Based on the slogan “From Integrated Engineering to Integrated Operation – Discover the Potential of Digitalization” Siemens is focusing on the topic of digitalization at the Achema 2015 trade fair.
With a booth area of some 1300 square meters, Siemens demonstrates how companies in the process industry can boost their efficiency and productivity – and thus also their competitiveness – by using integrated solutions.
“On the basis of our existing range of products and services for electrification and automation, we are promoting digitalization within the process industry. This is because digitalization permits the integration of individual process steps over the entire plant lifecycle – from engineering and operation, through to continuous optimization. And as a reliable partner, we are supporting our customers all the way.” explained Eckard Eberle, CEO of the Process Automation Business Unit and stand manager of the Siemens booth.
“In order to implement the Industrie 4.0 project in the process industry, we are focusing on three action fields: the digital plant, modularization and production optimization.” One of the most important objectives on the road to the digital plant is the creation of an integrated data landscape. Siemens already provides data consistency across all phases of the lifecycle: from engineering with the Comos CAE tool, commissioning using the Simit simulation platform, to operation based on the Simatic PCS 7 process control system and XHQ Operations Intelligence for real-time corporate decisions. The benefits are greater transparency, reliability and fast time-to-market. Virtual commissioning using the Simit Simulation Framework software, for example, means plants can be put into service more than 50 percent faster than before, while at the same time improving operational safety.
With XHQ Operations Intelligence Siemens provides another example of how “smart data” can be generated from “big data”. The software captures data from a wide variety of sources, brings it together efficiently in one management cockpit and helps users to make well informed decisions. This allows operating costs to be cut by as much as 8 percent. From a servicing viewpoint, access to data from the engineering and operating environments helps to optimize processes: Using data-based services such as control performance analytics, process and status data from closed-loop control systems can be analyzed and then optimization measures drawn up. Comos MRO (Maintenance, Repair & Overhaul) makes it possible to handle all the administration, planning and organization of operation and maintenance work, including plant documentation, in a single system. This means that any changes to the plant due to maintenance processes are also immediately available in the engineering data.
Using the Comos Walkinside Immersive Training Simulator (ITS), operators and maintenance engineers can take a virtual tour of their plants: the simulation of real scenarios optimizes maintenance work and improves safety for personnel by means of virtual training. Users can also reduce operating and maintenance costs thanks to predictive maintenance (of pumps, for example) and remote services.
Siemens is showcasing integrated industry-specific solutions on two exhibition highlights in the center of the booth: For the pharmaceutical industry, a modular Chem-API batch plant demonstrates the seamless interaction of engineering and production planning software with automation systems and process instruments in a hygienic application version. The special features include the use of a new paperless manufacturing solution: the production data is electronically captured and documented, considerably speeding up the process of executing, checking and releasing pharmaceutical production processes and batch protocols. The second exhibition highlight model – a separation column from chemical production – also illustrates the benefits of integrated data communication. This not only improves the transparency and optimization of production, but also plant availability and process reliability through redundancy concepts and integrated safety functions.
Integration increases efficient use of resources and energy
The efficient use of resources and energy is a central theme in the process industry. Siemens is presenting integrated solutions for efficient consumption – from the power supply with Totally Integrated Power (TIP), through Integrated Drives Systems (IDS), to energy data management systems and modern closed-loop control processes, such as Advanced Process Control for Simatic PCS 7. A key role is assigned here to the process control system: Siemens simplifies the integration of field devices, power supplies or medium-voltage switchgear – even those from third-party suppliers. Integrated Drive Systems (IDS), moreover, permit the economical and energy-saving operation of pumps, fans and compressors.
For the first time at Achema, Siemens is exhibiting the Flender N-Bipex coupling that extends the life of the entire drive system. Gas analyzers also contribute to greater sustainability, by reducing emissions and optimizing processes where raw materials are used. In this connection Siemens is presenting its extended Siprocess GA700 gas analyzer.
Thanks to its intelligent modular design, it can be used in many different applications and is easy to maintain. Further show highlights that demonstrate the efficient use of resources are the intelligent solutions for the treatment and disinfection of industrial wastewater, as well as energy-efficient pump applications. Siemens also sees new digitalization opportunities in the automation of bio processes. The chemical industry, for example, is increasingly using biological input materials. Process monitoring and control of a bio-fermenter with PCS 7 Lab and Sipat speeds up production through the simplified use of statistical and deterministic models and online-optimization measures.