chemical Industry.

totally integrated

Your competent partner in automation Siemens – a name recognized all over the world. A name

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

that stands for innovation, customer orientation and a

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

global competitiveness. Not only for 400,000 employees

that surround us and the electronic devices that make life

and millions of customers, but also for hundreds of thou-

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

sands of suppliers and partners in more than 190 countries.

more comfortable, more pleasant place to live.

It also stands for a unique range of products, systems and solutions. Siemens also embodies the timeless vision of its founder, Werner von Siemens: “Progress serving mankind”. With more than 50,000 employees in 70 countries, Siemens Automation and Drives (A&D) is one of the largest groups within Siemens AG. As a technology and market leader in automation and drives technology, we are continually making rapid advances in this field – and setting new standards again and again. Siemens A&D offers a unique, complete range of innovative products, systems and solutions. Totally Integrated Automation (TIA) and Totally Integrated Power (TIP) form the backbone of our portfolio – and the basis for customerspecific solutions in the field of automation and energy distribution.

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Industry Suite Chemicals – the customized solution for you In the Industry Suite Chemicals, the worlds of automation and power engineering merge into one comprehensive and modular offer for your needs – including the required services across the entire life-cycle of your plant.

Industry Suit Totally Integrated Automation Optimization of the complete workflow With Totally Integrated Automation, Siemens is the only supplier of an integrated range of products and systems for automation of chemical plants – from the field level and production control level to the enterprise level. Your benefit: considerably lower lifecycle costs for the plant, shorter time-tomarket and consequent improvement of your competitiveness.

Process know-how On the basis of our comprehensive industry know-how, we implement solutions that guarantee optimum fit and maximum process transparency for your plant – while requiring a minimum of manpower. Tailor-made energy concepts With our solutions in the field of energy supply, we make a decisive contribution to the smooth, economical and environmentally friendly operation of your plant. Process optimization by means of MES solutions Our MES solutions are essential to enable you to optimize your processes throughout the plant. They ensure integrated data transfer – vertically from the field to the enterprise level and horizontally from your suppliers to your customers.

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ur industry Basis of the Industry Suite Chemicals: Totally Integrated Automation and Totally Integrated Power – plus our comprehensive know-how in your industry.

te Chemicals Totally Integrated Power Power management and distribution from a single source On the basis of Totally Integrated Power (TIP), we implement integrated solutions for power distribution across all chemical production units and industrial buildings, from the medium-voltage supply to the outlet. Equipped with the same communication standards as Totally Integrated Automation, all resources – for automation, power distribution, energy management and building automation – can be seamlessly integrated and comprehensive solutions can be implemented in your plant.

Drive solutions Innovative technology, precisely coordinated components and comprehensive engineering know-how are your guaranty that our drive solutions will meet even your highest requirements – in terms of performance, torque, dynamics, availability, diagnostics capability and cost effectiveness. Life-cycle services Our comprehensive range of services is an efficient lever ensuring continuous optimum performance of your plants. With our solutions we cover the entire life-cycle of your plants – from planning and implementation to modernization and maintenance. System integration In order to guarantee perfect system integration, we cooperate with numerous competent partners – internally with Siemens Industrial Solutions and Services and externally with selected solution partners forming a worldwide network.

Content Your Partner in Automation ..............................

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

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

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Process Competence .........................................

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

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Manufacturing Execution System ..................... 13 Field Devices .................................................... 14 Industrial Communication ................................ 16 Drive Systems .................................................. 18 Process Instruments and Analytics ................... 20 Industrial Controls ............................................ 22 References ....................................................... 24

Improve your competitiveness in your industry. With Totally Integrated Automation With Totally Integrated Automation (TIA), Siemens offers a unique, integrated portfolio of products and systems for the implementation of automation solutions. TIA fulfills your objectives with Siemens technology and products providing an impressive and unique level of integration. This not only reduces the cost of interfaces, but also ensures maximum transparency across all levels – from field, through the production level to the corporate management level. For all processes in the Chemical Industry from bulk chemicals, specialty chemicals to consumer products. It goes without saying that you benefit with TIA throughout the life-cycle of your plant – from the product design phase, through the operation to

On the basis of Totally Integrated Automation, we implement solutions that are perfectly tailored to your special requirements in the Chemical Industry and which are characterized by their excellent integration. In this way, TIA makes an essential contribution to the optimization of your production processes.

the modernization. With a high level of consistency and integration of our products and systems, we provide you a high security of investment – avoiding unnecessary interfaces in the system.

ERP Enterprise Resource Planning

Totally Integrated Automation Control

SIMATIC NET Industrial Communication

MES Manufacturing Execution Systems

Ethernet

Production Order Management

Material Management

Production Operations Recording

Equipment Management

SIMATIC IT Framework Ethernet

SINAUT Telecontrol System

Production Modeler

Detailed Production Scheduling

SIMATIC Software

SIMATIC Machine Vision

Ethernet

Plant Information Management

SIMATIC PCS 7 Process Control System

SIMATIC Controller/ Automation System

Industrial

Industrial Ethernet

Industrial Wireless Communication/ MOBIC

Safety Integrated

SENTRON Circuit Breakers

SIMATIC Distributed I / O

PROCESS FIELD

PROFIBUS Field Instrumentation / Analytics

PC-based Automation

Sensor Technology IQ-Sense

AS-Interface Building Technology GAMMA instabus

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Micro Automation and Actuator-Sensor Interface Level

ECOFAST IP65 Distributed Automation System

SIMOCODE pro Motor Management System

HART

PROFIBUS PA

The answer to growing demands Productivity, flexibility, safety and resource efficiency are the key to economic success in the production processes of chemical plants. Only companies that can successfully master these challenges can meet the market demands for short delivery times, ensured quality and prices that are always in line with the market. You know the factors required to achieve higher productivity in chemical plants: a maximum degree of automation, consistent quality – and, last but not least, the highest possible availability. Advantages for plant operation

Thanks to the system-oriented engineering environment as well as the integrated communication and diagnostics options of TIA, your plant will benefit in every phase of the life-cycle. What is more, the consistency in ongoing product innovation offers you maximum security of investment in case of modernization.

The Siemens range of products and solutions is specifically tailored to your requirements. Top priority is placed on integration and openness – in all key areas from automation to drives right up to process instrumentation. These solutions are based on proven industrial standards and are optimized to achieve the highest possible degree of economic efficiency throughout the entire life-cycle of a plant. Advantages for system integration Growing pressure on the production side, ever shorter product life-cycles, rising production demands and an ever greater complexity. On the one hand, the end customer demands for you as a system integrator are immense. On the other hand you require solutions, which let you execute and engineer your customer projects more quickly, precisely and economically – from the design to commissioning. Totally Integrated Automation is the foundation for: shorter time-to-market from the planning to the delivery higher system availability and flexibility improved quality of engineering

Product Specification Management System

shorter and easier engineering and commissioning cost savings in projects

Laboratory Information Management System

Advantages for the EPC As an EPC, you must respond to a continuously rising competitive pressure. At the same time, more is being expected of your solutions all the time and the demands that you must meet are becoming increasingly complex. SINUMERIK Numeric Control

SIMOTION Motion Control System

SIMATIC HMI Human Machine Interface

Totally Integrated Automation is the foundation for: standardized interfaces between E&I engineering packages highest availability of plant equipment lower design and engineering costs faster project execution higher productivity and flexibility

SIMODRIVE

SINAMICS

Drive Systems/ SINAMICS

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Competence for the processes in the Chemical Industry

To ensure economic success in the chemicals business, you need top productivity, highest flexibility, maximum safety and the efficient use of resources in all your production processes. This is the only way to meet the demands for fast delivery, high and constant quality, and competitive prices.

Extraction

Typical process units in chemical plants

Distillation

Reaction

Two key parameters determine the economic efficiency of the distillation process: how much energy is used for vaporization and condensation, and – as with heat-sensitive substances, for example – whether environmental conditions can be completely controlled.

The reaction process is at the heart of chemicals production, and the greater the efficiency and performance of the catalyst, the better the product yield and quality. To ensure the best possible results, key process parameters such as temperature, pressure and flow must be controlled with great precision. Heat Exchange When process media are being warmed or cooled, it’s crucial for heat exchangers to quickly and precisely reach the right temperature. At the same time, of course, it’s important to prevent any contamination or unnecessary energy loss.

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Using the best possible extraction agents, together with seamless integration of heat with downstream columns, brings long-term cost savings in extraction while maximizing product quality and minimizing environmental impact.

Absorption Successful, efficient absorption of gaseous product mixtures depends on selecting the right absorbing agent and controlling all process parameters. High process and product quality can only be achieved when all factors are optimally combined and coordinated.

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Tailored to the demands of the Chemical Industry: Siemens automation solution with SIMATIC PCS 7

SIMATIC® PCS 7 is the Siemens distributed control system (DCS), based on TIA, using standard hardware and software components and can easily be connected to the Manufacturing Execution System level (MES).

SIMATIC PCS 7 benefits for the Chemical Industry: One common engineering tool PCS 7-ES for the complete process – saves engineering time One common visualization of all data in all PCS 7 operator stations with a standard alarm visualization – reduces production downtimes Field instrumentation, motors and drives are fully integrated in TIA and PCS 7, relative to engineering, operation, maintenance and diagnostics Pre-configured function blocks and libraries, adapted to different industry requirements, simplify configuration High performance automation systems with SIMATIC S7-400 controller on Ethernet up to 1 Gbps. At the field bus level, PROFIBUS DP and PA is provided Redundant controller and PROFIBUS communication for high-availability processes keep the process running and reduce production downtimes Safety Integrated with the PROFIsafe profile on a single PROFIBUS cable, using one controller and one engineering tool. This saves time and the expense of additional components Standard and fail-safe remote I/O modules on PROFIBUS DP ensure reliable data transmission and diagnostics. SIMATIC ET 200M remote I/O modules provide a large variety of digital and analog input and output channels.

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Flexibility and scalability – from a small laboratory system up to distributed client/server architectures As a result of its modular and open architecture that is based on selected hardware and software components from the standard SIMATIC range, SIMATIC PCS 7 can be applied effectively in small and large plants. It allows easy expansion or system modification (online) to enable customers to meet the changing production requirements of their facility. SIMATIC PCS 7 is scalable from a small single system consisting of approx. 160 measuring points (motors, valves, PID controllers), such as might be used for a laboratory system or a pilot plant, up to a distributed multi-user system with client/server architecture and approx. 60,000 measuring points, such as might be used for automation of a very large production plant or for groups of connected facilities.

Depending on the plant’s requirements, the operator and the planning engineer can Select from various automation systems with graded performance characteristics Use distributed (remote) or central I/Os step-by-step Layout an optimum architecture for the operator system: from single-user standalone stations up to distributed multi-user system Select the engineering and runtime system software according to the size of the system (scaled by process objects) Configure communication networks and determine network components to support required levels of redundancy and availability Extend the functionality of the operator stations by adding various hardware and software modules, e.g. using SIMATIC BATCH or with a standalone, redundant archive server Integrate applications connecting SIMATIC PCS 7 to legacy systems and the IT system.

Stand-alone systems

Scalable from small applications (~160 process objects) …

Production facilities

Various plants of a production site

… to the distributed system in client/server (~ 60,000 process objects)

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SIMATIC PCS 7: the distributed control system in Totally Integrated Automation

Open DCS for the future

Common and integrated system

SIMATIC PCS 7 is based on modular SIMATIC hardware and software components. The innovative process control system is fully harmonized with TIA. It is flexible, expandable and open for future enhancements through the use of standard interfaces with long-term stability.

SIMATIC PCS 7 can be used on its own or in combination with Motion Control and further SIMATIC components.

SIMATIC PCS 7 consistently applies state-of-the-art, powerful technologies together with internationally established industrial standards such as IEC, XML, PROFIBUS, Ethernet, TCP/IP, OPC, ISA S88 and ISA S95, to mention just a few. The openness of SIMATIC PCS 7 covers all levels and applies equally to automation systems, process I/Os and field devices as to operator and engineering systems, industrial communication networks or the SIMATIC IT framework. Furthermore, the system offers completely integrated function blocks for motors, valves and control devices.

High performance, flexibility and ease-of-use, together with common data management, communication and configuration, guarantee that the typical demands placed on a process control system can be met and exceeded by SIMATIC PCS 7: Simple and safe process control Intuitive operation and visualization Powerful system engineering tools with a common interface simplify the engineering and save money throughout the entire plant life-cycle Online modifications possible throughout the system System openness at all levels makes plant enhancements easy Redundancy at all levels makes high availability scalable to your needs Flexibility and scalability simplifies plant improvements Automation solutions avoid any injury to humans and damage to equipment and provide high process availability at the same time Comprehensive fieldbus integration makes the connection of field devices easy and optimizes the handling Direct interfacing to the IT system opens the DCS.

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Maximum plant availability, with overall redundancy through all levels Availability is one of the most important criteria in a chemical production, and consequently the availability of the automation solution itself plays a key role in the economical effectiveness of the plant. On the one hand the capital investment for a chemical plant is extremely high, and on the other hand, any production loss due to shut-down and start-up operations can imply huge economical loss. Plant shut downs must then be avoided as far as possible – with periods usually reaching from once a year to less than one shut-down every 5 years for example for a steam cracker. To guarantee the highest availability of the automation system, all system facettes have to be taken into consideration: starting from the controllers up to the operator level and including the whole plant communication networks, from the field to the production control level.

Depending on each of your specific requirements, environmental and vulnerability aspects of your plant, TIA and SIMATIC PCS 7 can provide you the best adequate redundancy configuration. Based on a flexible, comprehensive concept we can offer up to the highest availability levels, seamlessly integrating all plant levels, from the sensor/actuator to the control room – while responding to the harshest Chemical Industry environment conditions. Operator stations (OS) and batch clients Operator station bus level (terminal bus): • Use of standard off-the-shelf components (switches, cards etc.) • Increased availability, with single ring architecture or terminal bus split into several LAN segments Multi-monitor operator stations, up to 4 monitors per client Batch client/server architecture, permitting up to 32 OS/SIMATIC BATCH clients to access the data of a single OS/Batch server.

Redundant OS clients and SIMATIC BATCH clients

OS- and batch servers

OS-LAN (Ethernet) segment 1

OS-LAN (Ethernet) segment 2

OS server

Redundant OS server, with automatic and transparent switch-over of the OS client stations, between primary and backup server Redundant batch server

BATCH server

BATCH server

Double redundant Industrial Ethernet plant bus

Process data can be archived on each OS server or can be stored on a standalone, and optionally redundant, plantwide historian Critical OS/SIMATIC BATCH running as a background task on the server are continuously monitored for faults that would result in a client switchover

S7-400H high-availability automation system optionally with redundant power supply ET 200M

Actuator/Sensor

Process data and alarm messaging archives can be automatically synchronized when a partner server is returned to service, thus eliminating data gaps.

Redundant PROFIBUS DP

ET 200M

ET 200M fail-safe

Redundant DP/PA Link

PROFIBUS PA

Y-Link Connection of non-redundant PROFIBUS DP devices on redundant PROFIBUS DP

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Automation system and plant bus Dedicated Ethernet LANs for client-server and server-server communication Communication between automation systems, engineering stations, operator systems over Industrial Ethernet plant bus, at up to 1 Gpbs; both line or ring topology possible Increased availability with redundant ring architecture Redundant, high-availability S7-400H automation systems, connected to plant bus over dedicated Ethernet communications processor (CP) Optionally, for even higher level of redundancy, each of the 2 automation station CPUs can be connected via two separated CPs, thus each CPU to be connected simultaneously to both networks of redundant plant bus architecture. Redundancy at the distributed I/O level Multiple PROFIBUS DP segments can either be connected to distributed I/Os via the onboard PROFIBUS DP interfaces, or using additional PROFIBUS communications processor modules Using the ET 200M distributed I/O system, redundancy can be extended down to the I/O module level, whereby a single sensor/actuator can be connected to redundant I/O modules Using redundant controllers, each ET 200M unit is connected to the redundant PROFIBUS DP segments. Redundancy of field devices Intelligent field devices on PROFIBUS PA fieldbus segment can be connected via a redundant DP/PA link Non-redundant PROFIBUS DP devices can also be connected to a redundant PROFIBUS DP network segment, using our Y-link.

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Asset Management for systematic automation and maintenance of plants Siemens offers an efficient solution for plant maintenance: SIMATIC PCS 7 Asset Management. The particular highlight here is that the new feature is simply integrated into the SIMATIC PCS 7 process control system. No additional hardware or software tools are required. Plant operators and maintenance engineers use the same SIMATIC PCS 7 tools and operator interfaces with information that has been filtered and prepared for the relevant application area. Complete integration of field devices SIMATIC PCS 7 is optimized for integration of distributed field equipment into the process control systems, and is based on PROFIBUS technology. It supports redundancy and failsafe architectures, in addition to online expansions, and can be used in standard environments or in hazardous areas. The plant can be equipped with conventional SIMATIC ET 200 distributed I/Os, or with state-of-the-art, intelligent field devices.

SIMATIC IT: the basis for increased productivity

Maintaining a highly flexible and efficient production process allows chemical manufacturers to maintain market position and deal with competition. SIMATIC IT is the Manufacturing Execution System from Siemens. It enables chemical manufacturers to optimize production. This is possible by bridging the gap between business systems and the control level and by synchronizing operations all along the production and product life-cycle. SIMATIC IT offers integrated quality assurance, product specification management, tracking and tracing and comes with functionality specifically tailored to the needs of the Chemical Industry, complying ISA-95 standard. MES – Manufacturing Execution System SIMATIC IT SIMATIC IT links the plant floor with the business systems and increases plant visibility. Due to its modular, object oriented, open and scaleable architecture, SIMATIC IT enables customers to standardize repeatable processes at the production level while increasing flexibility at the operational level. SIMATIC IT Production Suite is composed of the SIMATIC IT Framework and SIMATIC IT Components. These components include MES functionality for order management, material management, personnel management, report management and messaging. SIMATIC IT Framework provides the graphical environment to model the production process, allowing for a clear understanding of the plant’s behavior and visualization of the production.

SIMATIC IT Historian is a collection of software modules to collect, store and quickly retrieve process and production information for Quality Assurance, Reporting, Certifications, Statistical Analysis, Performance Monitoring, Down Time Management, Overall Equipment Effectiveness (OEE) etc. SIMATIC IT Historian delivers business information for decisionmaking and plant optimization and complies with the FDA’s 21 CFR 11. SIMATIC IT Historian is part of SIMATIC IT or can be implemented separately. SIMATIC IT Interspec is the specification management system that handles product specifications for raw materials, semi-finished and finished products, as well as packaging materials. This incorporates company-wide specifications as well as individual specifications for a single plant, supplier or customer. SIMATIC IT Interspec can be implemented separately or as integrated part of SIMATIC IT. SIMATIC IT Report Manager is an optional component of SIMATIC IT and offers advanced, fully integrated and userfriendly reporting functionality. The Report Manager meets regulatory requirements for standard and ad hoc reporting (for example, the upcoming REACH and Global Hazard Classification System) and offers valuable operational insights.

SIMATIC IT Unilab is the Laboratory Information Management System that models and manages the complete workflow of all quality data in the laboratory and on the production line, optimizing the collection, analysis, retrieval and reporting of laboratory data. SIMATIC IT Unilab is able to manage all types of analysis in a lot of languages and helps organizations to deal with critical issues in communication between the laboratory and customer service, by making it easier to share information with internal as well as external customers. SIMATIC IT Unilab complies with regulatory rules such as FDA (cGMP, GLP, 21 CFR 11), GALP, GAMP4, ISO 9000:2000, and ISO17025.

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SIMATIC S7: the comprehensive range of controllers – highly reliable and powerful SIMATIC S7 controllers provide network communication, IT service functionality etc. with the help of highly efficient operation processing, flexible communication extension and reliable, powerful control capabilities. That is why SIMATIC S7 controllers have the highest global market share.

SIMATIC S7-400: powerful, for system solutions in chemical plants With a large memory, high quantity of I/O framework and an extremely high speed, they ensure high tech combined with economical benefits for any automation solution.

SIMATIC S7 controllers can be installed and operated in different environmental conditions, such as dry tropical, low temperature, humid tropical etc.

SIMATIC S7-400H: high-availability, guaranteeing maximum uptime

Our controllers meet the following standards: DIN, EN, IEC, UL certification, CSA certification, Class FM1 Sec.2; group A, B, C, D, temperature group T4 (°