process · sipat pat software for pharmaceutical applications case studies sugar industry 22...
TRANSCRIPT
Systems and Solutions for the Process Industry
processnews
12th edition July 2|2007
s
Partial Stroke Test:
ExtendingMaintenanceIntervalsBraumat PCS 7 andSitrans P at Ziemann:
Pilot Micro-brewery
Partial Stroke Test:
ExtendingMaintenanceIntervalsBraumat PCS 7 andSitrans P at Ziemann:
Pilot Micro-brewery
Faster, Fitter PharmaSystems and solutions for the pharmaceutical industry
Faster, Fitter PharmaSystems and solutions for the pharmaceutical industry
proce
6 12 22
The new production facility for influenzavaccine at GSK Biologicals in Dresden wasautomated using Siemens componentsand concepts
In just three weeks, Siemens installeda new process control system based on Simatic PCS 7 at JanssenPharmaceutica in Belgium
Simocode pro enables high plantavailability in the water treat-ment unit at a sugar refinery ofSüdzucker in Germany
process news 2/2007
Cover picture:Liquids & Creams Facility, Janssen Pharmaceutica
Photo: Wolfgang Geyer
Gla
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W. G
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3 EDITORIAL
4 NEWSContinuous monitoring of blood supplieswith RFID
USP purified water system upgrade for Puerto Rico plant
Simatic PCS 7 and switching system for printing plate production in China
New EU directive simplifies certification of process instruments
COVERPharmaceutical industry
6 Doubling CapacityExpansion of the GSK Biologicals site in Dresden
Pharmaceutical industry10 Answering the Need for Innovation
Interview with Marc Sohet, head of globaltechnical services at GSK Biologicals
Pharmaceutical Industry12 Added Value
Migration of the process control system to Simatic PCS 7 at Janssen Pharmaceutica
Pharmaceutical Industry14 Fitter, Faster Pharma
Innovation and expertise for the pharmaceutical industry
Pharmaceutical Industry15 Accelerating Pharmaceutical Innovation
Sipat PAT software for pharmaceutical applications
CASE STUDIESSugar Industry
22 Reliable at Full LoadMotor management with Simocode ensures system availability at Südzucker
Breweries26 Pilot Microbrewery
Braumat PCS 7 and Sitrans P in brewery pilot plant
Sensors28 An Eye for Detail
Vision sensors optimize company logistics at Zentis
Process Instrumentation30 Safe Control
Univar enhances operations with new level system
ess
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As partners to the pharmaceutical industry, we areliving in exciting times. New regulations, new tech-nologies, new products – all provide our customerswith many new opportunities. However, there are also new challenges. Increasing R&D costs as well asgreater competition in a globalized market requirecourage – the courage to rethink and take innovativeapproaches in development, production, and distri-bution. Reason enough to make our work in thepharmaceutical industry the focus of this issue ofProcess News.
We are proud to accompany our customers on thischallenging journey into the future, supporting themwith our expertise, experience, and technology. Forthis reason, we have expanded our product portfolioand consistently pushed ahead with the introductionof new technologies. And we are successful togetherwith our customers. In Dresden we implemented acomprehensive solution for GSK Biologicals for themanufacture of flu vaccines, and in Belgium we mod-ernized the process control technology within a shorttime using our Simatic PCS 7 process control system.These examples will be showcased in this issue, alongwith many other innovations and applications.
The growing importance of the pharmaceuticalindustry and also our commitment to it was docu-mented by impressive illuminated advertising in con-junction with our appearance at the most importantpharmaceutical event in the United States – Interphexin New York from April 24 to 26, 2007 – in the heart of New York City, in Times Square. For me as head ofthe Pharma Competence Center, this was a reason tolook back with pride and satisfaction on our perfor-mance. And, simultaneously, an incentive to use ourinnovative and proven technologies in the future tofurther help our customers achieve their goals.
I hope this issue of Process News can give you somevaluable ideas!
Simatic VS130-2 vision sensors read datamatrix codes on outer packaging at Zentisin Germany at high speeds and withreliable results
process news 2/2007
Wolfgang ScheidingHead of the Competence Center PharmaSiemens Automation and Drives
Dear Readers:
EDITORIAL
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TECHNOLOGIESProcess Automation
17 Simple, Modular, and FlexibleSimatic PCS 7 Lab: Automation system for experiments in process laboratories
Process Safety18 Extending Maintenance Intervals
The Partial Stroke Test as a module in the process safety concept
Advanced Process Control21 Focus on Control
Advanced Process Control solutions increase process controllability
Process Instrumentation24 Innovative, Robust, and Versatile
New products for process instrumentation
31 DIALOGUE
process news 2/2007
4 NEWS
A leading pharmaceutical company has chosenSiemens Water Technologies to supply a
turnkey USP (United States Pharmacopoeia) puri-fied water system upgrade for its biotechnologylaboratory in Puerto Rico. The US $1.1 millionproject will begin operation in April 2007.
The company is adding an additional system tothe two systems already supplied by Siemens in2003. Each automated train includes pretreatmentequipment and a reverse osmosis (RO) systemfollowed by a continuous deionization system.
The use of these hot-water-sanitizable tech-nologies allows the pharmaceutical plant to takewell water and reduce the conductivity, total or-ganic carbon, and bacteria levels to those requiredto validate the water as USP purified water. �
S iemens has collaborated with severalpartners to develop a solution for the
comprehensive monitoring of blood do-nations that is based on radio-frequencyidentification (RFID). In addition to makingtransfusions safer in the future by identify-ing blood via radio chips – virtually elimi-nating the possibility of mix-ups – the sys-tem is also equipped with a temperaturesensor that enables continuous monitoringof the cooling chain.
The new system’s RFID chips with tem-perature sensors are affixed to blood bags,and the blood temperature can be called up at any time using radio-equipped read-ing devices. The chips must be able towithstand extreme conditions. They mustundergo a sterilization and pasteurizationprocess during production, for instance, and are later subjected to a force of up to 5,000 g when being processed in a cen-trifuge. The Siemens RFID chips passed allthe required tests, and after the project iscompleted the appropriate authorities willevaluate them to determine their suitabili-ty for commercial use. The new system isscheduled to be ready for use in 2008.
Specialists at Siemens Automation andDrives in Nuremberg and Vienna, as well as
Continuous monitoring of bloodsupplies with RFID
Safe Transfusions
Identificationvia RFID chipsvirtuallyeliminates thepossibility ofblood supplymix-ups
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experts from Siemens IT Solutions andServices in Vienna, have been working onRFID labeling of blood bags for years.Siemens developed its new RFID temper-ature-sensor system in cooperation with
Schweizer Electronic, the blood bank ofGraz University Hospital, and the blood bagproducer MacoPharma. �
Find out more:www.siemens.com/water
Find out more:www.siemens.com/rfid
USP purified water system upgrade for Puerto Rico plant
Doubling Total Flow
process news 2/2007
Anew EU directive (MID Directive), whichcame into effect at the end of October
2006, aims at simplifying the free trade ofprocess instrumentation devices in Europe.It internationalizes and eases the approvalsprocedures by reducing the number of ap-provals required. Each process instrumen-tation device requires only one certificationto allow it to be used Europe-wide.
Internationally oriented customers inparticular will benefit from this directive ina number of ways. They can now use thesame process instrumentation device typein several countries. They also have moreprocurement alternatives and thereforemore options when attempting to select thebest and most cost-efficient device fromthose available.
Although the MID Directive is relativelynew, some companies have already speci-fied devices that will obtain approvals in ac-cordance with the directive. Siemens is oneof these companies, having already select-ed three of its flowmeters – Sitrans F M MAG8000 CT, Sitrans F M MAG 6000 CT, andSitrans FUS380. �
Kodak’s Graphic CommunicationsGroup (GCG) is one of the three mar-
ket leaders for offset printing plates; itsstrengths lie especially in the manufac-ture of modern “computer to plate” (CTP)printing plates. Kodak’s customers areprimarily large printers and publishingcompanies.
Kodak’s GCG contracted Siemens tosupply the PCS 7 process control systemand low-voltage switchgear for its Coat-ing Preparation Facility (CPF) – a subunitof the new facility for manufacturing off-set printing plates. In the manufacture ofoffset printing plates, an aluminum stripis first (electro)chemically treated and
then has a light- or heat-sensitive coat-ing applied in the CPF. The image is latertransferred onto this coating when im-aging the printing plate.
Kodak’s first printing plate line in Chi-na, owned by the Kodak China GraphicCommunications Company Ltd., is beingbuilt at an existing Kodak site in Haicang,a new special industrial estate in the cityof Xiamen in Fujian Province. What isunique about this project is that Siemensproducts are now being used for the firsttime on a large scale at this location thatis dominated by Siemens competitors.The Siemens engineering team fromFrankfurt am Main was already involved
in the initial basic engineering in 2004and has been entrusted with the detailengineering, the procurement of impor-tant subsystems, and the project man-agement for the integration of the sub-systems since August 2005. Assemblybegan at the end of 2006, and the sys-tem should begin operation in the sec-ond half of 2007. Siemens in Karlsruheis now also involved as a hardware andsolution provider. �
Simatic PCS 7 and switching system for printing plate production in China
Computer to Plate
Find out more:www.siemens.com/sp
New EU directive simplifies certification of process instruments
Open Market
At the Siemens test laboratory, the devices were prepared for theapprovals procedure according to the EU directive
5
Find out more:www.siemens.com/processinstrumentation
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Expansion of the GSK Biologicals site in Dresden
DoublingCapacityThe GSK Biologicals facility in Dresden is one of thecompany’s key plants for flu vaccine production. WhenGSK Biologicals decided in 2005 to double the productioncapacity in Dresden to 60 million doses per year, theproject had to be completed in record time to meet the deadline for the 2008/2009 flu season. Experiencedpartners and a solution based on proven systems andproducts from Siemens helped GSK Biologicals completethe modernization on schedule.
The new influenzavaccine productionfacility in Dresden willdouble the productioncapacity in Dresden to 60 million doses per year
process news 2/2007
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says Denis Fabris, senior project manager
in Dresden. “So we are talking about a com-
pletely new pharmaceutical production line
in addition to the existing plant.” The main
aim was, of course, to increase the bulk
manufacturing capacity and to increase the
capacity for filling syringes. However, this
project also offered an opportunity for GSK
to improve both the process and the pro-
duction practices.
A major challenge during the expansion
was the tight schedule. In order to be able
to produce the first commercial batch in
time for the flu season of 2008 and 2009,
the plants had to be built in about 20 per-
cent less time than is usually required for
such a project. Denis Fabris explains: “The
F lu vaccines are produced in a com-
plex, multistage process. Traditional-
ly, influenza vaccines are produced
in fertilized chicken eggs. Eleven days
after fertilization, the influenza virus – each
strain is grown separately – is injected into
the eggs and accumulates in the fluid sur-
rounding the embryo. A high-yielding
donor strain is co-injected. The embryo be-
comes infected so that the virus can multi-
ply. After several days of incubation, ma-
chines open the eggs and harvest the virus.
Then the virus is carefully purified, chem-
ically inactivated, and used to produce the
vaccine.
Dresden is GSK Biologicals’ center of ex-
pertise for flu vaccine production, offering
the required know-how and technology, so
when the company decided to increase its
capacities for flu vaccine, expanding the
facility in Dresden was the logical choice.
Challenges and opportunities
The expansion work in Dresden comprised
building a totally new production line for
everything from egg inoculation to inacti-
vation, including inoculation and harvest-
ing units, incubators, ultracentrifuges, and
units for ultrafiltration and storage vessels.
“We also increased the boiler capacity for
industrial steam, and we have our own elec-
trical substation, air compressor, water
production, black and clean utilities, a lab-
oratory, a warehouse, and related offices,”
process news 2/2007
8Pharmaceutical Industry
COVER
Parts of the automation solution in Dresden use the component-based automation approach, a comprehensiveconcept for drug manufacturing that reflects the followingrequirements of the pharmaceutical industry and the OEMs:
B Scalability and modularity B Suitability for different equipment typesB Horizontal integration of linesB Vertical integration (e.g., for reporting or OEE) B Open industry standards B Compliance with GMP regulations
Each OEM can equip its machine with either a Simatic or aSimotion controller, scalable for the individual functions thatit needs to perform. Local operation and visualization of amachine are realized using the SCADA software WinCCflexible. Each machine can be separately developed and GMPqualified on its own.
Using Profinet and component-based automation, allmachines are horizontally integrated very rapidly and effi-ciently and linked to a central WinCC SCADA system for linesupervision, batch management, and equipment statusoverview.
The use of open communication standards also allows theintegration of third-party components. Vertical integrationwith the plant’s enterprise resource planning (ERP) system isperformed by a manufacturing execution system (MES) thatlinks the data collected from the production lines withenvironmental control data.
The ERP, MES and central SCADA systems together deliverall the needed functionalities for improved manufacturingperformance, built-in quality, and an optimized supply chainin the drug manufacturing plant.
The package units exploit thecomponent-based automationconcept from SiemensG
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Component-based automation in pharmaceutical production
prerequisites for all our projects are quali-
ty and safety. For me as a project manager,
the challenge was to build a new plant
meeting these stringent requirements in
a very short time. Consequently, we devel-
oped a strategy to shorten the project
phase, with one focus on shortening pro-
curement activities by using a standard
solution from Siemens.”
Proven solutions and experiencedpartners
The construction began in August 2005
with more than 250 construction workers
on the site in two-shift operation during
the peak construction time. The structural
work was completed in June 2006, and GSK
Biologicals is currently in the operation
qualification phase. After that, the facility
will undergo performance qualification
with eggs and produce a consistent lot
to demonstrate that production quality is
strictly stable. Production of the first com-
mercial lot is scheduled for March 2008,
so that the vaccine can be delivered to doc-
tors and patients in September 2008 when
vaccinations begin for the upcoming flu
season.
Siemens was involved in this project at
several levels. Siemens was directly con-
tracted to implement a uniform building
management system for all production-
related air-conditioning units and utilities,
including project management, software
engineering, and hardware supply. This
system is based on Desigo PX. Siemens was
also contracted to automate the air-condi-
process news 2/2007
9
Process instrumentation for pharmaceutical production
For another project at GSK Biologicals, Siemens was awarded thecontract to automate key parts of a vaccine plant, including the air-conditioning and various supply units (utilities), and also to deliverthe process instrumentation for the utilities.
Measuring tasks for the project included controlling and moni-toring levels, temperatures, pressures, and flow rates as well as pHand conductivity values in tanks and vessels. Measuring mediainclude fluids such as glycol water, cooling water, deionized water,industrial water, city water, and others.
From the wide range of Siemens process field instruments,numerous different device types can be used to perform thesemeasuring tasks, for example, the Sitrans LC 500, which is de-
signed for operation under extreme and critical process condi-tions.
Siemens offers a comprehensive line of process instrumenta-tion products for pharmaceutical applications:B Pressure: Sitrans PB Temperature: Sitrans T KB Flow: Sitrans F O flowmeterB Level: Sitrans CLS 200 inverse frequency shift capacitance
switch and Sitrans LC 500 inverse frequency shift capacitancelevel controller
B pH: Sipan pH liquid analyzerB Conductivity: Sipan Cond liquid analyzer
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tioning system for the incubators, which
are one of the most critical components of
vaccine production. The chicken eggs that
are being incubated require strictly con-
trolled ambient conditions.
Another important part of the Siemens
contribution was implementation of the
automation concept for the package units
in the vaccine production line. The concept
uses the component-based automation
approach based on Profinet and Simatic
technology, in which package units are de-
signed as completely validated units that
need only be connected to the plantwide
Profinet network via a specified interface.
This approach helps facilitate the integra-
tion of package units supplied by different
vendors and significantly reduces the work
required for validation (see box).
With GSK Biologicals, Siemens defined
the system standards and performed a
proof of concept on a prototype. After that,
Siemens specified design guidelines for all
OEMs involved in the project for the types
of hardware and system software to be ap-
plied in the automation of package units.
These guidelines also specified the data
flows between the package units and the
production data management system and
the interface to the environmental and
alarm monitoring systems as well as be-
tween the package units via Profinet.
Siemens supported both OEMs and the sys-
tem integrator in implementing the auto-
“The challenge was to build a new
plant meetingthese stringent
requirements in avery short time.”
Denis Fabris, GSK Biologicals senior project
manager in Dresden
�
process news 2/2007
10Pharmaceutical Industry
COVER
need a certain amount of time to develop a
product, to build a facility – and all the
while the product itself is still going
through the clinical trials. Obviously this
can cause problems, because even if you
have a new product, you still need a lot of
time before you can go to market. This costs
a lot of money, and you need a strong com-
pany to sustain such a process. A vaccine is
a biological product, and as such it is very
difficult to characterize. So to produce a
vaccine, the process has to be robust in or-
der to ensure the quality of the product.
This is also important for inspections: we
have to prove to the inspectors that we are
in full control and have full knowledge of
our process. We have to know what is be-
hind, for example, a signal lamp. We need
full system transparency to prove that our
process is robust.
Because a vaccine is an injectable prod-
uct, the conditions have to be as perfect as
possible, and any contamination has to be
avoided. In vaccine production, the staff is
a main source of possible contamination, so
you need a high level of containment be-
tween the personnel and the process – and,
of course, you need space. So what we need
is innovation – to reduce costs, but mainly
to reduce contamination.
Interview with Marc Sohet, head of global technical services at GSK Biologicals
Answering the Need for InnovationSeizing market opportunities in the vaccine business requires a strong company, not only to finance research anddevelopment but also to support time- and capital-intensive investments in new facilities. Moreover, vaccineproduction requires robust, fully controllable processes. According to Marc Sohet, his company views innovationas the key to solving these challenges – together with innovative and reliable partners.
Mr. Sohet, the vaccine market is currently
growing strongly, with a projected growth
of more than 10 percent per year until
2012. How do you intend to seize these
opportunities?
Marc Sohet: In order to grow in our busi-
ness, you have to plan five years ahead. You
Publ
icis
“In order to grow in our business,you have to planfive years ahead.”
Marc Sohet, head of global technical services at GSK Biologicals
mation solution. The system integrator
on/off engineering was responsible for the
integration of the package units. “We are al-
so very satisfied with this aspect of the proj-
ect implementation,” says Denis Fabris.
The plant is equipped with Siemens sys-
tems throughout. More than 50 Simatic S7
PLCs are installed in the various systems at
the Dresden facility, and Simatic WinCC and
Simatic WinCC flexible are used as visuali-
zation systems. Siemens also supported
GSK Biologicals with a broad range of ser-
vices – for example, installation, commis-
sioning, validation, and computer ac-
ceptance test consulting – and provided ex-
perienced personnel to support GSK
Biologicals during staff shortages.
Dedicated to success
The project is on track for the scheduled
production start-up. Thanks to the consis-
tency of the technology and solutions im-
plemented, the GSK staff is already trained
on the Siemens systems, which accelerates
commissioning. “The project is not yet fin-
ished,” says Fabris, “but so far, the collab-
oration has demonstrated a very positive
spirit. Of course, we have had some diffi-
culties and challenges, but they are being
resolved systematically.” Denis Fabris is
quite confident that the project will be
completed on time: “Siemens clearly wants
to make this project a success. When you
have this positive spirit on a project, there
is little doubt that the result will be positive
as well.” In the meantime, additional joint
projects between GSK Biologicals and
Siemens have been initiated in Belgium
and France that will also benefit from the
standardized approach implemented in
Dresden. �
Doubling Capacity
Find out more:www.siemens.com/pharmaE-mail: [email protected]
process news 2/2007
11
What role does automation play
in this context?
Marc Sohet: Our vision for vaccine pro-
duction is a closed process in which there
is no interaction with the vaccine and its
environment – especially by personnel.
Such a process requires a high degree of au-
tomation. With regard to automation, there
are many areas of improvement where new
technologies can be introduced, for exam-
ple, Process Analytical Technology. We want
to focus on our core expertise, so we expect
our suppliers to support us in maintaining
the site – that includes technology, spare
parts, and consulting, but also training at
the site level.
Also, whenever we are building a new fa-
cility, we have to deal with the specific re-
quirements of the product and the process.
We never do the same thing twice. What we
need are contractors who understand the
complexity of the project and the complex-
ity of what we do – and who can add agility
to the process, not only in order to act
quicker, but also to understand quicker and
to present a new solution quicker. As our
facilities are quite large and very complex,
implementing a new production facility is
like trying to navigate with a very large
ship. We have many interfaces with exter-
nal parties, and due to that we have many
uncertainties and many changes.
Do you see Siemens as a partner that can
help you maneuver those large ships?
Marc Sohet: From my experience, I would
say yes. One important factor for us is the
broad range of solutions Siemens offers.
Siemens is not only a supplier of automa-
“For us, the price is not the decisiveissue – we arelooking at the totalcost of ownershipand all aspects ofthe relationship.”
tion technology, but also of building
technology and communication technol-
ogy, and is also providing the full range
of services, spare parts, and so on.
Siemens has a large research department
and is a leader in technology – also
through its shares in many leading com-
panies – and offers a good global net-
work. It is beneficial for us to work with
such a company.
Of course, the high-quality products
that have become a de facto standard so-
lution for many OEMs and other compa-
nies besides ourselves are also an impor-
tant factor in our decision to work with
Siemens. Overall, I would say that for us
the price is not the decisive issue – we are
looking at the total cost of ownership and
all aspects of the relationship.
So Siemens is a strategic partner for your
company?
Marc Sohet: Definitely. Siemens is a
partner in automation and especially in
innovation – for example, RFID (radio-
frequency identification). This is a tech-
nology that is especially important in
tracking the logistics chain of a vaccine
– to show that our product has been
correctly handled during transport, stor-
age, and so on until it has reached the
customer – as well as with respect to
counterfeiting, tampering, and modifi-
cations.
I have already mentioned Process An-
alytical Technology (an area in which
Siemens is also active), which is one pos-
sible way to improve our processes. An-
other new development in our processes
will be the disposable process in which
the active pharmaceutical product is pro-
duced in single-use process containers,
and for that we have to develop new com-
ponents, which, of course, will include
sensors and automation solutions.
Another area in which we would like to
see some improvements concerns stan-
dard interfaces between systems and
equipment so we can pick best-of-breed
solutions from various suppliers and link
them. And we want to develop new and
improved strategies for automation, be-
cause, as I mentioned before, we want to
achieve a closed process. So automation
and Siemens will continue to be of inter-
est to us in the future, too.
Thank you for speaking with us. �
�
process news 2/2007
12Pharmaceutical Industry
COVER
weeks to avoid the risk of running out of
market stock. Consequently, choosing the
right partner for this project was crucial.
Janssen wanted to keep the existing re-
mote I/O devices in place and replace only
the automation and operator systems. As
Siemens had supplied the existing process
control system, Janssen invited Siemens to
participate in the tender. After extensive
considerations, Janssen Pharmaceutica de-
cided that Simatic PCS 7 Version 6 would be
the best solution for the plant at Beerse.
Detailed study for smooth transition
Planning was everything during this
project, as Janssen Pharmaceutica senior
project manager Kris Buys confirms: “It is
essential to work out a detailed project ex-
ecution plan and project qualification strat-
egy, including documentation, and that all
work during the shutdown be planned ex-
actly in order to be able to complete the fac-
tory acceptance test.”
In the second quarter of 2004, Siemens
performed a detailed project study. The
project team defined the functional speci-
fications, software and hardware design,
and coding and internal testing. This study
also included the user requirement speci-
fications, a detailed validation plan, and a
The Beerse L&Cr liquids and creams
plant produces a wide variety of prod-
ucts for treating diverse disorders and
infections. The Beerse site comprises pilot
plants, secondary units, and research and
development facilities. The L&Cr plant pro-
duces about 50 different products and
processes 5,000 orders per year.
Batch production in the multipurpose
facility goes through several stages and is
equipped with a clean-in-place system. Wa-
ter, raw materials, and bulk ingredients are
mixed in a boiling vessel and a processing
unit. Then they are transferred to holding
and buffering tanks before the semi-
finished product is transferred to the sec-
ondary unit for finishing and packaging.
A new core
The existing process control, based on
Simatic S5 controllers and the Coros LS-B
supervisory system, had not undergone a
major upgrade in 12 years, and some sys-
tem components were approaching the end
of their service life. Consequently, in 2003,
Janssen Pharmaceutica decided to mod-
ernize the system and replace the automa-
tion level with a new solution. The compa-
ny also wanted the new system to provide
possibilities for future expansions and up-
grades, as the frequency of control system
upgrades is expected to rise. Additionally,
the new system was to be capable of linking
with the higher-level manufacturing exe-
cution system (MES) and enterprise re-
source planning (ERP) system.
The major challenge for the system mi-
gration, however, was the very tight time
frame for the conversion. The production
shutdown period was not to exceed three
Migration of the process control system to Simatic PCS7 at Janssen Pharmaceutica
Added ValueIn just three weeks, Siemens installed and commissioned a new processcontrol system at the liquids and creams plant of Janssen Pharmaceuticain Beerse, Belgium. Detailed preparation and an experienced projectteam were the decisive factors in completing this challenging project –and the entire validation and qualification of the new system – in thistight time frame.
Project highlightsB Migration of process control
system for multipurpose batch
production facility
B Tight time frame of only three
weeks for the migration
process news 2/2007
13
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risk and 21 CFR Part 11 assessment. Siemens
was also responsible for the detail engineer-
ing, including GxP and business-criticality
analysis, evaluation of various solutions and
migration approaches, and updating and
finalizing the user requirement specifi-
cations and the final tender document.
In mid-2005, the execution phase of the
new solution implementation was initiated.
Siemens took on the engineering of the
new system hardware, including installing
and commissioning the system on-site in
Beerse, and was also responsible for the op-
erator training. Siemens also provided val-
idation support and compiled the docu-
mentation for qualification and validation.
To mitigate the risks associated with the
migration, Siemens performed a pretest of
the new system during the Christmas
break. The new PCS 7 system was connect-
ed to and tested with all types of I/O devices
to make sure there would be no problems
during the real shutdown.
Experienced partners
All systems were up and running before
the final project deadline of August 1, 2006.
This success was made possible by the ex-
cellent preparation and good team effort,
as Kris Buys recalls: “The shutdown period
was very intense. During one weekend, the
team took the old system out and put all the
new systems in, so we had an operational
system for the testing and qualification pro-
cedures after just one weekend. And the re-
sult was very positive: after the system went
into operation, we did not have even a sin-
gle major incident. This was, of course, due
to the excellent combined preparation of
Janssen and Siemens.”
The project team from Siemens also in-
cluded individuals who had already imple-
mented the old Simatic S5 / Coros LS-B sys-
tem and who were familiar with both the
plant and the control system. “For us, this
was a major added value,” says Buys. He
was also quite impressed with the quali-
fication and validation support: “Siemens
provided us with a very good qualification
file that was very defensible with the FDA –
which, of course, is very important.” �
In the liquids and creams plant, about50 different products and 5,000 ordersper year are processed in multistagebatch processes
Local operation is enabledby Simatic Panel PCs
Find out more:www.siemens.com/pharmaE-mail: [email protected]
New system architecture B Production
B 1 batch Server + batch API for CIP scheduling
B 1 redundant PCS 7 server with 250,000 variables (in use: +/- 170,000)
B 1 engineering station (unlimited license)
B 1 redundant domain server B Simatic Logon/Electronic Signature
B 19 PCS 7 clients B 8 OS clientsB 11 Panel PCsB 6 AS 417 stations
B Test StationB 1 PCS 7 server/batch serverB 2 AS417 stationsB 1 Panel PCB 1 OS client
process news 2/2007
14Pharmaceutical industry
COVER
The challenges the pharmaceutical in-
dustry is facing require a partner that
can offer both established industry
knowledge and a broad, versatile, and glob-
ally available portfolio. This partner must
also be in a position to help the industry
meet future challenges.
Siemens has always provided its cus-
tomers with excellent support in this con-
text, having consistently extended and ex-
panded its product line for the pharma-
ceutical industry. Automation solutions
from Siemens have been applied with great
success in the pharmaceutical sector. One
recent example of this is an order from
Janssen Pharmaceutica. The company,
owned by Johnson & Johnson, will use
Simatic PCS 7 in a new chemical develop-
ment pilot plant.
Solutions for API production
Simatic PCS 7 provides comprehensive
functionality for the rapidly growing sector
of biotech production in particular, and
offers a high degree of scalability. The most
recent product is Simatic PCS 7 Lab, which
now enables processes to benefit from a
universal automation platform from the
laboratory to production. In blood fraction-
ation – carried out in part using high-per-
formance systems with more than 20,000
I/O devices – Simatic PCS 7 is applied in
plants of all major players in this segment,
making it the de facto market leader.
Integrated concept for drugmanufacturing
The concept for drug manufacturing com-
bines the efficient automation of diverse
production machines (for example, with
Simatic and Simotion components) with
their simple integration into production
lines and entire plants via systems such as
component-based automation (CbA) and
Simatic IT. The unique flexibility of the hor-
izontal and vertical integration facilitates
the universal control and optimization of
the production processes – a crucial ad-
vantage that increases competitiveness.
Versatile expertise and innovation
Siemens is simultaneously strengthening
itself by acquiring industrial partners that
are specifically certified for work with the
pharmaceutical industry. In order to offer
its customers the best service at reasonable
prices, Siemens has established a partner
program. Siemens is currently working
with approximately 20 partners in Europe,
Asia, and the United States – and this
network will be further expanded in the
future.
Innovation plays a central role in the
pharmaceutical product line. From the
outset, Siemens has supported the devel-
opment of Process Analytical Technology
(PAT) as a key to continuous manufacturing
and, with Sipat, is now making a flexible
platform for PAT available. Tracking and
tracing solutions, with both RFID (radio-
frequency identification) and 2-D matrix
code, are another innovative focal point, as
are solutions for new process variants such
as Siprocess in microreaction technology
and new process concepts using disposable
equipment. This ongoing development of
its product line ensures that Siemens will
continue to be a partner that provides the
right solutions for fitter, faster pharma. �
Find out more:www.siemens.com/pharmaE-mail: [email protected]
Innovation and expertise for the pharmaceutical industry
Fitter, Faster PharmaGrowing with the customer – Siemens has committed itself to this motto for its customers in the pharmaceuticalindustry, and for years it has continued to develop its portfolio of pharmaceutical products, systems, and solutions.
The billboards onTimes Square markingSiemens’ appearanceat Interphex alsounderline Siemens’strong commitment tothe pharmaceuticalindustry in the UnitedStates
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15COVERPharmaceutical Industry
R egulatory and financial forces are
pushing pharmaceutical manufac-
turing toward rapid change. PAT
represents an exceptional opportunity
for pharmaceutical companies to improve
manufacturing performance, reduce man-
ufacturing costs, reduce time to market,
and improve supply chain responsiveness.
PAT allows companies to design quality
into the process and move to real-time
product release.
The scope for process improvement in
many aspects of pharmaceutical manufac-
turing is considerable. The US Food and
Drug Administration (FDA) has noted that
the potential worldwide cost savings from
efficiency improvements could be as high
as US $90 billion, which is equivalent to the
cost of developing 80 to 90 new drugs
every year.
Regulations as a driver for change
The pharmaceutical industry has been slow
to adopt PAT in the past, in large part be-
cause regulation based on off-line batch
inspection slowed progress toward more
innovative continuous in-line manufactur-
ing. Now, however, the regulatory land-
scape has changed. The FDA is engaged in
a major drive to encourage the spread of
PAT as part of its quality initiatives and
cGMPs (current Good Manufacturing Prac-
tices) for the 21st century. The FDA’s PAT
guidance emphasizes the agency’s belief
that significant opportunities exist for
improvement and innovation in pharma-
ceutical manufacturing by moving from
empirically derived trial-and-error meth-
ods to rigorous mechanistically based and
statistically controlled processes.
Part of the PAT approach: Sipat
Siemens has been closely involved in moves
by the FDA and the European Medicines
Agency (EMEA) to encourage the adoption
of PAT in drug manufacturing. Now this
work is being given a boost with the launch
of the new Sipat software that was devel-
oped and piloted by Siemens as part of a PAT
project at the Dutch vaccine institute NVI.
The project, in collaboration with Ap-
plikon Biotechnology and the NVI, and sub-
sidized by the Dutch government, began in
2003. The start roughly coincided with the
release of the FDA’s draft guidance on PAT,
which gave the project both impetus and
wider importance. “This meant that from
the start of the project, the regulatory cli-
mate was rapidly evolving toward a situa-
tion that would allow the exact same ap-
proach to process development and manu-�
Sipat PAT software for pharmaceutical applications
Accelerating Pharmaceutical InnovationSiemens is using its considerable experience in the application of Process Analytical Technology (PAT) in industries suchas food and beverages and the chemical industry to help accelerate change in pharmaceutical manufacturing. With thelaunch of the Sipat software suite, Siemens is applying its expertise to assist pharmaceutical companies in theirimplementation of PAT.
process news 2/2007
16Pharmaceutical Industry
COVER
Vaccine cultivation breakthrough
Using this system, the NVI is now building
a process model addressing all the critical
process attributes for the cultivation of
the Bordetella pertussis bacterium. This
process step is the most critical step in the
manufacturing of a vaccine against whoop-
ing cough. The project team intends to use
the knowledge gained in this project to im-
plement PAT in other cultivation processes
at the institute (e.g., tetanus, diphtheria,
polio), but also in other unit operations
such as freeze-drying. Mathieu Streefland
sums up the initial results: “The project has
given the NVI a head start in the PAT field
for biopharmaceuticals, and we strive to
keep it that way.”
A big leap toward “right first time”
Sipat will significantly assist pharmaceuti-
cal companies in their implementation of
PAT. Sipat is scalable and modular, allowing
controlled growth as a company’s PAT
initiative expands. The software is able to
interface with existing manufacturing ar-
chitecture, allowing full transparency of
quality-related issues from the unit opera-
tion level up to enterprise resource plan-
ning (ERP), manufacturing execution sys-
tems (MES), and laboratory information
management systems (LIMS). With Sipat,
pharmaceutical companies are now able to
achieve greater process understanding,
strive for continuous process improvement,
develop processes based on “quality by de-
sign” principles, and manufacture “right
first time.” The use of Sipat in combination
with the right PAT tools will enable phar-
maceutical companies to improve manu-
facturing performance, reduce manufac-
turing costs, reduce time to market, and
improve supply chain responsiveness. �
facturing control that we wanted to investi-
gate in this project. The outcome is what we
believe the very first automation system
capable of developing and executing full
PAT cultivation processes,” states Mathieu
Streefland, project leader at the NVI.
The Sipat software enables the full inte-
gration of all information flows during pro-
cessing and online comparison of this
process data with historical data. This
means the institute is able to integrate lab
models with sophisticated Near Infrared
(NIR) measurements, as well as data that
are gathered by taking samples, to build a
full process model. The NVI hopes to use
such a model to monitor process perfor-
mance, predict process end points, and, of
course, predict end-product quality.
Find out more:www.siemens.com/sipatE-mail: [email protected]
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The Sipat software enables the full integration of all information flowsduring processing and online comparison with historical data
�
Main benefitsImplementing PAT offers a high return
on investment. Sipat offers significant
business benefits:
B Cost reduction
B Improved quality
B Shorter time to market
B Larger market share
B Improved company image
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process news 2/2007
17TECHNOLOGYProcess Automation
L aboratory experiments are an impor-
tant step in process development and
define central properties of a process
for the large-scale application. Conducting
the experiments necessary for the process
development can already at this stage be
simplified by process automation. A major
prerequisite is that the process automation
be designed, above all, simply and flexibly.
Employees with no special knowledge of
the handling of process control systems
must also be able to add a measuring point
or change a configuration.
Flexible solution
With Simatic PCS 7 Lab, Siemens presents
a control solution for laboratories that is
smoothly integrated into the Simatic PCS 7
process control system environment and
is also flexible and user-friendly.
Simatic PCS 7 Lab uses Simatic compo-
nents so that the control solutions can be
transferred easily during process scale-up.
The system consists of a processing module
based on Simatic PCS 7 Box with automa-
tion, an operator and engineering system,
and an input/output module that acquires
signals from the laboratory instruments
and sends them to the processing module.
More safety, more productivity
With Simatic PCS 7 Lab, the process de-
velopment in the laboratory can also ben-
efit from the advantages of a sophisti-
cated control system. Automated routines
and integrated parameter logging make
the experiments reliably reproducible and
the results safely verifiable. The system
monitors the configured limit values and
reliably triggers alarms when they are ex-
ceeded – but also in other unforeseeable
situations – thereby ensuring greater pro-
ductivity.
Because Simatic PCS 7 Lab also enables
remote monitoring and intervention, the
process technician does not need to be
present. And because the automation
methods are easily transferable, other
processes benefit directly from the pre-
liminary laboratory work in the process
scale-up. �
Simatic PCS 7 Lab: Automation system for experiments in process laboratories
Simple, Modular, and FlexibleWith Simatic PCS 7 Lab, Siemens has developed a control systemsolution that effectively supports development in process engineeringlaboratories. Automatic routines and uncomplicated engineering makeit easier to conduct experiments quickly and reproducibly.
Find out more:www.siemens.com/pcs7www.siemens.com/chemicalsE-mail: [email protected]
Main benefitsB High reliability with automation
B Reliable control and monitoring ofreactions with integrated managementand safe handling of alarms
B Rapid assembly/reassembly andcommissioning using plug connections
B Simple methods for evaluating measureddata using export features
Simple design: Laboratory instrumentscan be connected to the input/outputmodule using plug connections
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process news 2/2007
18Process Safety
TECHNOLOGY
Operational safety is a centralfunction of process instrumentationand automation in the chemicalindustry. These systems must alsosimultaneously guarantee continuousoperation of the plant. Siemenssupports its customers in fulfillingboth of these requirements byproviding a comprehensive range ofintegrated solutions for processsafety. One example of this support is the Partial Stroke Test for valves.
koep
pel p
hot
oDes
ign
Partial Stroke Test at INEOS Paraform in MainzINEOS Paraform has been using solutions from the Simatic line, including Simatic Safety
Integrated, for some time. At its site in Mainz, Germany, a large formaldehyde plant is
controlled and monitored by Simatic PCS 7.
INEOS Paraform is always looking for innovative ways to further optimize its processes,
increase process safety, and reduce maintenance costs. That is why the company decided
to implement the new Partial Stroke Test (PST) concept from Siemens as a pilot customer.
The concept was implemented at INEOS Paraform’s tank farm in Mainz and subjected
to comprehensive testing. The results of the pilot application were very positive, as
confirmed by Richard Frey, who is responsible for monitoring and control technology:
“By reducing the time spent on the annual tests of the safety circuits, we see excellent
application opportunities for this solution, in particular at our continuously operating
plants, where downtime is infrequent and brief.”INEOS Paraform is the pilot customerfor the Partial Stroke Test concept
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The Partial Stroke Test as a module in the process safety concept
ExtendingMaintenanceIntervals
process news 2/2007
19
To ensure reliable, safe operation,
chemical production plants are fitted
with safety integrated systems (SIS).
In the case of a fault, these systems prevent
plant damage and the release of hazardous
materials. These SIS must undergo rela-
tively costly function tests at regular inter-
vals. These tests interrupt the continuous
operation of the plant.
Plant operators are therefore always
looking for opportunities to extend these
test cycles without compromising plant
safety. These testing requirements are par-
ticularly relevant to actuators within safe-
ty technology, as this is where both the
greatest risks and the greatest potential for
rationalization can be found. A typical ex-
ample is the stop valves that prevent the re-
lease of hazardous substances (e.g., toxic
fluids or gases).
Function testing during operation:Partial Stroke Test
In practice, many of these valves are rarely
closed. Over time, the friction increases,
particularly the breakaway torque of shear
valves or the initial breakaway torque of
pivot fittings, due to corrosion or increas-
ing scaling on the shaft or the interior fit-
tings. This means that when the safety
valves are used in an emergency, they of-
ten lock.
A so-called Partial Stroke Test (PST) at
specified intervals can effectively prevent
such malfunctions. This test typically in-
volves moving the fittings by around 10 to
15 percent. This process does not interfere
Main benefitsB No need to dismantle the fittings
from the plant
B Extended maintenance intervals
B Following a successful PST, the fittingsare cleaned as well: caking and scalingare removed
B High reliability in emergencysituations: fittings do not lock up, no response delay
B Simple online function controlwithout disrupting the processes
B Faults can be detected early
B Cost savings due to lowermaintenance expenditure and less downtime
IEC 61508With PST (4x/year)Proof tests all
2 years = SIL 2
SIL 1
SIL 2
SIL 3
SIL 4
PFD(t)
PFDavg
TimeProof test interval
Without PSTProof tests
Annual = SIL 2
Test intervals can be extended using the Partial Stroke Test
In addition tonumerousdiagnosticfunctions, theSipart PS2intelligentpositioner alsooffers integratedPartial StrokeTest functionality
measure of the mobility of the fitting.When
a valve is commissioned, the response time
is saved as a reference value for the PST.
This value is later used for comparison pur-
poses.
The maintenance requirement is clearly
and concisely signaled to the user with a
OK (no maintenance request)
Maintenance request
Priority maintenance request
(Imminent)
failure of the instrument
Fault
code
Current
position
Priority of
maintenance request
In the three-stagealarm concept formeasuringtransducers inaccordance withNAMUR recom-mendation NE107,three color-codedsymbols makeclear the priorityof the main-tenance request
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with the operation of the plant but does
demonstrate the mobility of the fittings.
Intelligent and integrated: Sipart PS2
The Sipart PS2 intelligent positioner mea-
sures the reaction of the valve during the
PST. It uses the venting time as a reliable �
process news 2/2007
20Process Safety
TECHNOLOGY
three-stage alarm concept for measuring
transducers in accordance with NAMUR
recommendation NE107. Operating per-
sonnel can start the PST with Sipart PS2 in
four different ways: via the process control
system or the Simatic PDM process device
manager, via the front buttons on the Sipart
PS2 control panel, via the binary input of
the device, or by parameterizing particular
cyclical time intervals in the device.
Flexible test functions with Simatic S7-400FH
In addition to the PST with the Sipart PS2
positioner, Siemens offers integrated PST
functionality for the Simatic S7-400FH safe-
ty system as an add-on product. Preconfig-
ured logic for the execution of the PST, as
well as the optional solenoid valve test, is
supplied for the S7-400FH protection sys-
tem as well. The associated screen module
for the Simatic PCS 7 OS user interface pro-
vides a rapid overview of the status and
alarms, permits access to configuration pa-
rameters, provides the status of the last
PST, and has a command interface for start-
ing and breaking off the PST.
The test can be started manually, auto-
matically, or on request, and comprises
two stages. In the first stage, the actual
PST/valve startup test, a safety stop valve is
moved from the fully open position (oper-
ating position) to a defined set point by the
S7-400FH safety system via the additional-
ly fitted positioner system. The closing
process must reach the set point with the
defined hysteresis within the specified test
time. Once the test time has expired, the
safety stop valve is returned to the fully
open position (operating position). In an
optional second step, the associated sole-
noid valve can be tested.
Integrated module of the Simaticprocess safety concept
The integration of test processes for valves
into the control system, either via the Sipart
PS2 intelligent position controller or as an
integral variant for the Simatic PCS 7 pro-
tection/process control system, significant-
ly simplifies the execution of safety-ori-
ented tests. By automating the procedure,
including the comprehensive documenta-
tion of progress, which previously had to
be done manually, quality has increased
markedly while costs have simultaneously
fallen.
The solutions for the PST are only one
module in Siemens’ comprehensive process
safety concept. In order to provide users
with optimal support for all safety features
throughout the entire life cycle of their
systems, Siemens offers a complete range
of integrated solutions for process safety. A
key component of this is the Simatic Safety
Matrix, which addresses the entire safety
life cycle, from analysis to implementation
to operation. This package of software
tools, hardware components, and services
for fault-free process control technology
ensures maximum operational safety and
optimal plant operation in all phases of the
plant life cycle. �
Find out more:www.siemens.com/chemicalswww.siemens.com/processinstrumentationE-mail: [email protected]
Standards for functional safetyIn the process industry, applications, materials, or reactions sometimes require partic-
ular safety measures to mitigate risks to the plant, personnel, and the environment.
Automation technology components are now increasingly being used for these mea-
sures. The correct operation of these systems and components is collectively referred
to as functional safety. The conditions for the use of such systems are specified in two
standards: IEC 61508 and IEC 61511.
IEC 61508 is the basic standard for the safety standards. As an application-oriented
standard for the process industry, IEC 61511 is a standard used in the planning,
implementation, and operation of safety systems in process systems. These systems,
comprising controllers, sensors, and actuators, ensure that the status of the process
remains safe should defined limit values be exceeded.
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s
Safety shutoff with positioner
Industrial Ethernet
AS: S7-400FH
Protection
Set-point valve positioning
Feedback valve positioning
Solenoid valve/control valve
PCS/OS for:B Operation/monitoringB AlarmsB ArchivingB Printing reports
S7-400FH:B Partial Stroke TestB Solenoid valve testB Interface to OS
Air supply
ES OS
The PST with Simatic S7-400FH and Simatic PCS 7 checks all function-criticalcomponents of the stop valve, triggers an alarm in the control system if necessary,and offers report functions
�
Advanced ProcessControl ensuresconsistent productquality in manyareas of industry,for example, the glass or thechemical industry
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process news 2/2007
21TECHNOLOGY
Find out more:www.siemens.com/pcs7www.siemens.com/glassE-mail: [email protected]
Advanced Process Control
T oday, traditional proportional-inte-
gral-derivative (PID) control is the
workhorse in automated plants, sim-
ply because those controllers are so easy to
implement and operate in control systems.
However, very often PID loops do not oper-
ate at the engineered point, or operators
simply switch them to manual control
when the control quality achieved does not
match expectations.
Adapt to optimize
An alternative that solves these problems is
the adaptive PID controller. It works on the
basis of a process model that is executed in
the background to determine the results of
an operator interaction, thus evaluating
and predicting results – for example, to
forecast the process temperature when
opening a steam valve to a certain extent.
Or – vice versa – it identifies and applies the
valve setting required to achieve or main-
tain a defined temperature.
Another step forward
However, adaptive PID control cannot deal
effectively with more complicated process-
es. Multivariable and predictive controllers
(MPCs) overcome the limitations of tradi-
tional control. These controllers simplify
complex plant dynamics and permit early
elimination of faults based on artificial in-
telligence and model-based control. These
mathematical tools are complemented by
process knowledge and project experience
to generate a plant “autopilot” that is able
to keep the installation operating at its best
for long periods of time, thus optimizing
costs and ensuring that quality is within
the defined limits. Additionally, it provides
for complex process control. Both con-
troller models are included as add-ons in
the Simatic PCS7 control system. The han-
dling of complex plant dynamics is drama-
tically simplified, thus eliminating costly
trial-and-error procedures.
Freedom to choose
In the area of adaptive as well as multivari-
able/model-predictive control, Siemens col-
laborates with companies implementing
their expertise in advanced products. These
solutions ensure high performance control
by keeping relevant variables within a
small band, offer automated and flexible
process operations by obtaining predictive
and reproducible results, and provide con-
tinuous optimization by minimizing ener-
gy and raw material consumption. �
Advanced Process Control solutions increase process controllability
Focus on ControlApplying model-based advanced control strategies for processoptimization is a prerequisite for better exploiting plant potential.Advanced Process Control (APC) helps customers in many industrieswith dedicated applications better control their processes.
Main benefits
B The handling of complex plant
dynamics is dramatically simplified,
eliminating costly trial-and-error
procedures
B Advanced methods directly address
the reduction of process variation and
optimize tuning procedures, therefore
leading to significant cost reduction
process news 2/2007
22Sugar Industry
CASE STUDY
The production process at SüdzuckerAG in Rain am Lech, Germany, runsaround the clock during the sugarcampaign from September toDecember because the sugar beetsmust be processed as quickly aspossible to achieve the highestpossible sugar yield. “All systems must work perfectly,” explains Günter Leinfelder, chief electrician atSüdzucker in Rain, “and that includesthe preparation of the water used forunloading and cleaning the beets.”Efficient motor management,achieved with Simocode, has recentlybeen ensuring availability in thisprocess section.
The sugar beets are rapidly unloaded
from the arriving trucks with a high-
pressure water jet and at the same
time precleaned. The water required for
this runs in a circuit and is continuously re-
circulated. However, the process also cre-
ates a water surplus, which is treated in the
factory’s own sewage plant. In addition to
an anaerobic and an aerobic stage, the plant
contains so-called oxidation ponds in which
oxygen is added to the wastewater.
These ponds are ventilated by air jets.
Every jet is supplied with air by its own fan,
which is driven by a conventional three-
phase-current asynchronous motor with a
power of 15 to 30 kilowatts. A new feature
at Südzucker in Rain is a motor manage-
ment system that allows the control and
monitoring of every individual fan from a
central control station. Südzucker chose
Simocode pro V because this solution al-
lows the motor functions to be monitored
directly on-site at any time from the central
control station.
Rapid replacement of equipment
In order to ensure an uninterrupted pro-
duction process during the critical cam-
paign phase, Südzucker was looking for a
solution that would enable rapid, easy
equipment replacement without affecting
the ongoing production process – a de-
mand that could be met with Simocode pro.
A special memory module mounted on the
basic unit serves to enter, trace, and record
all the parameter settings, so that when the
motor management system needs to be
Motor management with Simocode ensures systemavailability at Südzucker
Reliable at Full LoadThe sugar beets are unloaded from the arriving truckswith a high-pressure water jet
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process news 2/2007
23
but we have never been able to do this until
now.”
But Simocode pro can do much more be-
sides. In addition to analyzing the current
drain, a version of the controller is also
available that measures the voltage curve in
the main circuit and is therefore able to
process and monitor power-related mea-
surement variables in the device. With a
temperature module, it is also possible to
monitor the current temperatures of the
drives and display these values at the con-
trol station. An extension module for ana-
log signals between 0.4 and 20 milliam-
peres is also available, with which levels,
positions, or flow values, for example, can
be measured.
Preemptive maintenance
Simocode pro also enables calculation of
the actual active power of the drive by
measuring the cos phi power factor. The
plant owner can therefore keep an eye on
the aging of the fan drives and decide, be-
fore the annual campaign begins, whether
a drive has to be changed for reliability
reasons.
Südzucker’s aim was to set up an exten-
sive energy management system with the
possibility of switching every drive on and
off individually. Simocode pro’s ability to
transfer all measured values continuously
to the control station at cyclic intervals and
trigger an alarm when faults are detected is
a great benefit to the company. Every drive
is combined with 3RT contactors and 3RV
circuit breakers for remote control of the
fan drives.
Status information and fault messages
are not only displayed in the control center
but can also be directly visualized locally at
any time. To do this, a special operating
module simply has to be plugged into the
control unit. The compact unit, which has
four freely assignable keys and seven freely
applicable LED indicators, allows critical
operating and control functions to be per-
formed directly on-site, making a major
contribution to speed and flexibility in the
elimination of technical problems.
Fit for the next heat
For Leinfelder, the functionality of
Simocode pro is a great improvement be-
cause the availability of the water treatment
system can be guaranteed even while the
sewage plant is operating under full load
for several months. “Like athletes, we have
to consistently use the best equipment to
stay fit for the next heat in the race,” he
says of Südzucker’s decision to implement
the latest motor management technology
from Siemens. �
Find out more:www.siemens.com/simocodewww.siemens.com/sugarE-mail: [email protected]
Simocode pro: Smart, flexible andsophisticatedB Extremely rapid replacement of
the control unit, enabled by theremovable module for operating-parameter storage
B Open Profibus DP communication formeasuring data and alarm messages
B Pluggable operating module for localmonitoring and control
B Monitoring of drive aging throughcalculation of the current activepower
B Optional modules for temperaturemonitoring and input/output ofanalog signals
B Measuring of the current and voltagecurve to monitor performance-relatedmeasurement variables
The sugar refinery in Rain am Lech Sirius protection and switchingdevices are also used in Rain
changed, the operator simply removes this
module and mounts it on the replacement
device. The system can then continue op-
eration immediately, with the same pa-
rameter settings. Leinfelder is delighted:
“Changing the memory module takes only
about 30 seconds. That’s just what we need,
process news 2/2007
T he new Siflow FC070 Coriolis flow-
meter takes the idea of Totally Inte-
grated Automation right down to
the process instrumentation level. This
compact device is designed for direct in-
tegration into Simatic systems, enabling
multiple parameters to be measured in
gases and liquids. Siflow FC070 covers a
broad spectrum of flow applications for
the majority of gases and liquids and is
easy to install.
Thanks to its seamless integration into
Simatic, the device is easy to configure,
which reduces the level of complexity in a
plant. Siflow FC070 diagnoses the plant sta-
tus and has standard interfaces to Simatic
Manager, PCS 7, and Simatic PDM. It is also
available as an independent unit capable of
exchanging data with devices from third-
party vendors via Profibus or Modbus.
The device simultaneously monitors flow,
temperature, density, and volumetric flow
as well as fractional flow with an error of
less than 0.1 percent, making it well suited
for all industry applications in which accu-
rate flow measurement is essential.
Robust flowmeter
The high-performance Sitrans FUS060
ultrasonic flowmeter is specially designed
for industrial plants that require robust
devices and rely on fault-resistant measur-
ing components – for example, in the oil-
refining industry, petrochemical plants,
power station systems, or wastewater pu-
rification plants. Sitrans FUS060 is pre-
pared for the OIML R117 standard and can
be used in all respective applications.
The certified instrument has a HART in-
terface and can be operated either with two-
jet technology or with four-jet technology
for higher performance and accuracy. The
FUS060 transmitter offers fieldbus com-
munication via Profibus and is PDM com-
patible. Its die-cast aluminum housing is
designed with an IP65/NEMA4 enclosure
rating.
Level measurement transmitter for challenging applications
The new Sitrans LR460 radar level mea-
surement transmitter is based on the Sitrans
LR400 device and can measure virtually any
solid medium, including cement powder,
fly ash, coal, gypsum, flour, grain, aggre-
gates, and plastics. The transmitter is par-
ticularly suitable for continuous level mea-
surement in difficult solids applications with
extreme dust or high temperatures. Sitrans
LR460 features 24-gigahertz FMCW (fre-
quency modulated continuous wave) tech-
nology with advanced Process Intelligence
echo processing. The 24-gigahertz wave-
length can create a stronger signal than
New products for process instrumentation
Innovative,Robust, andVersatileSiemens has expanded its product portfolio in the field of processinstrumentation. New flowmeters as well as a new level measurementtransmitter, weighing instrument, and temperature transmitter open upnew areas of application, function well in difficult process conditions,and provide additional automation options.
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The robust, high-performance SitransFUS060 ultrasonic flowmeter
Range of up to 100 meters: SitransLR460 level measurement transmitter
The Siflow FC070 Coriolis flowmeteris designed for direct integration withSimatic S7
24Process Instrumentation
TECHNOLOGY
process news 2/2007
and wastewater plants. As a complete solu-
tion, the device contains general PLC pump
station functions in a single preconfigured
unit. Sitrans LUC500 replaces the Milltron-
ics EnviroRanger ERS 500, maintaining the
same proven features and benefits.
Sitrans LUC500 combines noncontact-
ing ultrasonic technology, echo-processing
techniques, and proven application soft-
ware to provide accurate level control of
liquids in wet wells up to 15 meters deep. It
also monitors flow in flumes, weirs, and
5.8-gigahertz technology, so the instru-
ment has a long range of up to 100 meters.
After initial setup, the Process Intelligence
software responds automatically to chang-
ing material slope conditions and physical
silo features such as fixed obstructions or
buildup.
Complete solution for pump stations
Sitrans LUC500 integrates advanced ultra-
sonic level control and monitoring for du-
plex lift stations run by operators of water
New micro gaschromatographThe new Sitrans CV natural gas chromatograph featuresfast, precise, and reliable determination of calorificvalues. The main area of application for the micro-technology-based Sitrans CV is in the natural gasindustry, especially for tasks with mandatory calibra-tion, such as pipeline monitoring, gas transfer anddistribution stations, and LNG (liquefied natural gas)
terminals, where gas is liquefied or converted back to gas. The compact device with arugged, explosion-proof housing is suitable for extreme ambient conditions of –20 to +55degrees Celsius. It can be mounted near natural gas pipelines, provides complete informa-tion on the natural gas quality, and delivers the measuring results in less than three min-utes. The new device has already impressed the first customers. After exhaustive tests in itscentral test and calibration laboratory, the largest oil and gas drilling and productioncompany in Poland, Polskie Gornictwo Naftowe i Gazownicto (PGNiG), recommendsSitrans CV for the analysis of natural gas in Polish networks. The tests concentrated on therepeatability of the measuring results, any memory effects, the influence of the ambienttemperature on the precision of Sitrans CV, and pressure fluctuations in the sample supply,using test gas concentrations typical for natural gas. The results of the tests were com-pletely positive. PGNiG was particularly impressed by Sitrans CV’s short analysis times, lowcosts, and MEMS (micro-electro-mechanical systems) analysis technology.
The new Milltronics MBS belt scaleoperates without a cross-bridge
Sitrans LUC500: Integrated unit forlevel monitoring and control induplex lift stations
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The Sitrans TH 400 head transmitter isavailable in versions for Foundationfieldbus and Profibus PA communication
Find out more:www.siemens.com/processanalyticsE-mail: [email protected]
other open channels. The device improves
efficiency and reduces energy consump-
tion and maintenance costs by decreasing
pump failures and site visits.
Belt scale for continuous weighingreliability
The new Milltronics MBS belt scale for reli-
able, continuous weighing is a modular
system for medium-duty applications. It is
suited for applications involving aggre-
gates, sand, gravel, or crushed stone. This
new belt scale does not have a cross-bridge,
which reduces material buildup and allows
universal fit on most conveyor widths.
When combined with a Milltronics BW100
integrator and a Milltronics TASS speed
sensor, the system provides a dependable
and economical belt scale package.
Fieldbus-compatible head transmitter
Finally, there is also a new transmitter for
temperature measurement: the fieldbus-
capable compact Sitrans TH 400, which ex-
tends the series of Sitrans TH head trans-
mitters. The instrument is available in ver-
sions for Foundation fieldbus and Profibus
PA communication and can also be used for
simple control jobs in a Foundation field-
bus segment. This development stresses
Siemens’ commitment to innovation in all
fields of process instrumentation. �
Find out more:www.siemens.com/processinstrumentationE-mail: [email protected]
25
process news 2/2007
26Breweries
CASE STUDY
The Ziemann Group has an excellent
reputation in the brewing industry
for its ultra-precise brewing solu-
tions. High quality and continuous R&D are
the distinguishing characteristics of this
company, which has been using Siemens
automation technology for decades. In June
2006, Ziemann commissioned a one-of-
a-kind pilot plant at its headquarters in
Ludwigsburg, Germany. It can reproduce
all conventional brewing processes on the
market on a smaller scale, and its automa-
tion technology is state of the art.
The primary purpose of the plant is to test
new technologies under live operating con-
ditions. The miniature brewery is equipped
with the same technology as large-scale
plants. It uses Braumat process control
technology based on PCS 7 and operates
down to the field level with Siemens com-
ponents. At just 100 square meters, the
small-scale brewery plant has all the fea-
tures of a full-grown brewhouse and can be
run in a fully automated manner via the
Braumat PCS 7 process control system. “We
want to use the pilot plant to develop opti-
mized processes, put new components such
as the Sitrans P300 pressure transducer to
the test, and carry out R&D together with
our business partners,” explains Dr. Hans-
Jörg Menger, manager of development and
technology at Ziemann.
On the open brewing tanks, a pressure
transducer measures the static pressure of
the liquid column and from that value de-
termines the level. The level in the closed
tanks of the fermentation and storage ves-
sels is monitored with two pressure trans-
ducers.
SIP and CIP as hygiene benchmarks
Hygiene is essential in the food and bever-
age industry, so all measuring instruments
must satisfy stringent hygiene require-
ments and, for example, be SIP (steriliza-
tion in place) and CIP (cleaning in place)
compatible – requirements that the Sitrans
P300 easily fulfills, thanks to the extreme-
ly hygienic design of its stainless steel
housing. “In the P300, even the analysis
electronics are encapsulated in stainless
Braumat PCS 7 and Sitrans P in brewery pilot plant
PilotMicrobreweryThe Ziemann production engineering company optimizes the brewingprocess and tests new components at its new pilot plant, a completebrewery on a small scale. The pilot plant is automated with BraumatPCS 7 and uses integrated technology from the Totally IntegratedAutomation line. One of the components used is the new Sitrans P300pressure transducer, developed especially for the food and beverageindustry. Ziemann tested the suitability of the transmitter for thebrewing industry.
The Sitrans P300 pressure transducer with a stainless steelhousing is characterized by an extremely hygienic design
Sitrans P300 pressure transducerB Hygienic design in accordance with SIP and CIP benchmarks
B Stainless steel housing with encapsulated electronics
B Intelligent design with front-flush measuring cell for measurementwithout dead space
B Temperature up to 150°C, with temperature isolator up to 250°C
B High long-term measuring precision (measurement deviation of 0.075%max., long-term drift of 0.25% in 5 years)
B Simple local and remote parameterization
B Comprehensive diagnostic functions and status messages for increasedsystem availability
process news 2/2007
27
acterized by long-term stable measuring
performance. The low measurement devi-
ation enables processes to be run even clos-
er to the optimal level of efficiency, there-
by increasing system productivity.
The transmitter can be integrated into
the production plant using all regular
thread types. Moreover, various hygienic
connections with front-flush membranes
fulfill the requirements of a process con-
nection free from dead space. A laser weld
seam joins the transducer connection with
the measuring cell membrane with a high
surface finish, eliminating the need for a
seal on the process side. This will prevent
the buildup of product deposits and the
possible growth of bacteria. Surface rough-
ness in accordance with the standards of
the European Hygienic Equipment Design
Group (EHEDG) is guaranteed for all com-
ponents and weld seams that come into
contact with the process medium.
Pressure transmitters are often used for
process media at temperatures that exceed
150 degrees Celsius. These devices provide
the required temperature decrease be-
tween the process and electronics. In such
cases, the membrane of the pressure trans-
mitter is located in front of the membrane
of the measuring cell, with the result that
this technology is associated with limited
measurement accuracy. The Sitrans P300
uses a temperature isolator, providing both
a cost-effective solution and unlimited
measurement accuracy.
Simple parameterization
The Sitrans P300 pressure transducer can
be installed and operated either directly
on-site or parameterized via the control
system. According to Gerhard Lillich, one
of its most positive and user-friendly func-
tions is that addresses can be adjusted lo-
cally on the devices: “It is a definite bene-
fit for us and saves considerable time.”
In addition, the simulation of ramp func-
tions via HART or Profibus PA simplifies
commissioning. A current sensor with an
output of 4–20 milliamperes was imple-
mented in the P300 especially for the com-
missioning of measuring circuits. The ver-
satile diagnostic functions of the status mes-
sages generated in the cyclical exchange of
data facilitate the analysis of faults, thereby
contributing to reduced downtime and in-
creased plant availability overall.
Lillich has great confidence in the de-
vice: “We have been using the Sitrans P300
for only a few weeks, so we have no long-
term experience, of course. However, we are
very satisfied with its stability and temper-
ature resistance. There have been no faults
to date and we are very taken with the de-
vice. Above all, the parameterization via the
control system for changes to the produc-
tion process really is an excellent idea.” �
Find out more:www.siemens.com/brewerieswww.siemens.com/processinstrumentationwww.siemens.com/sitranspE-mail: [email protected]
steel,” explains Gerhard Lillich, deputy
manager of development process automa-
tion at Ziemann.
The front-flush measuring cell therefore
meets the optimal requirements for mea-
surement without dead space and also
makes cleaning much easier. With a speci-
fied temperature range of up to 150 de-
grees Celsius, the pressure transducer
withstands sterilization in place without
drift.
Long-term measurement stability
The Sitrans P300 pressure transmitter,
which has a measurement deviation of a
maximum of 0.075 percent and long-term
drift of 0.25 percent over five years, is char-
The new pilot plant atZiemann represents ascaled-down versionof the completebrewing process; it isequipped andautomated like alarge-scale plant
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The Sitrans P300 isused in the pilotplant to measurethe pressure in theclosed vessels
process news 2/2007
28Sensors
CASE STUDY
W ith a staff of 1,600, Zentis is not
only one of the largest German
jam and preserves manufactur-
ers; it also supplies cereals, raw marzipan,
sweet bars, and marzipan eggs to the food
processing industry and retailers. The 190
employees at the Factory II in Aachen-
Eilendorf alone produce approximately
12,000 tons of sweets per year.
The company’s internal logistics were
reorganized to clearly identify the origin
and route of the products, both during and
after production. “Many of our customers,
especially discount stores, are demanding
that the outer packaging no longer carry
the normal EAN or UPC codes to avoid po-
tential conflicts with the codes of the goods
management systems and the associated
problems at their scanner cash registers,”
explains Achim Minten, the European
maintenance manager responsible for au-
tomation at Zentis Factory II. “We therefore
print the boxes with a data matrix code that
can be read, decoded, and evaluated by
camera systems.” The 12-by-12-millimeter
dot matrix contains the production line, the
assignment of the palletizing station, and
the article number.
Automatic and reliable performanceeven at high speeds
A special solution for detecting the DMC at
the end of the production lines was needed
where the goods are packed in automati-
cally assembled boxes and conveyed to the
palletizing stations via various rails. To re-
liably identify the boxes before discharging
them to the assigned station, the manufac-
turer chose Simatic VS130-2 vision sensors.
Three important factors supported the use
of this solution: the convincing perfor-
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Vision sensors optimize company logistics at Zentis
An Eye for DetailProcesses in the food industry operate with a high degree of automation.Consequently, even the outer packaging of foods must be labeledaccording to certain specifications. No EAN (European Article Number)codes may be used, for example, on outer packaging because thesecould cause problems in customers’ goods management systems. Outer packaging at Zentis in Aachen, Germany, is therefore identified by data matrix codes (DMCs) that are read quickly, automatically, andreliably by vision sensors.
The boxes at Zentis in Aachen are identified by data matrix codes to avoid conflictsin end customers’ goods management systems
process news 2/2007
29
al interface boxes or converters. Besides,
the configurer can access the processing
unit, change the parameterization, or call
and activate one of the 15 storable param-
eter sets directly from any terminal in the
network.
The conveyor system itself is controlled
by a highly available Simatic S7-400H con-
troller and visualized by a WinCC user in-
terface. A status census, that is, how many
boxes of a palletizing order have already
been detected, is displayed in addition to
the data detected by the camera. The census
criteria to be evaluated are freely definable.
Considerable improvements
The new code-reading systems have clear
advantages over the previous solution in
ongoing operation. “With the new system
we were able to improve both our logistics
and our quality assurance,” says Minten,
“because the DMC labeling allows tracking
of the products to the individual machine
and the respective batch. The cause of the
error and route of the affected products can
therefore be traced quickly in the event of
complaints.” Before the new system was in-
troduced, the box data had to be entered
manually and noted on a pallet slip, and
great additional effort was also required
for consistent data acquisition during pro-
duction.
Zentis is using four Simatic VS130-2
vision sensors at the Factory II in Aachen-
Eilendorf at the moment. They have all
been working to the user’s complete satis-
faction since being commissioned, and the
use of further systems in the area of the
four existing box assemblers is already
planned. The boxes are printed with a DMC
according to the requirements of the pro-
duction lines before assembly; this DMC is
read automatically and controls the distri-
bution of the assembled box to the appro-
priate production line. This increases pro-
ductivity and reduces the risk of error. �
Find out more:www.siemens.com/simatic-sensors/mvE-mail: [email protected]
mance of the camera system at high through-
put speeds, the support from Siemens in
developing a solution suitable for this in-
dustry, and time- and cost-saving unifor-
mity in conjunction with the existing au-
tomation technology. “Most of the systems
are very familiar to us,” says Minten, “and
the necessary know-how is usually passed
on in a single on-the-spot training session.
The uniformity of the Siemens technology
in configuration, data storage, and com-
munication makes work easier for our en-
gineering department in all areas, from set-
up to modifications to rapid troubleshoot-
ing – even without external help. Another
decisive advantage of the image processing
system is that the processing unit has both
a Profibus and an Ethernet interface.”
This approach completely eliminates
typical interface problems due to addition-
Simatic VS130-2 vision sensors at ZentisB Reliable reading processes at travel speeds of 0.7 m/s
B Reliable identification of DMC codings on different surfaces
B Variable reading distances of 75 to 3,000 mm, depending on the lens
B Variant with C or CS-Mount sensor head and protective housing with a front panel
of unbreakable plastic, in compliance with the International Food Standards (IFS)
regulations regarding the use of glass in food production
B CCD sensor with a resolution of 640 pixels x 480 pixels that compensates system-
related fluctuations (e.g., positioning, trigger inaccuracy, and printing position)
B Automatic adaptation of the read algorithms, providing a reliable reading
result despite focus and size fluctuations
B Control of the circular lighting unit by the processing unit of the VS130-2
in sync with the image feed, allowing an exposure time of 20 µs to 10 ms
at maximum light intensity
B A processing unit with both a Profibus and an Ethernet interface
The Simatic VS130-2 sensor is equipped with a circular lightingunit, which provides optimum illumination
An eye on the production: The status of the process and ordersis visualized by Simatic WinCC
process news 2/2007
30Process Instrumentation
CASE STUDY
Univar is a world leader in industrial
chemical distribution, with a net-
work of 163 distribution hubs in
North America and Europe. The company
processes, blends, and repacks bulk chem-
icals for specific customer needs. The depot
at Wellingborough in the UK supplies cus-
tomers in all industry sectors throughout
the UK. The site has 17 vertical cylindrical
tanks storing a range of chemicals.
Noncontacting solution
In November 2005, the local engineering
firm Stratos replaced the existing hydro-
static device with a Sitrans LR200 radar
transmitter. Each new radar instrument
was installed in a nozzle on top of the tank,
outside the tank wall. The microwaves pass
through the tank roof, so the devices are
never directly exposed to the chemical con-
tents. This innovative installation required
no drilling, and instruments can be re-
moved without emptying the tank. In addi-
tion, all tanks except the water tank were
equipped with a Pointek CLS100 capaci-
tance high-level switch as a fail-safe against
spills. These are also installed externally.
All instruments are wired into a Simatic
S7-300 PLC and a Simatic HMI panel. The
high-point level system is designed to
sound an alarm if the tank reaches a set
point, and the graphic display provides vi-
sual cues to indicate whether the tanks are
full, empty, or at normal levels.
Improved stock control
Because of the aggressive chemicals, non-
contacting radar proved the right technol-
ogy choice for these applications. Jez Hill,
regional engineering manager at Univar,
says, “The noncontacting approach reduces
the maintenance, which saves us a lot of
staff hours and downtime. We have great
confidence in the system.” �
Univar enhances operationswith new level system
SafeControlSince the Univar depot at Welling-
borough in the UK was commissioned
in 1988, process equipment such as
the hydrostatic level system had
become obsolete and needed
replacing. The hydrostatic transmitters,
inserted at the bottoms of the tanks,
were difficult to install and had to be
removed for regular calibration.
Because they were in direct contact
with corrosive chemicals, they needed
frequent cleaning and replacement.
Each time, this required emptying the
tank, causing downtime of up to two
days. Noncontacting level devices from
Siemens solved this problem.
Find out more:www.siemens.com/levelE-mail: [email protected]
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Main benefitsB External installation and noncontacting
measurement for increased reliability
B Easy-to-use central HMI with high-
point alarm system improves stock
control and operational safety
A Sitrans LR200 radar transmitter mounted on top of the tank provides continuouslevel measurement, while a Pointek CLS100 capacitance switch provides a high-level fail-safe; both instruments are installed outside the tank wall
The Simatic HMI panel providesthe status of each tank, with visualcues indicating level measurement
for increased reliability
Sitrain courses for Simatic PCS 7and process analyticsIn parallel with the introduction of the new Simatic PCS 7 Version 7,
Sitrain is offering an optimized-upgrade course as well as a 10-day
system course. The purpose of the 3-day upgrade course is to com-
municate to users already familiar with Simatic PCS 7 the new engi-
neering options available in Version 7, using examples. In the 10-
day system course, participants will learn about Simatic PCS 7 Ver-
sion 7 beginning at the very beginning and will learn how to apply
the variety of engineering functions effectively. Another sequence
of foundation courses will start in the fall of 2007.
In total, Sitrain has recently incorporated 22 new courses on
process analytics into its program. The training covers a wide range
of products, from Ultramat and process gas chromatographs such
as MicroSAM and Maxum edition II to applications for customer-
specific process gas analysis.
Information on training courses covering Simatic PCS 7:
www.siemens.com/sitrain-pcs7
Information on training courses covering process analytics:
www.siemens.com/sitrain-sc-pa
infoinfoDo you want to know more about the systems and solutions for
the process industry from Siemens Automation and Drives?
Simply visit our information portal on the Internet at
www.siemens.com/processautomation
onlineonline
events
www.siemens.com/processnews
Here you can download the current issue and past issues of
Process News in PDF format, or search directly for articles about
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events
31DIALOGUE
process news 2-07PublisherSiemens Aktiengesellschaft
Bereich Automation and Drives (A&D)
Gleiwitzer Str. 555, 90475 Nuremberg
Germany
www.siemens.com/automation
Group Executive ManagementHelmut Gierse, Hannes Apitzsch,
Dr. Peter Drexel, Anton S. Huber
Responsible for ContentPeter Miodek
Responsible for Technical ContentCornelia Dürrfeld
ConceptChristian Leifels
EditorCornelia Dürrfeld, Siemens AG, A&D CC P MC
Siemensallee 84, 76187 Karlsruhe, Germany
Tel.: +49 (0) 7 21 5 95-25 91
Fax: +49 (0) 7 21 5 95-63 90
Editorial CommitteePetra Belzner, Alexandre Bouriant,
Sigrun Ebert-Heffels, Michael Gilluck,
Birgit Gottsauner, Walter Huber, Bernd Langhans,
Silvana Rau, Rüdiger Selig, Wieland Simon,
Roland Wieser, Wolfgang Wilcke, Eugene Yeo
Publishing HousePublicis KommunikationsAgentur GmbH, GWA
Corporate Publishing, Medien 1
P.O. Box 3240, 91050 Erlangen, Germany
Tel.: +49 (0) 91 31 91 92-5 01
Fax: +49 (0) 91 31 91 92-5 94
Editor in chief:
Kerstin Purucker
Layout:
Jürgen Streitenberger
Copy editing:
Irmgard Wagner
DTP: der Döss für Kommunikation, Nuremberg
Printed by: Stürtz GmbH, Würzburg
process news is published quarterly.
Circulation: 34,000
Job number: 002800 581
© 2007 by Siemens Aktiengesellschaft
Munich and Berlin, Germany
All rights reserved by the publisher.
This edition was printed on environ-
mentally friendly chlorine-free paper.
ISSN 1430-2292 (Print)
The following products are registered trademarks of Siemens AG:BRAUMAT, DESIGO, MicroSAM, MILLTRONICS,
POINTEK, S7-300, S7-400, SIFLOW, SIMATIC,
SIMATIC HMI, SIMATIC IT, SIMATIC PCS 7,
SIMATIC Panel PC, SIMATIC Safety Integrated,
SIMOCODE, SIMOTION, SINAMICS, SIPAN, SIPAT,
SIPART, SIPROCESS, SIRIUS, SITRAIN, SITRANS,
SIWAREX, TELEPERM, TOTALLY INTEGRATED
AUTOMATION, ULTRAMAT, WinCC
If trademarks, trade names, technical
solutions, or similar are not listed above,
this does not imply that they are not
registered.
The information provided in this magazine
contains merely general descriptions
or characteristics of performance, which
in the case of actual use do not always
apply as described or which may change
as a result of further development of the
products. An obligation to provide the
respective characteristics shall exist only
if expressly agreed in the terms of contract.
Order No.: E20001-M6207-B100-X-7600
Printed in Germany
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Flexibility will …
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