Chemical Industry
for global
Pharmaceutical Industry
insulin quality
Lifecycle M...
2 process news | 2-2012
C o n t e n t s p r o c e s s n e w s | 2 - 2 0 1 2
p Cover
Lifecycle Management
4 A Plan for Life...
process news | 2-2012 3
“Guiding you
through change”
Axel Lorenz
Vice President
Process Automation
Industrial Automation D...
4 process news | 2-2012
C o v e r L i f e c y c l e M a n a g e m e n t
process news | 2-2012 5
p Lifecycle Management
A Plan for Life
From his office window, Joachim Birk can see
several BASF SE...
6 process news | 2-2012
ward, and we were also one of the trendsetters in
the industry with this approach.”
Another aspect...
process news | 2-2012 7
(MES) to be able to compile and transform system
data into key performance indicators (KPIs) for p...
8 process news | 2-2012
p Integrated Engineering
The Next Step
The basis for the compiler development is a
migration proje...
process news | 2-2012 9
Better integration, more competition
10 process news | 2-2012
I n d u s t r y C h e m i c a l I n d u s t r y
p Klüber Lubrication, Germany
Smooth Standards
process news | 2-2012 11
started. Siemens pursues the ...
12 process news | 2-2012
I n d u s t r y P h a r m a c e u t i c a l I n d u s t r y
process news | 2-2012 13
insulin crystals were imported from European
sources for the local production of Jusline. Julphar...
14 process news | 2-2012
begin fermentation. In the buffers preparation area,
the bulk buffers are formulated before fillin...
process news | 2-2012 15
ity. To ...
16 process news | 2-2012
Curti Costruzioni Mecchaniche was founded
in 1957 in Imola / Italy with the aim of con-
process news | 2-2012 17
tems. The AVM is a fully elect...
18 process news | 2-2012
I n d u s t r y P h a r m a c e u t i c a l I n d u s t r y
p Alcon Cusí S.A....
process news | 2-2012 19
Bar Code Data Matrix RFID
External Enterprise Data Exchange
20 process news | 2-2012
Proccess feed
To produce a range of modern drugs, pharma-
ceutical manufactur...
process news | 2-2012 21
T mp pH pO₂Temp., pH, pO₂
Processsssssssssssssssssssssssssssssssssss aaaaaaaaaaaaaaaaaaaaaaa...
22 process news | 2-2012
Te c h n o l o g y P r o c e s s C o n t r o l Te c h n o l o g y
p BASF, Germany
Innovative Oper...
process news | 2-2012 23
ect manager Dr. Jens Bausa, “modern ...
24 process news | 2-2012
example, Siemens and its Solution Partners BST
Buck Systemtechnik, Rösberg Engineering, and
the o...
process news | 2-2012 25
At ACHEMA, BST will prese...
26 process news | 2-2012
p Industrial Security
Eliminating Vulnerabilities
with Updates and Patches
The first measure in a...
IT Security Hinweis
Es sind geeignete Schutzmaßnahmen (u.a. IT Security, zum
Beispiel Netzwerksegmentierung) zu ergreifen,...
28 process news | 2-2012
R u b r i k r o t R u b r i k g r a u
p Spenner Zement, Germany
Energy Efficiency
as a Business Pr...
process news | 2-2012 29
energy monitoring and management s...
30 process news | 2-2012
essnews www www.siemens
process news | 2-2012 31
D i a l o g u e
process news 2-2012
Siemens Aktiengesellschaft,
Gleiwitzer Str. 555, 90...
Answers for industry.
Guiding you through change
Join us for a journey through your plant lifecycle
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Magazine process news-2012-2-en

  1. 1. Chemical Industry Migration for global standards Pharmaceutical Industry Automation safeguards insulin quality Lifecycle Management A Plan for Life The Magazine for the Process Industry Volume 17, Number 2, 2012 news process
  2. 2. 2 process news | 2-2012 C o n t e n t s p r o c e s s n e w s | 2 - 2 0 1 2 p Cover Lifecycle Management 4 A Plan for Life Lifecycle Management 8 The Next Step Integrated Engineering p Industry Chemical Industry 10 Smooth Standards Klüber Lubrication, Germany Pharmaceutical Industry 12 Quality of Life, Quality of Product Julphar, United Arab Emirates 16 Clear Benefits Curti Costruzioni Mecchaniche, Italy 18 Targeting the Supply Chain Alcon Cusí S.A., Spain 20 Quality Medicine ICES, Singapore p Technology Process Control Technology 22 Innovative Operating Concept BASF, Germany 24 Partners for Global Solution Expertise Siemens Solution Partners 26 Eliminating Vulnerabilities with Updates and Patches Industrial Security Energy Management 28 Energy Efficiency as a Business Process Spenner Zement, Germany 30 Web Exclusive 31 Dialogue BASF benefits from a user-friendly and efficient operating concept for plant control systems that helps operators react fast and appropriately to changing process conditions Page 22 The new AVM machine series of Curti Costruzioni Mecchaniche can pack vials and ampoules fast and efficiently using a perfectly aligned automation and drive solution Page 16 Using Simatic technology, Klüber Lubrication implemented a standardized automation system covering the requirements of various batch processes and production plants Page 10 Klüber SiemensAG BASF-SE/Hans-JuergenDoelger
  3. 3. process news | 2-2012 3 “Guiding you through change” Axel Lorenz Vice President Process Automation Industrial Automation Division Siemens AG Our theme for the Achema 2012 is: “Guiding you through change – Your trusted partner for lifecycle innovation.” Every three years, experts and engineers from process technology, engineering, and process industry companies visit the world’s leading event for the process industry. The Achema has always been a trendsetting technology summit for chemical engineering, environmental protection, and biotechnology, and we are proud that we can make a contribution to innovation through our expertise and technology. This year, we will showcase a complete lifecycle management portfolio to reduce the total cost of ownership. The exhibits show how the process industry can benefit from our products, systems, solutions, and services in research and development, process development, plant design, production, and maintenance as well as optimization and modernization. In this issue of process news, we have included a special edition with some of our technology innovations, such as the latest version of our Comos and Sipat software. Several case studies illustrate how our process industry partners and customers can benefit from our solutions and services throughout their system and plant lifecycle. For example, read an interview with Dr. Birk from BASF on how lifecycle management can improve plant performance. Innovative products and solutions, process know-how combined with lifecycle services make Siemens a trusted partner for a sustainable business in dynamic times. We work with the world’s leading chemical and pharmaceutical companies to make sure that they get the most out of their plant and activities – and we will continue to develop and improve our offerings to that aim. Enjoy the read! E d i t o r i a l
  4. 4. 4 process news | 2-2012 C o v e r L i f e c y c l e M a n a g e m e n t Photo:BASFSE
  5. 5. process news | 2-2012 5 p Lifecycle Management A Plan for Life From his office window, Joachim Birk can see several BASF SE. He is director of the Center of Excellence for Automation Technology at BASF in Ludwigshafen and leads a team that has been the driving force in the development of new concepts for process control system lifecycle management. The Center of Excellence focuses on the contribution of automation to efficient, reliable plant operation when developing and deploying process con- trol systems. Birk ex- plains: “BASF SE, with its numerous plants and systems in different sizes and phases of life, is an ideal field of application for new concepts in pro- cess control engineer- ing. Together with our partners, we are constantly evaluating novel concepts, as automation technol- ogy is a critical component in the safety, productiv- ity, and availability of plants. We need to ensure this contribution with continuous system care.” Innovation as a challenge For Birk, one of the central tasks of lifecycle man- agement is coordinating the different lifecycles of plants and automation systems: “On average, we expect a process plant to have a life of 30 years in operation, even longer in the case of some plants here in Ludwigshafen. In comparison, lifecycles in Ten years ago, the Center of Excellence for Automation Technology of BASF SE in Ludwigshafen, Germany, started to develop concepts for effective and efficient lifecycle management of process control systems. In this context, the general technical framework for plant operation and system maintenance is one critical aspect. However, equally important is communicating benefits to users and management. automation technology are about 10 to 15 years for hardware and just 5 years for software components. We have to match and align these cycles, always keeping in mind that we can only implement new features or components when production operations permit this. In some cases, we can migrate systems during operation, but typically we need a plant shut- down to perform them efficiently. The top priority is not affecting plant operation in any negative way – innovations must pay off in daily pro- duction. We expect suppliers to respect these cycles with their products. This means that we need to develop a common understanding for those phases in which we can carry out upgrades.” Solutions for life The intensive work of the last 10 years has already paid off for Birk: “In our bids, we have succeeded in getting our suppliers to offer not only a price for the initial investment but also for the lifecycle costs, for example, for 15 years. This makes the maintenance of automation technology a plannable and above all a calculable component of the system lifecycle. We can assess how much a system will cost us in the course of these 15 years; this is a major step for- » Maintenance of automation technology must become a plannable and above all a calculable part of the system lifecycle. «
  6. 6. 6 process news | 2-2012 ward, and we were also one of the trendsetters in the industry with this approach.” Another aspect is standardization of automation technology. BASF actively promotes this both in terms of the compatibility of different systems and within the system software. For example, BASF uses standardized software modules for engineer- ing Simatic PCS 7 process control systems. These modules represent typical control system tasks that are frequently needed. BASF has developed this tool kit together with Siemens, one of its preferred suppliers for process control systems. “We use the tool kit worldwide in all the new BASF plants. Instead of having an individually programmed stand-alone system, we can work with a control system that is largely composed of standard com- ponents and uses customized functions only where expressly needed. An additional benefit of this approach is that it helps us migrate systems more efficiently. We have good documentation and can easily access all required information. This defi- nitely reduces the project complexity that you have with current control systems significantly,” explains Birk. “Our teams save time during engineering, and the tool kit makes many tasks simpler, plus we can reap additional benefits over the system lifecycle.” However, Birk says that it is essential to evaluate standardization in terms of the contribution it makes to efficient lifecycle management: “It is important to find the right balance between stan- dardization and customization, keeping the system simple and efficient. And we need to talk fre- quently with the project teams on-site to make sure the people who have to work with the systems at the construction site or in the plant share our approach.” Open exchange and common objectives Sharing and exchanging information are important for Birk, also to establish a good working relation- ship with suppliers and partners. “Siemens is not just someone who we have been working with for a long time, building a lot of trust. Both companies share common objectives, so we can openly discuss and evaluate ideas and concepts in the area of process control engineering,” Birk explains. “For example, we can assess together which innovations – for instance, in the area of operating concepts, IT secu- rity, or remote maintenance – should be introduced where and when. We also carry out beta tests together and match development activities to requirements. This dialogue is also important for us as it helps us put our own concepts to the test and remain open for new ideas. I think that our job is not so much to predict the future but to actively shape it – and Siemens is a partner that is already well posi- tioned for this.” Particularly the last point – developing joint ideas and speaking with each other – is an integral part of the corporate culture at BASF. “Consequently, we have many young and well-qualified employees, whom we train intensively,” says Birk. “We actively promote the exchange between specialists – not only within our BASF community for automation technology but also with our partners. Fostering knowledge in our teams is an important aspect when you talk about lifecycle management.” On a more technological level, Birk sees more untapped potential in the area of standards: “We collaborate actively in committees such as NAMUR (Standards Committee for Measurement and Control in the Chemical Industry) to improve and promote existing standards and to define new ones. It is our D r. J o a c h i m B i r k D i r e c t o r o f t h e C e n t e r o f E x c e l l e n c e f o r A u t o m a t i o n Te c h n o l o g y, B A S F S E Joachim Birk has been working for BASF for about 20 years. Today, he is the director of the global Center of Excellence for Automation Technology at BASF in Ludwigshafen and is involved in many fields of control technology such as Advanced Process Control (APC), manufacturing execution systems (MES), control systems and security systems, robotics, and laboratory automation. Birk started his career as an APC engineer and then worked as an electrical and automation engineer in research facilities. C o v e r L i f e c y c l e M a n a g e m e n t Publicis
  7. 7. process news | 2-2012 7 (MES) to be able to compile and transform system data into key performance indicators (KPIs) for per- sonnel in various groups and at various levels. “The KPI cockpit, which we are currently adapting together with Siemens to meet our requirements in the area of chemi- cal production, will help us argue our case. With it, we can provide opera- tion and manage- ment with KPIs that enable them to compare and evalu- ate their plant per- formance quickly – and this will trigger a request for advanced and efficient automation sys- tems that comes from the operational level, because they see what a benefit it offers for them and their plants. And that is what really counts.” p info contact firm belief that systems and products have to be widely established in the market to be sustainable and maintainable in the long term. As a result, we clearly pursue a strategy of using only mainstream products wherever possible.” Advanced concepts for the lifecycle Birk is also keenly watching another hot topic that is much dis- cussed in NAMUR: “In- tegrated engineering of process and auto- mation technology cer- tainly still holds enor- mous potential for im- proving efficiency and transparency of plant and engineering data throughout the lifecycle. This is definitely something that our strategic planning will look into.” Despite his innovative spirit, Birk’s main concern is for the BASF plants, not only in Ludwigshafen: “The top priority is that automation technology has to make a contribution to plant operation. And I see this as one of the most exciting and central ques- tions that we have to be able to answer: what is the operational benefit?” Therefore, BASF and Siemens are currently developing an appropriate infrastruc- ture within the manufacturing execution system » The top priority is that automation technology has to make a contribution to plant operation. « BASFSE
  8. 8. 8 process news | 2-2012 p Integrated Engineering The Next Step The basis for the compiler development is a migration project that is planned for a batch- ing tank at Sanofi-Aventis in Frankfurt. Dr. Thomas Tauchnitz, head of engineering of the Technol- ogy Process Group at the Frankfurt Pharma site of Sanofi-Aventis Germany, explains the details: “The objective is to specify the automation functions in The integration of Comos and Simatic PCS 7 is making the next step. Currently, a bidirectional compiler helps integrate the two systems. This project will also provide information for another important step: the specification of an interface in the context of a planned NAMUR (Standards Committee for Measurement and Control Technology in the Chemical Industry) recommendation. Comos at our site and then to transfer them via the compiler to Simatic PCS 7. We do not yet have the full functionality in use, but we are already using parts of it.” The developer teams at Sanofi- Aventis in Frankfurt and Siemens in Karlsruhe are working hard to improve the interface. Tauchnitz adds: “I see an important field for more advanced approaches here in particular, as the direct data interchange between Comos and PCS 7 also pro- vides critical information for improving the manu- facturer-independent integration of process engi- neering and automation technology.” A NAMUR study group is working with Tauchnitz on a recommendation that specifies a defined interface between the two systems (see box). “NAMUR intends to implement this interface using a data container with a generally binding structure that is accessed by both the process engineering planning and the automation systems.” An employee in quality control at Sanofi-Aventis in Frankfurt-Höchst. The company is currently developing a compiler together with Siemens for integrated engineering in pharmaceutical production Integrated engineering in the pharmaceutical industry: watch the video C o v e r L i f e c y c l e M a n a g e m e n t
  9. 9. process news | 2-2012 9 info contact Better integration, more competition The background is that plant operators would like to remain flexible in their choice of engineering sys- tems, but they would also like, above all, to have a future-proof solution for the interface. Tauchnitz says: “After all, we still need to be able to migrate and maintain our engineering data in 20 years – independent of the versions of the software and operating system that we will have then. Since the container specifies only a data structure and is largely system-independent, I think the proposed NAMUR recommendation is the right approach. Sys- tem suppliers only need to provide a corresponding import and export option for the data, which consid- erably reduces the complexity.” With Comos and Simatic PCS 7, Siemens is able to address the interface both from the engineering environment for the process engineering and from the automation technology side. In the latest ver- sions, Comos PT and Simatic PCS 7 are linked through a bidirectional interface for transferring hardware specifications as well as module types and instances for the process control system. In the con- text of the compiler development for Sanofi-Aventis, the interface will be improved so that it also covers types and instances for equipment modules. T h e N A M U R c o n t a i n e r NAMUR aims to design the integration between different systems for computer-aided engineering (CAE) to be as open and system- and manufacturer-neutral as possible. This should not only ensure that CAE tools and process control systems of different manufacturers can be combined with each other but also enable robust and reliable data transfer that is validated in a pharmaceutical environment, while at the same allowing for further develop- ments of methods and processes. NAMUR suggests a concept for this that is based on a manufacturer-independent intermediate database for engineering data, the so-called NAMUR container. The decisive factor here is that every supplier no longer needs to agree on an individual interface with every manufacturer for mutual data exchange, but instead each system in this data exchange must only provide one interface to the NAMUR data container to exchange data in both directions with any other system. Engineering data from the CAE system form the basis for the automation specification in the user requirements specification and functional specification. The technology objects, such as control module types and instances, are defined in the CAE system and linked to the functionally extended automation system modules. The container will work bidirectionally and also enable the maintenance of the stored data across the entire lifecycle as well as automatically synchronize changes to both sides. DenisFélix/InterlinkImagesfürSanofi-Aventis For this interface, the existing typicals at Sanofi- Aventis were modernized for automation in Comos PT. They now contain all the relevant control loops and interlocks as well as control and signal specifica- tions. Furthermore, corresponding basic objects in the project database were also provided by Comos PT. On this basis, the functions for the automation software can be specified for the process automation independent of the target system. Idea generator for the container specifications For Tauchnitz, the direct link between Comos and Simatic PCS 7 also serves as a kind of idea generator for the specifications of the NAMUR container. “We work closely together with the study group here and invite the experts to join our discussions with Siemens when appropriate,” he says. “My assess- ment: if we can implement a well-defined link between Comos and PCS 7, we will also be able to develop a well-defined NAMUR container.” p N A M U R CAE system Supplier A CAE system Supplier B DCS Manufacturer A DCS Manufacturer C DCS Manufacturer B
  10. 10. 10 process news | 2-2012 I n d u s t r y C h e m i c a l I n d u s t r y p Klüber Lubrication, Germany Smooth Standards Munich-based lubrication specialist Klüber Lubrication belongs to the Freudenberg Group and has more than 80 years of experience in this field. The company produces more than 2,000 different special lubricants for all kinds of applications. The Klüber production system is made up of a global network of production sites ranging from small plants with only a few reactors to complex produc- tion systems with tank farms. In the course of a step- by-step modernization of its production system, the company wanted to first bring its Salzburg plant up- to-date and thereby create a standard that could be applied worldwide to all other plants. They wanted to have a uniform system with consistent process visualization and automated recipe control. In addi- tion, the system should be able to document the batch processes in a simple and comprehensive way. Scalable solution for global implementation The company decided on a process control system based on Simatic PCS 7. Project manager Peter Luksch explains that the decisive factor for choosing Siemens was the standardized automation solution with respect to hardware and software as well as Siemens’ worldwide solution expertise. The consis- tently scalable architecture of Simatic PCS 7 can be easily adapted to Klüber’s plants of different dimen- sions. Additional functionalities such as asset man- agement, automatic batch processes, and material transport control as well as process data evaluation and management can also be integrated smoothly. How to design a globally standardized automation system to cover the requirements of many different batch processes and production plants of different sizes? Siemens found a convincing answer to this question raised by Klüber Lubrication. A particularly interesting application for Klüber was the Simatic Batch software package for the flexible automation of complex batch processes. Its modular design and scalability make optimum adaptation to every plant size possible. In addition, recipes can be developed centrally and then exchanged across loca- tions and modified on-site. The complete process documentation also supports Klüber in providing proof of quality documents such as those required by the automobile and pharmaceutical industries. Standardization in every detail Klüber wanted to have a modular implementation concept that could be deployed in large and small production sites alike. One component of this solution was PCS 7 with Safety Integrated. To ensure the reproducibility of electrical equipment, a control cabinet containing the electrical and automation equipment was assigned directly to each reactor. A general operating concept was also integrated into the navigation bar of the control panel. The result was a scalable automation solution based on stan- dards that was, at the same time, customized to meet the specific requirements of Klüber. Migration with integrated investment protection After the conversion of the Salzburg plant to Simatic PCS 7 in December 2010, the company is step-by- step migrating additional plants to Simatic PCS 7. At present, a plant located in Munich is being upgraded. Another plant in China is about to be commissioned. A project in Spain has just been
  11. 11. process news | 2-2012 11 info contact started. Siemens pursues the same migration strat- egy in all these projects: modernization of the exist- ing systems without plant shutdown as far as possi- ble and investment protection through retention of the existing hardware structure wherever possible. The worldwide standardization of the automation systems also forms the basis for central reporting and system integration from the field to the enter- prise resource planning (ERP) level. An archiving and reporting system, PCS 7 Process Historian, is to be introduced at Klüber Lubrication later this year. p KlüberLubrication »The decisive factor in favor of Siemens was the standardized automation solution with respect to hardware and software. « Peter Luksch, project manager, Klüber Lubrication The operators were trained on-site on the new system A view into the production facility KlüberLubrication Backgroundphoto:Fotolia
  12. 12. 12 process news | 2-2012 I n d u s t r y P h a r m a c e u t i c a l I n d u s t r y SiddharthSiva
  13. 13. process news | 2-2012 13 insulin crystals were imported from European sources for the local production of Jusline. Julphar invested $136.1 million in its new plant in Ras Al Khaimah. Julphar XI is one of the most modern biotechnolog- ical plants producing recombinant human insulin crystals and is built in accordance with EMEA (Euro- pean Medicines Agency) regulations. Improvements on the process are now ongoing to achieve the yield. The fermentation facilities are designed to produce 450 batches of 10,000 l fermentation broth per year, yielding 1,500 kg of insulin crystals, which will enable Julphar to produce more than 40 million vials of insulin. The plant has six operational suites. In the media preparation area, bulk media is formulated before inoculation and seed vessels are filled to Julphar, United Arab Emirates Quality of Life, Quality of Product Thanks to a fully automated production unit for insulin, Julphar (Gulf Pharmaceutical Industries) in the United Arab Emirates makes a contribution to providing affordable high-quality medicine to patients and improving the quality of life for diabetes patients in the Middle East.q y p Diabetes in the Middle East is rising rapidly. Illness and healthcare are causing a financial strain on regional governments and many families. Offering high-quality, affordable treatment to a growing number of patients would help ease the burden. With this in mind, Julphar, a pharmaceutical manufacturer in United Arab Emira- tes, worked with Siemens to auto- mate its biotechnology process in its new insulin production plant, Julphar XI. Established in 1980, Julphar is the first pharmaceutical manufacturer in the Arab Gulf States and a leading pharmaceutical producer in the region. Julphar has 11 state-of-the-art pro- duction facilities in UAE, which adhere to the highest standards of manufac- turing. Its commitment to high stan- dards has led it to procure ISO 9001 and ISO 14001 certifications. Its pro- ducts are marketed on five continents and in 2011 crossed over AED 1 billion in sales. A new facility for fighting diabetes Julphar’s insulin production plant (Julphar XI) is its latest facility under construction and is expected to widen its product offerings and bolster its market presence, especially in diabetic care. Since diabetes afflicts sizable sections of the Middle East popula- tion, Julphar’s foray into bulk insulin production could not have been more timely. Julphar’s first insulin production began eight years ago when »Julphar recognized a gap in the market for locally produced insulin crystals. This production will allow us to respond to an increasing market demand, making insulin more affordable and accessible. « Dr. Ayman Sahli, CEO Julphar
  14. 14. 14 process news | 2-2012 begin fermentation. In the buffers preparation area, the bulk buffers are formulated before filling storage vessels for chromatography purification. A buffer hold stores formulated buffers in vessels for further use. The fermentation suite consists of four seed fermenters and four 5,000 l production fermenters, which produce 10,000 l of bacterial broth per batch. In the recovery area, the E. coli is removed and the pre-poinsulin is harvested and treated with buffers to assist it in attaining its tertiary structure. In the purification suite, peptides are removed and the pre- proinsulin is cleaved using CPB to modify its primary structure and then separated by chromatography and finally crystallized. A trusted partner Julphar was happy with previous Siemens solutions, such as in its Julphar VI plant for liquid and semi- solid pharmaceuticals. This plant is fully automated with Simatic components and has minimal human intervention in all stages of production. Siemens’ first-class biopharmaceuticals knowledge and expe- rience, and its innovative automation products and solutions, were the main reasons that Julphar chose Siemens to help build its new plant, the Julphar XI. In early 2009, Julphar and Siemens discussed coop- eration for Julphar XI. Construction continued in 2010 and was accomplished in two phases. In phase 1, the user requirement specifications and process-related functional specifications were deter- mined. In phase 2, the hardware and software for the control systems were designed. The control sys- tem was configured, hardware was integrated, and the system was tested. In 2011 the control system was delivered and the plant was completed. In March 2012 site acceptance was performed and operation started. “This is the start of a long-term relationship, initially focused on successfully completing what Julphar considers to be one of their most strategic projects during recent years,” said Dr. Ayman Sahli, CEO of Julphar. Full automation for bulk production Siemens delivered a comprehensive process control solution based on Simatic PCS 7, including batch and route control. The solution includes the automation of insulin crystal production and the affiliated tank farm, the integration of the fermentation process, and the communication to third-party packages. The system comprises 11 Simatic S7-417s for the dif- ferent suites within production, connecting remote stations with 6,000 I/Os to operate sensors and valves. Over 7,000 m of data cable were laid to connect the PLCs, PCs, and cabinets with industrial Ethernet and Profibus. Operating and monitoring can be done from the process control room and in the field with remote HMI panels. Every operation is logged safely and all executed batches are archived in a central server. Project management a crucial factor Considering the high standards for the pharmaceuti- cal industry, the need for bulk production, and the desire to reduce total costs, expert project management and engineering was a must. The Siemens project manage- ment approach PM@Siemens strictly followed the V model and complied with the latest GAMP regulations. From the start, project approaches were specified, the responsible roles defined, and expected results described. In addition, devia- tions in the process were antic- ipated and planned for. This helped minimize project risks and improved project transpar- ency and control. Project inter- faces were also standardized to ensure easy communication between all stakeholders. A project quality plan served as a base for all referenced documents. This ensured compliance with relevant standards, so proj- ect goals could be met efficiently. Siemens developed the quality-related documents during the early phase of the project in cooperation with Julphar. Testing plans and standard operations were created and used during the entire project lifecycle. The complete set of documentation was given to Julphar for its own quality assurance and regulation acceptance. »We have chosen Siemens as they are world leaders in automation process control systems, for both the pharmaceutical and biopharmaceutical industry. They were able to provide a good platform suitable for our manufacturing needs. « Eng. Essam Hammad, Julphar Diabetes I n d u s t r y P h a r m a c e u t i c a l I n d u s t r y
  15. 15. process news | 2-2012 15 info contact ity. To ensure that Julphar can benefit from the full performance of the system over the entire lifecycle, Siemens will provide ongoing service for the installed base. For Julphar, this means that Siemens solutions and expert project management not only contributed to completing the project on time and meeting pro- duction goals but will also continue to improve its manufacturing process as time goes on – to make sure that the new plant will keep improving the lives of diabetes patients in the Middle East. p To create more value for customers and best fulfill requirements, Siemens combines solutions services from different organizational units. For this project, a team of several experts was formed. The core proj- ect management and engineering operations were executed in Karlsruhe and Marburg as well as on-site in Ras Al Khaimah. This project team delivered excel- lent performance for the customer. Service for life With Simatic PCS 7, Julphar is well positioned to serve the needs of the growing market for diabetes medication. The process control system makes a sig- nificant contribution to optimizing operating costs, protecting investments, and securing plant availabil- J u l p h a r X I : t h e k e y p o i n t s The new facility will serve the growing market for insulin in the Middle East 3 By choosing a fully automated bulk process, Julphar wanted to be able to provide high-quality, affordable products 3 A Simatic PCS 7 system with 11 S7-417s was used to automate the plant’s six production suites and 6,000 I/O points, reducing production costs 3 Siemens automation, expert project management, and customizable after- service solutions ensure that the plant is on target to achieve its production goal of 40 million vials of insulin each year “This is the start of a long-term relationship,” says Dr. Ayman Sahli, general manager of Julphar. The new plant, Julphar XI, was completed in 2011 but Siemens will provide ongoing service for the installed base over the entire lifecycle. allphotos:SiddharthSiva
  16. 16. 16 process news | 2-2012 Curti Costruzioni Mecchaniche was founded in 1957 in Imola / Italy with the aim of con- structing machines and devices for the tex- tile and agricultural industries. During the course of time, the company has specialized in the aerospace industry as well as the development and manufac- turing of packaging machines for the food process- ing, cosmetics, and pharmaceutical industries. With the new AVM 100 and 150 cartoning systems, the engineers of the Curti packaging division have developed a novel design that provides outstanding cost-effectiveness and efficiency. The AVM machine series makes it possible to standardize packing sizes depending on the types of containers being pack- aged and utilize packaging resources efficiently. The machines are also easy to operate and service. Natu- rally, the AVM machine series is equipped with bar- code readers to trace products, as required for phar- maceutical applications. The machines can option- ally be linked with higher-level IT systems to log production data. All electronic system To achieve this, the engineering department departed from the classic machine design principles and deployed only latest-generation automation components using solely Siemens products and sys- p Curti Costruzioni Mecchaniche, Italy Clear Benefits Lower costs, reduced variety of components, and optimum usage of packaging materials and energy – those were the objectives of the new AVM machine series by Curti Costruzioni Mecchaniche, which packs vials and ampoules with high speed and high efficiency thanks to a perfectly aligned automation and drive solution.y g I n d u s t r y P h a r m a c e u t i c a l I n d u s t r y
  17. 17. process news | 2-2012 17 info contact tems. The AVM is a fully electronic cartoning machine – an asynchronous motor turns the carou- sel; servodrives synchronize the individual work sta- tions with the main drive. The Sinamics S120 con- verter and Simotics S-1FK7 motors are not only ide- ally suited to performing highly dynamic movements but can also power various drive concepts with syn- chronous or asynchronous motors (control modes U/f, vector with/without regeneration, servo) with only one twin-axis module, reducing type variety. Curti uses Simotion D as the high-level control in the new machine series. Simotion also handles the artic- ulated arm robots so that no additional robot con- troller is required. The Simotion systems can com- municate via numerous field bus interfaces and are therefore easily integrated into a large variety of communication architectures. The individual motors are linked via Drive-CLiQ, which greatly simplifies commissioning and servic- ing, since motor parameters are automatically to the controller using an electronic nameplate and safety functions are immediately available. This enables the machine operator to replace motors easily and with- out errors. The controller matches the motor data stored on the electronic nameplate with the approved motor types, so that only suitable motors can be operated. Flexible and simple project engineering Curti’s electronics department uses both Structured Text (ST) and Motion Control Chart (MCC) as well as the classic ladder diagrams (LAD) and function block diagrams (FBD) for programming. The high-perfor- mance Simotion Scout development environment enables the easy creation of machine logic with LAD/ FDB, the flexible implementation of the axes coordi- nation with ST, while creating complex coordinated motion sequences with the predefined motion func- tion blocks in MCC. As a result, the AVM machine series can be adapted easily to a variety of tasks; this flexibility makes it a perfect package with clear ben- efits for packaging ampoules and vials. p T h e n e w m a c h i n e s e r i e s : p e r f o r m a n c e r i g h t d o w n t o t h e l a s t d e t a i l The new AVM 100 and AVM 150 cartoning machines consist of a carousel with 12 stations through which the vials and ampoules pass during the packing. In the first work step, the vials are fed from below into the box; then the adhesive is applied and the box is closed. The machines can also customize the packaging by applying a quality seal or making the box resealable. 3 Box size: 60 x 40 x 35 mm to 90 x 190 x 80 mm 3 Visualization, machine operation, and recipe management: Simatic MP370 Touch Panel 3 Control system: Simotion D445 integrated into the control unit of the Sinamics S120 drive system 3 8 servo axes with Simotics S-1FK7 servomotors 3 1 asynchronous motor as the main drive 3 4 asynchronous motors for the auxiliary equipment The controller coordinates all Sinamics drives and handles not only the motion functionality with the internal technology functions but also the temperature control and the PLC functionality. Fotolia–Dusk SiemensAG
  18. 18. Fotolia–Delphimages 18 process news | 2-2012 I n d u s t r y P h a r m a c e u t i c a l I n d u s t r y p Alcon Cusí S.A., Spain Targeting the Supply Chain Alcon’s serialization solution enables the traceability, integrity, and transparency of products throughout the global supply chain and helps the company fulfill its current and future legal requirements in various markets and protect its brand from counterfeit products. With the establishment of the Alcon Pre- scription Laboratory in Texas in 1945, two pharmacists, Robert Alexander and William Conner, laid the foundation for one of the most successful business stories of all time. Today, Alcon Laboratories Inc. is number one in the world with its pharmaceutical and surgical products for ophthalmology, contact lenses, and eye care prod- ucts. In 2010 the company generated sales of US $7.2 billion. Alcon operates facilities in 75 coun- tries, serves 180 markets, and employs 23,000 people. Artificial tears from Spain One of the company’s main products is lubricant eyedrops and ointments, which Alcon sells in various countries, especially in France and Turkey. Each packaging unit must receive a unique ID with a serial number as a data matrix code (2-D bar code), which makes them fully traceable and which complies with the legal requirements of the respective countries. This serialization provides the products with an elec- tronic “pedigree” and allows them to be monitored without interruption, in accordance with the various
  19. 19. process news | 2-2012 19 Bar Code Data Matrix RFID ERP External Enterprise Data Exchange ePedigree Track/Trace Authentication Serialization Line System Serialization Line System* Code Reader/Scanner RFID Encoder/Reader Printer Hand Reader Other Lines* Reject Station Siemens AutoID ConnectorSieme The pester pac coding unit applies a unique code to each package info contact SiemensAG statutory requirements, and to be documented – an important feature for Alcon, which exports its products to many different countries. Together with the Munich-based company Atos, Siemens imple- mented a complete solution for serialization, rang- ing from the packaging machines on the production floor to the enterprise resource planning (ERP) sys- tem. The machine solution was fully integrated into Alcon’s six existing packaging lines. It is based on standards and was implemented in close coopera- tion with pester pac automation based in Wolf- ertschwenden in Germany. Integrated automation The automation system in the serialization units attaches the data matrix code to the folded boxes. Two cameras determine whether the printout is cor- rect and whether the single folded boxes were packed completely in a 10-unit bundle. Siemens’ line system (Siemens Line Controller) manages this infor- mation and sends it as an aggregate via the Atos AutoID Connector (AAC) to the back-end ERP system, which processes and archives it. The AAC assumes other tasks: It receives and processes the batch files from the ERP level and the motion control informa- tion system (MCIS) and prepares them for the line system. In addition, it generates the unique serial numbers for the folded boxes. This solution was also integrated as a retrofit into two machines that operate at a higher speed. Thus, the printers, cam- eras, and machinery had to be calibrated accordingly and coordinated with the line software. A smart approach minimizes loss of production The serialization solution at Alcon meets all the re- quirements for traceability of products in the phar- maceutical industry and ensures high integrity and transparency across the entire global supply chain. Its open system architecture allows integration into the existing machine environment, the inclusion of third-party devices, and expansion as needed. The project was started in June 2010, and the first machines were already delivered at the beginning of November 2010. The machines and the retrofit were phased in over the course of the following year, which allowed production interruptions to be mini- mized. During the start-up phase, Alcon ordered an additional machine. The entire project was processed on the basis of the V-model typical for the pharma- ceutical industry, according to GMP standards, and was completed successfully and with the perfor- mance qualification (PQ) in February 2012. Thanks to the combined expertise of the project team and good collaboration between Siemens, its partners, and Alcon, even nontypical requirements and chal- lenges were overcome. All technical issues were dis- cussed with the team and together with Alcon. Even the quality management systems of the companies involved complemented each other seamlessly throughout the project. p
  20. 20. 20 process news | 2-2012 Proccess feed Cllosed-loo control To produce a range of modern drugs, pharma- ceutical manufacturers must face the chal- lenges of developing and controlling sophis- ticated chemicals processing in a tightly regulated environment. In the past, regulatory barriers tended to inhibit manufacturers from moving beyond established practices to adopt newer, state-of-the- art manufacturing processes. Recognizing this dilemma, the US Food and Drug Administration (FDA) introduced new guidances in 2004 to encour- age innovation in pharmaceutical manufacturing p ICES, Singapore Quality Medicine A research institute in Singapore finds the formula for the manufacture of advanced pharmaceuticals with the support of the Sipat process analytical technology software. and quality assurance (QA). This initiative involves Pharmaceutical Manufacturing in the 21st Century, and process analytical technology (PAT) was launched as the cornerstone of the FDA’s Pharmaceutical Good Manufacturing Practices. Controlling manufacturing processes PAT is a system for designing, analyzing, and control- ling manufacturing processes. It is based on in-line measurements of performance and quality parame- ters of raw materials, in-process materials, and pro- cess variables. The philosophy of PAT is that reliably capturing and analyzing the flow of critical infor- mation relating to process chemistry, unit opera- tion, and scaling-up issues will facilitate faster pro- cess understanding. With a complete understand- ing of the processes, a manufacturer can take new drugs more quickly from the research and develop- ment (R&D) lab to pilot testing and hence full manu- facture. The key to PAT is the automated control of critical- to-quality parameters based on mathematical mod- els using real-time process data. With a predictable process and product quality, the finished goods may be dispatched direct from the line without holding for QA batch release. Through PAT, the costs of man- ufacturing, inventory, validation, and regulation can all be dramatically reduced. Pilot plant In Singapore, the Institute of Chemical and Engi- neering Sciences (ICES), a national research institute under the Agency for Science, Technology, and The integration of Sipat into the WinCC environment provides a unique operator interface for each phase of the process, resulting in a simple, yet complete and accurate, picture of all operations SiemensAG I n d u s t r y P h a r m a c e u t i c a l I n d u s t r y
  21. 21. process news | 2-2012 21 T mp pH pO₂Temp., pH, pO₂ p op Processsssssssssssssssssssssssssssssssssss aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaalllllllllllllllllllllllllllllllllllyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeerrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrr mp., pH, pO₂ ressureeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee .................................. Sample info contact tions), reactor temperatures, flow rates, levels, stir- ring speeds, and so on. The raw data were processed by Sipat based on the knowledge obtained from engineering analyses of the various stages of the chemical processes. The resulting intelligent output was then presented to the operators via script-based programming of the WinCC interface. The result was a unique operator-level graphical user display for each phase of the process, providing a simple, yet complete and accurate, picture of all operations. All of the user data provided, such as process-specific alarm management and MATLAB analysis of Raman spectroscopy data, were automated through the WinCC/Sipat integrated platform. All data were logged in compliance with FDA 21 CFR Part 11 electronic records requirements. The ICES integrated platform, powered by Sipat and WinCC, demonstrates the ability to link process ana- lyzers, process control tools, data mining tools, data analysis, and knowledge management tools into a single system architecture. Through online quality control, Sipat helps ICES provide better process insight, manufacturing performance improvement, regulatory compliance, and scalable PAT rollout and deployment. p Research (A*STAR), provides support for the growth and development of Singapore’s chemical and phar- maceutical sectors. A pilot plant run by ICES is used to develop novel chemical processes and manufac- turing techniques. To shorten the development time of these processes, ICES has implemented an integrated platform to support PAT, with the aim of obtaining key operational data and of increasing confidence in process implementation at full-scale manufacturing sites. The integrated platform employs Sipat, the software solution from Siemens for the application of PAT, together with WinCC supervisory control. To test the capabilities of the integrated platform at the pilot plant, ICES implemented a pilot-scale syn- thesis of 4-D-erythronolactone (4-DEL). The synthe- sis involved a four-phase hybrid process with both batch and continuous unit operations. During opera- tion, the critical process parameters were monitored in real time via the WinCC SCADA system. This sys- tem was dynamically linked to the Sipat software, which managed all critical process data through Object Linking and Embedding (OLE) for Process Control (OPC) protocols. Sipat also delivered data to a MATLAB software server for more sophisticated analysis. The MATLAB results were then fed back into Sipat and WinCC and were stored by Sipat in an SQL database. Applying intelligence to data The process data monitored included Raman spec- troscopy (to measure reaction mixture composi- Fotolia–IngorNormann
  22. 22. 22 process news | 2-2012 Te c h n o l o g y P r o c e s s C o n t r o l Te c h n o l o g y p BASF, Germany Innovative Operating Concept Ludwigshafen, Germany, is home to the largest BASF production site worldwide. The more than 100 million cubic meters of wastewater gener- ated on-site every year are treated in the facility’s own wastewater treatment plant. Another 20 million cubic meters come from the surrounding towns and Quick identification of critical process states, process trends, and priorities, as well as reacting purposefully – achieving these goals is no problem for BASF, because the company is now benefiting from a user-friendly and efficient operating concept for plant control systems. municipalities. The total volume corresponds to the amount of wastewater that approximately three mil- lion persons in private households would generate. In the context of the OPAL 21 project, this treatment plant was to be designed according to the standards of Operational Excellence. To achieve this, says proj- The BASF wastewater treatment plant in Ludwigshafen handles the wastewater from the company’s industrial plants as well as sewage from the surrounding towns and municipalities
  23. 23. process news | 2-2012 23 info contact ect manager Dr. Jens Bausa, “modern automation infrastructure and tools” were required, “to support continuous improvement of the process.” Specifi- cally, this meant reducing complexity through stan- dardized and simplified operator interfaces, effec- tive alarm management, and uniform data inter- faces. New requirements Today’s operating concepts have to match the cur- rent situation in modern process plants, in particular the high automation level, the adjusted number of employees, the challenges that go with demo- graphic changes in staff, and the high demands in terms of safety and availability. Operator systems of state-of-the-art control systems such as Simatic PCS 7 support operator performance through a graphical user interface and high-resolution 22-inch screens. In addition, there are enhanced libraries with new process icons for the visualization of oper- ating states. With the innovative Human Machine Interface PLUS (HMI+) operation and visualization concept, which was implemented in an industrial wastewater treat- ment plant for the first time here, Siemens met the high expectations of the BASF Excellency Project OPAL 21 with regard to the optimization of process visualization and operation. A dedicated HMI+ ser- vice team develops a visualization solution tailored to the plant together with the plant operators. An efficient operation and visualization concept must be based on the latest findings on ergonomics and usability, but it must also be specifically adapted to the workflows of the users. It is therefore imperative to include the plant operators in the development process to make sure that the experience accumu- lated over years of system use and the valuable asso- ciated know-how is incorporated and safeguarded in the design of the control system. For this reason, a workshop was organized for the BASF employees to introduce them to the functional- ity and methodology of HMI+. Among other things, it addressed the color concept used, the new hybrid displays, and the task- and topology-oriented pre- sentation of the process-group level. Transition in three phases First, the available process charts were discussed with all the participants to identify to what extent they represent the actual processes and support the required operating steps. Higher-level process-group descriptions were created from the insights gained, and the corresponding ideal representation – digital, analog, and/or curve diagram – was determined. This resulted in the level 2 process diagrams that will cover 85 percent of all operating procedures. In the subsequent optimization phase, the plant operators had the opportunity to assess these process dia- grams from the user’s point of view and to make additional suggestions for improvement. Afterward, the process visualization was finalized in PCS 7. During the stepwise DCS migration, the first stage of expansion of the HMI+ project was also completed in the BASF treatment plant in Ludwigshafen. The per- sons responsible at BASF are highly satisfied with the result: “The active integration of all participants and aspects into the design of the operating graphics led to broad acceptance of the new operating concept.” This opinion is also shared by the plant operators: “We value the clearly displayed process visualization, which, with a few clicks, makes recognizing critical process states, process trends, and priorities easier.” Meanwhile, the HMI+ project has been enhanced and extended to three additional areas of the sew- age treatment plant. p H M I + p r o j e c t : k e y f a c t s 3 Human Machine Interface PLUS (HMI+) project as an add-on to the PCS migration project of the production facility’s sewage treatment plant in Ludwigshafen 3 Upgrade of the operator interface to the HMI+ user interface integrated into PCS 7 in four expansion stages (flue gas washing water treatment, drainage, incineration plant, and biology) 3 Complete operation of the effluent plant from a central measuring station by four plant operators (one per plant section) with the help of only 50 information-oriented process-group representations (level 2 overviews); the 500 conventional process charts support the process operation, for example, for diagnostics. BASFSE/Hans-JuergenDoelger
  24. 24. 24 process news | 2-2012 example, Siemens and its Solution Partners BST Buck Systemtechnik, Rösberg Engineering, and the on/off group will be represented this year at ACHEMA, where they will exhibit innovative solutions. Process safety specialists: BST Buck Systemtechnik BST Buck Systemtechnik in Brunsbüttel, near Ham- burg, is a typical Siemens Solution Partner. The sys- tem integrator, founded in 1989, has acquired an exceptional breadth and depth of knowledge about batch processes and is a specialist for Simatic Batch. BST implements factory acceptance tests (FATs) much more efficiently with the Simit simula- tion solution and can thus decisively accelerate the start-up of operation. In addition, BST is one of only 14 Siemens Solution Partners that are certified as Simatic PCS 7 Safety Specialist Partners. p Siemens Solution Partners Partners for Global Solution Expertise The industry thinks and acts on a global scale – and consequently, the solution part- ner program provides a global network of approximately 1,200 Solution Partners in more than 60 countries. They are not only certified by Siemens and work according to uniformly defined quality criteria but they also keep their expert knowledge up-to-date and verify their qualifica- tions in repeated certification workshops and audits. Solution Partners engage in continuous exchange of know-how with Siemens and have extensive knowledge about the various Siemens products and systems. With the help of the Solution Partner Finder on the Siemens web portal, customers can find the solution partners that match their requirement profiles. Joint appearances at trade fairs and events are also part of the Solution Partner program. For Process control technology is a field for specialists with technology know-how as well as comprehensive industry expertise. Siemens Solution Partners offer exactly that. They are selected system integrators for automation and drive technology that implement qualified solutions based on Siemens products and systems. » Siemens Solution Partners are a global network of certified system integrators that covers a broad field in the process industry with a wide range of competencies. Siemens supports its partners regularly through ongoing know-how transfer and expert support and makes superior solutions possible with global quality standards. « Joachim Kessler, director, Siemens Solution Partner Program Te c h n o l o g y P r o c e s s C o n t r o l Te c h n o l o g y
  25. 25. process news | 2-2012 25 info contact At ACHEMA, BST will present the PCS 7 extension BST ExPlate, which makes it possible to identify and display PCS 7 faceplates for certain process control loops on an Ex-protected handheld computer via RFID. With appropriate authorization, operation and the display of maintenance information from SAP is also possible. Continuity that counts: Rösberg Engineering GmbH A process control system is only one component influencing the success of an automation project. The specification of the instrumentation, the design of the protective functions according to SIL, and ensuring explosion protection as well as its docu- mentation are at least as important. Besides, excel- lent project management is also absolutely essential. This is exactly the point at which the system integra- tor Rösberg Engineering GmbH, founded in 1962, comes in. The specialists from Karlsruhe in Baden- Württemberg master the entire range of services and offer their customers a complete solution from a single source as a responsible engineering, procure- ment, and construction (EPC) contractor. Further- more, Rösberg provides a smooth flow of informa- tion between the computer-aided engineering (CAE) system, the manufacturing execution system (MES), and the enterprise resource planning (ERP) world. In this context, Rösberg supplements the solution with applications for master data and document management as well as for resource planning. Solu- tions from Rösberg, such as the database-supported PCS-CAE system PRODOK and LiveDOK for efficient plant documentation, have proved themselves in the international market for many years. New dimensions made to measure: on/off group Customized process control solutions are key to cre- ating or maintaining a competitive edge. With this knowledge, the on/off group implements compre- hensive solutions from the fieldbus level up to the process control system. The Siemens Solution Part- ner from Wunstorf, near Hannover, relies on its com- prehensive industrial expertise and adapts its solu- tions specifically to the processes of its customers. The company is established throughout Europe and is a specialist for industries such as pharmaceuticals, food and beverages, water and sewage, and energy and the environment. A typical case story is the planning and installation of a new production center for single- and multi- chamber bags for B. Braun AG in Melsungen. To meet all the requirements and at the same time ensure the necessary flexibility of the system, extremely modularized object-oriented structuring of the software was carried out and strict standard- ization of the interfaces to the adjacent systems defined. The Simatic PCS 7 process control system with the Simatic Batch option and the standardized MES interface were used as a basis. With the devel- oped system, the complete vertical integration of all production and documentation processes (electronic batch record) was implemented. p allphotos:SiemensAG
  26. 26. 26 process news | 2-2012 p Industrial Security Eliminating Vulnerabilities with Updates and Patches The first measure in a defense-in-depth secu- rity strategy consists of recognizing and eliminating known risks. This includes, in particular, protection against malware. Systems can be secured against viruses, Trojans, and other attacks with patch management. To prevent the penetration and spread of harmful software, sys- tem operators and persons responsible for IT can employ three tactics: scheduled installation of software updates such as Microsoft’s security hot- fixes and firmware updates, use of antivirus soft- ware, and use of whitelisting software for preven- tive system protection. Updates: protection against known threats Windows Server Update Services (WSUS) is a signifi- cant component for updating operating systems, as it handles the supply and distribution of provided patches. On every second Tuesday of the month, Microsoft publishes security hotfixes for its systems. Siemens checks these hotfixes to ensure that they are com- patible with its systems and applications. Two weeks A majority of attacks on industrial IT systems aim at vulnerabilities for which patches are already available. However, few systems have all available patches installed. Consequently, the first step to an effective security strategy consists of efficient update management for virus protection and security patches. later, a list of the tested hotfixes is provided for download. The Siemens support websites publish detailed information on how to install the patches and what to pay attention to in this process. Antivirus software: security up-to-date Using antivirus software is a good complement to the installation of patches, since manufacturers of antivirus software usually react most quickly in terms of recognizing and removing newly appear- ing harmful software. Their databases are gener- ally updated daily and therefore contain the new- est virus definitions. A virus scanner, which is regu- larly provided with updates, is not only able to defend against attacks against the system from the outside. It can also free already infected systems of harmful software. Here as well, the prerequisite is that a specific solution be already implemented in the system design. For example, by creating a management console specifically for downloading and distributing the newest virus definitions to the individual clients. Siemens regularly tests all virus scanners that are available on the market for com- patibility with its systems and applications and Te c h n o l o g y P r o c e s s C o n t r o l Te c h n o l o g y
  27. 27. IT Security Hinweis Es sind geeignete Schutzmaßnahmen (u.a. IT Security, zum Beispiel Netzwerksegmentierung) zu ergreifen, um einen sicheren Betrieb der Anlage zu gewährleisten. Weitere Informationen zum Thema Industrial Security finden Sie im Internet unter process news | 2-2012 27 info contact publishes all compatible versions on a special sup- port website. Whitelisting: what isn’t listed isn’t permitted Both software updates and antivirus software have one fundamental disadvantage: they only enable a reaction to threats to the IT system that have already become known. Therefore, the use of whitelisting software is recommended as the third step in an effective defense strategy. Such solutions are based on a whitelist that contains all executable programs required to operate the system. If a user wants to install or execute a pro- gram not included on this list, this is prevented in the same way that the execution of harmful software entering the system by another route is blocked. The whitelisting software can be set to an update mode for installing updates and new programs. After installa- tion, the new programs are added to the whitelist. Thinking in context Together, the measures discussed here provide low-level IT system protection that can prevent a large share of attacks – but not all of them. There- fore, installing further measures and intensively raising the awareness of employees is essential. The next part of our industrial security series will focus on user administration, system hardening, and protection using firewalls and secured connections. p D e f e n s e - i n - d e p t h The defense of automation systems consists of a series of obstacles that require various attack strategies to overcome. Eight basic protective measures are used in this concept: Physical protection Guidelines and directives Security cells and DMZ Firewalls and VPN System hardening User account management Patch management Malware detection and prevention (antivirus, intrusion detection) DCS Potential threat IT security note Suitable protective measures (including IT security, e.g., network segmentation) must be taken to ensure secure operation of the plant. Further information on industrial security can be found at D.Obertreis
  28. 28. 28 process news | 2-2012 R u b r i k r o t R u b r i k g r a u p Spenner Zement, Germany Energy Efficiency as a Business Process Founded in 1926, Spenner Zement, a medium- sized family-run business in Erwitte, Germany, produces cement, lime, and dry mortar in 10 locations and generates annual sales of more than €100 million with approximately 220 employees. The decision to introduce an energy management system (EMS) in accordance with DIN EN 16001:2009 was made for two reasons: energy is the decisive cost fac- A comprehensive energy management solution with products and systems from Siemens helps Spenner Zement identify savings potential and establish a sustainable process for energy efficiency.ppp gygygyy yyy tor in the production of cement, and Spenner Zement has declared its commitment to a sustainable and environmentally sound development in its guiding principles. One system for three different plants On the technical part, Spenner Zement opted for the Simatic B.Data software solution from Siemens as its Te c h n o l o g y E n e r g y M a n a g e m e n t
  29. 29. process news | 2-2012 29 info contact energy monitoring and management system (EMS). B.Data can be completely parametrized, allowing Spenner Zement to easily add further measuring points, define new key performance indicators (KPIs), generate reports, and adapt the system to changed requirements in the future. The task con- sisted of integrating the Felsenfest, Diamant, and Nordstern plants into a uniform EMS and creating a central control room with the initial intention of monitoring electrical power. Thanks to the expertise and excellent collaboration of the joint project team of Spenner Zement and Siemens, the ambitious proj- ect was implemented during running operation within only six months. The new EMS records measured values with 7KM PAC3200 multifunction measuring devices at pres- ently some 90 measuring points, which are con- nected via Profibus to a central controller and a higher-level control system, where parameters are collected, processed, and archived. Simatic B.Data retrieves the data from the control system database. Siemens was responsible for installation of the hard- ware and software, engineering for the integration of the measuring devices, and parameterization and engineering of the control system as well as the commissioning of Simatic B.Data. Two key aspects were the ability to create and display energy KPIs and various reports. Energy flow, consumption, and balance With the new system, Spenner Zement can not only display and examine all energy flows in the works but also exactly balance the energy that was required and actually consumed. Consumption per product can also be recorded and evaluated, for example, kilowatt-hours per ton of cement. An important advantage is the automatic creation of cost center reports. Managers of the individual plants can easily obtain all the necessary informa- tion to further optimize consumption in their own areas. In the future, they should be able to generate reports themselves to analyze the energy efficiency of individual plant units, for example. The energy consumption can be evaluated and compared across any period. The load profiles for all core processes – breaker, raw mill, rotary kiln, cement mill, and so on – create the basis for active load management. This helps prevent expensive load peaks. In addition, qualitative conclusions can be drawn to coordinate production process and energy consumption more effectively and lower the basic load profile overall. Spenner Zement is already thinking ahead and wants to further optimize its energy purchases with sophisticated reporting and increased transparency. Based on the positive experience with Siemens as a supplier, the persons responsible are also willing to show the solution to external interested parties as a reference project for the cement industry. p E n e r g y m a n a g e m e n t a t S p e n n e r Z e m e n t O b j e c t i v e s 3 Increasing energy efficiency 3 Reducing energy consumption 3 Active load management 3 Optimization of energy purchases Te c h n o l o g y 3 Simatic B.Data energy management system 3 Simatic PCS 7 control system 3 Simatic S7-400 controller 3 Simatic ET 200 I/O system 3 7KM PAC3200 multifunctional measuring devices R e s u l t Robust and open, comprehensive solution that enables 3 adding measuring points quickly and easily, 3 defining new KPIs, 3 defining reports, and 3 making adaptations. Franz-Josef Haselhorst, deputy manager of the electrical engineering department, is very satisfied with the new solution: “The reliability and robustness of the lower-level system for recording and processing measurement values with the 7KM PAC3200 multifunctional measuring devices enables us to comprehensively record consumption.” Photos:SpennerZement
  30. 30. 30 process news | 2-2012 essnews www www.siemens news www.siemens news www.siemens www.siemens news www.s W e b E x c l u s i v e New in Process Automation Finding the Pattern The ability to obtain process knowledge and understanding supported by dedicated tools and methods facilitates the development of process innovations and technologies. With PCS 7 LAB Collection and Sipat, Siemens supports research and development as well as process optimization and development. The tools facilitate information acquisition and help to detect and understand variations in the product quality during the development and manufacturing process. As an output of this advanced information management online changes like adaptations of parameter settings can be implemented in real time, for example, by using the by default available Advanced Process Control (APC) methods. p Read the full story online: New in Chemicals Pure Automation The world‘s largest lactic acid factory, operated by Purac, was equipped with a Simatic PCS 7 control system by Siemens system integrator ZI Argus and Siemens Thailand. In the meantime, another plant for lactide was also automated with Simatic PCS 7 and more projects are being discussed. p Read the full story online: New in Engineering&Services More than just SIL “Functional safety” has been equated with the use of IEC-conforming hardware and software. However, what is really key to safer plants is introducing a safety culture into the operation, which is described by the corre- sponding standards. A challenging task that can be made easier with dedicated services from Siemens. p Read the full story online:
  31. 31. process news | 2-2012 31 D i a l o g u e process news 2-2012 Publisher Siemens Aktiengesellschaft, Gleiwitzer Str. 555, 90475 Nuremberg, Germany Drive Technologies Division CEO Ralf-Michael Franke Industry Automation Division CEO Anton S. Huber Editorial Responsibility in Accordance with the German Press Law Arno Hoier Responsible for Technical Content Cornelia Dürrfeld Concept Christian Leifels Editor Cornelia Dürrfeld, Siemens AG, I IA AS S MP 7 Siemensallee 84, 76187 Karlsruhe, Germany Tel.: +49 (0) 7 21 5 95-25 91 Fax: +49 (0) 7 21 5 95-63 90 Editorial Committee Elisabeth Desmet, Ute Forstner, Petra Geiss, Michael Gilluck, Walter Huber, Ingo Kaiser, Doina Pamfilie, Elke Pilhöfer, Andrea Hammerl, Roland Wieser Publishing House Publicis Publishing Postfach 32 40, 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: Stefanie Eger, Nadine Wachter Copy editing: Sabine Zingelmann DTP: Mario Willms; Döss Design Kommunikation Realisation GmbH Printing: Wünsch, Neumarkt, Germany process news is published quarterly Cover photo: D. Obertreis Circulation: 34,000 Job number: 002800 40314 © 2012 by Siemens Aktiengesellschaft Munich and Berlin All rights reserved by the publisher. This edition was printed on environmentally friendly chlorine-free paper. ISSN 1430-2284 (Print) The following products are registered trademarks of Siemens AG: B.Data, COMOS, DRIVE-CLiQ, ET 200, MP370, S7-400, SIMATIC Batch, SIMATIC PCS 7, SIMIT, SIMOTICS, SIMOTION, SIPAPER, SIPAT, SINAMICS, 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. IWI: TPOG Order number: E20001-M6212-B100-X-7600 Printed in Germany on location Open doors at the Munich University Talking with the Experts of Tomorrow When Munich University had Open Doors on April 21 this year, the institute for paper process engineering, Akzo Nobel, and Siemens presented a joint project: a paper plant for experiments and tests. Siemens provided a state-of-the-art automation solution for the plant so that paper processing experts-to-be get excellent training for their future work – and to make sure that the paper machine can be easily modified for experiments and trainings. On the same occasion, Siemens presented its comprehensive portfolio for paper processing in its Pulp&Paper Truck that was on location in Munich for the event. More information on the truck and the Sipaper solutions is available online: online Browse through thought leadership articles on what drives the process industry today and what strategies can help address key industry challenges. You can access additional news, case studies, detailed technology articles, and videos on key topics, plus read all past issues of the print edition. Via RSS feed, you will be instantly notified of new publications on the site. Stay ahead today! info Do you want to know more about the systems and solutions for the process industry from Siemens? Simply visit our information portal on the Internet at:
  32. 32. Answers for industry. ACHEMA 2012 Guiding you through change Join us for a journey through your plant lifecycle At ACHEMA 2012, Siemens will present its comprehensive portfolio of products, systems, solutions, and services covering the entire lifecycle: from research and development, process development, plant design, production, and mainte- nance to optimization and modernization. Experience how we will leverage our expertise and capabilities to be a reliable partner in the changing process industry landscape and contribute to increasing productivity and efficiency. Explore how Siemens can help guide you through challenges occurring today and in the future in the chemical and pharma- ceutical industry. ACHEMA 2012, Frankfurt am Main, Germany from June 18 to 22, 2012 Visit us in Hall 11.0, booth C3 More information: Siemens at ACHEMA on your Smartphone: scan the code!