process news - The Future of Manufacturing

Transcrição

process news
ACHEMA special
June 2015 | siemens.com/processnews
Discover the potential of digitalization
From Integrated Engineering
to Integrated Operation
process news ACHEMA special 2015 | Contents
ACHEMA
Process analytics
03From Integrated Engineering
to Integrated Operation
04Discover the potential of
digitalization together
24 More modules – more possibilities
26 Reliably monitoring process analytics
Process instrumentation
27 Farewell to ad hoc solutions
Software
08 Intelligence for operations
10 Viewed from the inside
28 One that controls everything
Industrial communication
12 Pushing past paper
29 Easily integrating distributed stations
14 Cloud solution for even greater ease of use
15 On the way to production scale
16 Efficiency through simulation
Process automation
17 E
fficient engineering
Extremely flexible for all outdoor uses
entral process control
18 C
A strong foundation
Power supply
30 Reliable power supply
Industrial identification
31 Identification facilitates optimization
Energy efficiency
32 Pure “green” hydrogen
19 Specific drive solution
Integrated Drive Systems
33 Increased service life of the drivetrain
Services
20 With Lifecycle Services plants never look old
21 Well thought out from the very beginning
34 Efficiency and safety in hazardous environments
35 Energy-efficient drive systems
22 End-to-end service
process news ACHEMA special 2015
Publisher:
Siemens AG
Process Industries & Drives Division
Digital Factory Division
Gleiwitzer Str. 555
90475 Nuremberg, Germany
[email protected]
© 2015 by Siemens Aktiengesellschaft
Munich and Berlin.
Editorial responsibility in accordance
with the German press law:
Winfried Wittmann
Editors: Kerstin Purucker, Dorit Gunia,
Gabriele Stadlbauer
Responsible for technical content:
Cornelia Dürrfeld
Circulation: 3.000
Editorial committee:
Peter Berghäuser, Mareike Blettner,
Elisabeth Desmet, Ute Forstner,
Maik Friedrich, Petra Geiss,
Birgit Gottsauner, Martina Häring,
Andrea Kerber, Andrea Lüdecke,
Alma Mirojevic, Doina Pamfilie,
Carolin Remler, Svitlana Schmitt
2
All rights reserved.
Publishing house: Publicis Pixelpark,
P.O Box 32 40, 91050 Erlangen,
Germany
Print: Passavia Druckservice, Passau
Photos: Siemens AG,
unless otherwise stated
Cover photo: Siemens AG
The following products are registered trademarks
of Siemens AG:
CALOMAT, COMOS, MAXUM, MicroSAM, OXYMAT,
PCS 7, S7-300, S7-400, S7-410, S7-1200, S7-1500,
SCALANCE, SILYZER, SIMATIC, SIMATIC HMI, SIMATIC IT,
SIMIT, SIMOTICS, SINAMICS, SINAUT, SIPAT, SIPROCESS,
SITOP, SITRANS, STEP, 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 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 only exist if expressly agreed in the terms of
contract.
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ACHEMA | process news ACHEMA special 2015
Discover the potential of digitalization
From Integrated
Engineering
to Integrated
Operation
At ACHEMA 2015, Siemens is
demonstrating how companies
in the process industry can use
integrated solutions to increase
efficiency and productivity and
thus their competitiveness.
D
igitalization enables the integration of individual process steps over the entire plant lifecycle – from engineering and operation to continuous optimization.
One of the key goals on the way to the digital plant is the
creation of an integrated data landscape. Siemens is already
providing data consistency across all lifecycle phases, from
engineering with the Comos computer-aided engineering
(CAE) tool to commissioning with the Simit simulation platform to ongoing operation with the Simatic PCS 7 process
control system and XHQ Operations Intelligence for business
decisions in real time. The advantages: greater transparency
and safety and reduced time to market. For service, access
to data from engineering and operations makes a decisive
contribution to optimizing processes. With data-based services such as Control Performance Analytics, process and
status data of control loops can be analyzed, allowing optimization measures to be derived.
Highlight exhibits
For the pharmaceutical industry, a modular Chem-API (chemical active pharmaceutical ingredient) batch plant demonstrates the seamless interaction of engineering and production planning software with automation systems and process instruments in hygienic design and a new paperless
manufacturing solution. The second highlight model with a
separation column illustrates the advantage of continuous
data communication, which not only allows optimization of
production but also increases plant availability and process
safety.
News at ACHEMA 2015
• Simatic IT eBR: Electronic batch records enable
paperless production in the pharmaceutical
industry and accelerate execution, review, and
approval of pharmaceutical production
processes and batch reports.
Page 12
• Siprocess GA700: The enhanced gas analyzer
with intelligent modular design is flexible and
easy to maintain.
Page 24
• Flender N-Bipex coupling: It extends the life of
the entire drive system.
Page 33
More information is available on the Internet:
siemens.com/achema
Resource and energy efficiency
Another focus is on integrated solutions for the efficient use
of resources – from power supply with Totally Integrated
Power (TIP) to Integrated Drive Systems (IDS) to energy data
management systems and modern control technologies such
as Advanced Process Control for Simatic PCS 7. In the area of
resource efficiency, the fair program showcases intelligent
solutions for water treatment and disinfection of industrial
water as well as energy-efficient pump applications.
3
process news ACHEMA special 2015 | ACHEMA
Siemens at ACHEMA 2015
Discover the potential of
digitalization together
Peter Herweck
CEO, Process
Industries and
Drives Division
4
Mr. Herweck, you are inviting visitors to discover
the potential of digitalization together with
Siemens. Why is this topic so relevant for the
process industry?
Peter Herweck: Digitalization is the key to the longterm success of our customers. In the future, every
plant will have a digital twin, a virtual image. You
have to remember that in the process industry, investments are made for more than 40 years in some
cases. Over this plant lifecycle, the market, technologies, and competition naturally change significantly.
For this reason, operators are forced to continuously
modernize and expand their processes to remain
competitive. With the opportunities offered by digitalization, we can modularize plants more effectively
and better handle complexity during the lifecycle.
Therefore, it is crucial for us as a partner of the process industry to support our customers from the initial idea to the end of the lifecycle of their plant. In
this way, we help to sustainably increase efficiency
and productivity.
“From Integrated Engineering to Integrated Operation –
Discover the Potential of Digitalization.” Under this slogan,
Siemens is building a bridge from integrated engineering to
integrated plant operation at ACHEMA. What contribution is
Siemens making toward greater efficiency and competitive
ness in the process industry? An interview with Peter Herweck
and Eckard Eberle addresses a few of the highlights.
Mr. Eberle, this integration of processes and systems throughout the lifecycle and thus the first
approaches to digitalization were already addressed at the last ACHEMA. How has the topic
moved on since then?
Eckard Eberle: Integrated engineering – that is, the
planning and configuration of all components of a
system in a common tool – certainly serves as an important foundation for digitalization. However, today
the integrated data landscape goes beyond the engineering phase. I’ll give an example in terms of software products from the Siemens portfolio: from
Comos and Simatic PCS 7 to Simit for simulation and
XHQ for visualization, we have a deeply integrated
platform for digitalization. The information from
planning must be updated so that the tool reflects
the actual plant status and can also be used to proactively plan, implement, and document maintenance work and modifications as needed. In this way,
operators can continue to take advantage of knowledge and experience to optimize the plant as a whole.
Eckard Eberle
CEO, Process
Automation
5
process news ACHEMA special 2015 | ACHEMA
We call this approach integrated operation, and
we are confident that it can enable our customers
to improve the performance of their processes.
Peter Herweck: Software tools for the collection
and analysis of data need to work closely with systems on the automation and process level. In recent years we have therefore expanded and complemented our historically strong automation technology, instrumentation, communications, and
drive technology product portfolio with the addition of innovative and powerful software for the
industry. The goal is to provide data transparency
in the process on all levels up to the management
level. The information is intended to help our customers make the right decisions at every level.
At ACHEMA, in addition to digitalization, the
focus is on bio-based production, industrial
water management, and innovative process
analysis. What answers does Siemens have
in these areas?
Eckard Eberle: Bio-based processes are a key issue
in creating impetus for growth. So-called single-
use technologies that support the trend toward
smaller production volumes, that is, more flexible
production, are emerging. Here we can support
safe and efficient process management with many
products, systems, and solutions, from process
analysis to modern software tools that enable the
evaluation of direct and indirect process para
meters. With biological processes in particular, it
is not always possible to directly determine the
product quality because the corresponding pro-
cesses take place inside the cells. For this reason,
we need tools that can also be used to evaluate
other information. In the area of process analysis,
at ACHEMA we are presenting an analyzer series
that is more flexible and easier to maintain thanks
to its intelligent modular design. In addition, we
have developed solutions for efficient central management of distributed analyzers. When it comes
to water, we also have a wide range of products
and systems that help enable this central resource
for growth and prosperity to be used efficiently
and sustainably. Whether the task is water treatment or disinfection of industrial water, the
ever-increasing requirements relating to verification and maintenance of water quality can only be
met by means of modern process instrumentation
and automation.
Resource efficiency has gained tremendous
importance in recent years. How can Siemens
support its customers in the process industry
in this area?
Peter Herweck: Resource efficiency is a key competitive factor. In addition to economical use of
energy and raw materials, it includes more efficient
use of the resource of time. That’s why we also offer
solutions that accelerate processes in engineering,
plant optimization, and production, relieving employees of routine tasks. Incidentally, we are the
leading provider in the market for many products
and systems that increase energy efficiency …
Eckard Eberle: … and we are exhibiting numerous
examples of this technology leadership at ACHEMA.
»We have powerful tools that collect data from multiple
sources and merge them into a management cockpit –
an application that shows how big data is active in the
process industry.«
Eckard Eberle
CEO, Process Automation
6
»We reliably support our customers over the
entire lifetime of their plant, from engineering
services to lifecycle services to the optimization
of control system performance.«
Peter Herweck
CEO, Process Industries and Drives Division
Our solution for paperless production in the pharmaceutical industry links information from the
manufacturing execution system and automation,
thus making it possible to monitor all quality-
related information automatically – without the
usual extensive manual operations and paper
batch records.
Our energy-efficient systems and solutions not only
save resources but also usually pay for themselves
within a very short time. This is especially true for
the drive technology, where we offer an innovative
means of optimizing the entire drivetrain with
Integrated Drive Systems. In addition to this, we
have developed advanced software tools that capture energy consumption in detail and make it transparent, thus supporting energy-efficient operation
of the plant. In the process itself, modern control
solutions such as our Advanced Process Control
solution for Simatic PCS 7 can help ensure that resources are used as efficiently and productively as
possible. Many customers already use a solution for
remote operation, with which a central operation
center can control the autonomous, distributed processing systems. Together with well-known companies in the process industry, we developed operating solutions that consolidate information from
the plant and effectively assist the staff in daily production. And to collect and consolidate the wide
array of information for the operational control and
management level, with Simatic IT and XHQ we
have brought powerful tools to the market that collect data from multiple sources and merge them
into a management cockpit – in my eyes an excellent application that shows how big data is active
in the process industry.
Apart from new products, systems, and
solutions, what are the other success factors
for your customers in your view?
Peter Herweck: When deciding on major investments, partnership is very important. Even if the
automation, instrumentation, or drive system is a
relatively small part of an overall system, these
components significantly influence the economic
viability of the investment. In a mine, this can be
a large drive that can cost in the double-digit millions to purchase – but it also costs a million every
day when it stands still. For us, the relationship
with our customers does not end with completion
of the transaction – we reliably support our customers throughout the entire lifetime of their
plant. We do this through service, advice, and new
ideas for system extension and modernization,
from engineering services to lifecycle services to
optimization of control system performance. We
are a partner that contributes its knowledge and
expertise to get the most out of a plant. Continuity,
reliability, and industry expertise are three crucial
factors at the core of our positioning for the process industry. I am proud that we have the opportunity at ACHEMA to present ourselves as a strong
and reliable partner, and I am looking forward to
discussions with visitors.
Mr. Herweck and Mr. Eberle, thank you for
speaking with us.
You can find out more online about the Siemens
booth at ACHEMA 2015:
siemens.com/achema
7
process news ACHEMA special 2015 | Software
The XHQ Operations
Intelligence platform enables
the establishment of a
continuous-improvement
practice and provides
near-real-time visibility of
operations within a process
manufacturing facility
XHQ Operations Intelligence platform
Intelligence for operations
In the process industry, big data has been
in use for decades. Virtually every process
plant is equipped with systems that manage
transactions, automate processes, and, in
general, execute the company’s business.
These systems generate huge volumes of
data; however, usually only a few trained
“power users” can turn this information
into operational improvements. With the
right platform for operations intelligence,
companies can share information in real time
with the wider organization – an important
step toward operational excellence.
8
B
atch processes play an integral role in the chemical industry, which is often characterized by the need for
versatility in the form of diverse product lines to meet
constantly changing market needs. The objective of batch
processes is to produce product within the required quality
specifications and with the minimum feasible cycle time
while maximizing the overall yield but minimizing by-
products or recycling. This challenge is further heightened
by the fact that the production environment is subject to an
array of variables and constraints, some of which are under
the control of operators and engineers to a reasonable
degree, while others are imposed by external factors.
A platform for continuous improvement
These requirements introduce various complexities in planning the production of distinct products using the same
asset, context switching within a manufacturing facility, the
Software | process news ACHEMA special 2015
XHQ Operations Intelligence
XHQ Operations Intelligence is a set of tools that help aggregate, relate, and present
operational and business data in real time to improve enterprise performance.
XHQ provides a single coherent view of information, enabling a variety of real-time
performance-management and decision-support solutions.
constant existence of transient states throughout production, and how making certain products may affect other
assets downstream in the production chain. The XHQ Operations Intelligence platform enables the establishment of
continuous-improvement practices while providing nearreal-time visibility of operations within a manufacturing
facility.
For batch processes, XHQ offers a set of tools that allow indepth batch analysis and provide insights into the operations
of batch plants. With XHQ, process engineers can promptly
analyze historical records and then define, for each reactor
or asset, the best-performing steps, operations, and batches.
Because these are based on actual history, they represent
attainable levels of performance that were found to be the
best for a particular product or recipe when produced using
a given asset, and they serve as the “golden batch” for that
product and asset combination. The engineers can also compare recent or current batches with the golden batch in near
real time and correlate less-than-ideal performers with quality results, process alarms, and manually entered comments
from plant operators, which may explain why deviations
from the golden standard are taking place.
Identifying causes and effects
To ascertain the causes of deviations, information related to
various aspects of the production process must be analyzed
together and within the context of the particular excursions
that are identified. This is often an arduous task in today’s
highly complex industrial IT landscape and requires plant
perators and process engineers to search through silos
o
of information in multiple IT systems in order to simply find
the data being sought before initiating the actual analysis.
By providing out-of-the-box connectivity to commonly used
tools in the chemical industry, the XHQ Operations Intelligence platform is able to offer applications such as inventory
management, maintenance management, and quality management that enable the root-cause analysis to take place in
an efficient and consistent manner, integrating all the disparate data sources into a single source of information that can
be contextualized under standards such as ISA-95 and/or
ISA-88. Once the reasons for the observed deviations on
less-than-ideal performers are found, the outcome of the
root-cause analysis can be recorded against specific steps,
operations, or batches, with predefined standard reason
codes used to categorize the discrepancies while also providing additional details of the specific occurrence.
Detailed visualization and reporting
Once categorized, reports can be visualized directly in XHQ
with summaries by shift, plant, site, country or region, business unit, or product line, providing key analytical decision-
support information that is based on actual plant conditions.
This is especially beneficial in a multisite and multiregional
set-up, as it allows users to define and compare benchmarks
across multiple production facilities and identify suitable measures to achieve operational excellence throughout.
siemens.com/xhq
9
Different disciplines can contribute their expertise
in the 3D virtual reality model of the plant early on
3D virtual reality with Comos Walkinside
Viewed from the inside
With Comos Walkinside, 3D engineering data can be used throughout a plant’s
lifecycle for 3D virtual reality representations.
T
he realistic representation of highly complex plant
models in 3D enables simple, fast, and comprehensive
access to relevant project and plant data during design, operation, and maintenance.
Using the Comos Walkinside software solution as a part of
Comos, project teams can access current plant data at any
time. Huge amounts of data can be visualized in real time
using 3D rendering technology so that users can move
through the plant as in a video game. This allows the 3D CAD
data generated in engineering to be efficiently deployed by
many user groups, not only for planning and monitoring but
also for operational and training purposes.
10
Engineering and design phases database
During engineering, the data set of the individual plant
objects is continually enhanced with specific information.
Comos acts as a global data center that allows all project participants worldwide to have constant access to consistent
information. In Comos, all the plant objects are clearly described and are stored and managed in an object-oriented
manner. In addition to machine documentation; piping and
instrumentation diagrams (P&IDs); circuit diagrams; and
automation, process, and service information, Comos also
stores planning data. The virtual reality model generated
with Comos Walkinside from the 3D CAD data can then be
linked to this information. Through this comprehensive information source, which is accessible without CAD or engineering expertise, the plant project and its progress are
available at a very early stage to all disciplines. In this way,
for example, safety issues can be addressed comprehensively and early in the planning phase, which leads to significant time and cost savings in on-site safety inspections.
Commissioning, plant optimization, and training
The handover of the plant and all documentation to the operator represents the “as-built” state of the plant. These data
form the basis for the extensions and alterations, repairs,
and modernization work that will be needed again and again
for the ongoing operation over the entire lifecycle of the
plant.
From the date of commissioning, Comos Walkinside can be
used as what is known as a 3D asset portal. As a 3D asset
portal, Walkinside allows all participants, regardless of their
role or location, to gain intuitive and immediate access to all
plant information. In a virtual tour of the 3D model, all
object-oriented data can be easily and directly accessed and
edited if necessary. In this way, workflows can be simulated
in detail. For example, process sequences can be tested and
optimized, and plant operators and maintenance personnel
can be safely trained at an early stage. Thanks to the realistic depiction of even complex plants, training scenarios can
be designed for customized individual or group training.
Even specific scenarios examining health, safety, and environmental aspects are possible, for example with simulated
incidents such as fire or gas leaks in the plant. In addition,
the operators in the control room can be efficiently trained
to work together in order to ensure smooth cooperation.
Efficient operation and simplified maintenance
During the operational phase, Comos Walkinside allows for
remote maintenance and operation. Using this remote operation capability, technicians can identify and solve problems
faster without deployment on-site. Historical data and
real-time process data such as alarms from the Simatic PCS 7
process control system enable a better understanding of the
overall context. Future faults can be prevented, allowing all
operations to run more efficiently.
With Comos MRO (Maintenance, Repair and Overhaul), plant
owners can precisely plan maintenance and repair activities
in the plant. The centralized access to these data, with exact
localization of the plant component within the 3D image, enables efficient preparation and execution of maintenance
operations. The documentation for maintenance steps that
have been executed is stored centrally in Comos together
with all other documents. It is fully traceable and can be
Technical features
• Realistic 3D visualization based on engineering data
• 3D asset portal provides centralized real-time access to
all plant data
• Visualization of the plant state over the entire lifecycle
for all project participants
• Effective and efficient training of operating personnel
for faster commissioning and improved plant safety
viewed and edited. In addition, the virtual 3D model allows
access to certain components to be evaluated, and a maintenance team equipped with radio-frequency identification
(RFID) transponders can be precisely localized and represented in the virtual model.
Each authorized user has access to the information in a form
that works best for him or her. All the participants can thus
Problems can be precisely located in the virtual plant
environment, allowing corrective and preventive measures
to be implemented
receive an overview of the current plant status and achieve
their goals more efficiently, quickly, and safely throughout
the entire lifecycle of the plant. Higher plant availability,
e conomic viability, and profitability meanincreased safety
for personnel, machinery, and the e
nvironment.
siemens.com/comos
11
Simatic IT
R&D Suite
LIMS
Simatic IT
Intelligence Suite
Preactor
APS/GPMS
Prod Specs
Dashboard
Reporting
Enterprise integration
Weigh &
Dispense
eBR
Native DCS integration
Operations Intelligence
Simatic IT
LMS
Simatic IT eBR
Warehouse
XHQ
Packaging
Control / Command integration
Overall Equipment
Effectiveness(OEE)
Down Time
Monitor (DTM)
Sipat
Quality-by-Design
Simatic PCS 7
BATCH
DCS
HMI
PLC
Sensors, drives, field instrumentation, ...
Simatic IT eBR is part of the Siemens solution platform for industry software and automation
Simatic IT eBR
Pushing past paper
One barrier to more efficient manufacturing in the pharmaceutical
industry is the frequent use of paper-based processes. Consequently,
the pharmaceutical industry is increasingly using modern IT and
automation solutions to make the move to paperless manufacturing.
With Simatic IT eBR, Siemens facilitates the implementation of electronic
batch management and provides added benefits through seamless
integration of the manufacturing execution system and control level.
B
y taking a risk-based approach to
pharmaceutical manufacturing,
regulatory bodies have encouraged pharmaceutical companies to
adopt the available technologies to
improve production efficiency and performance. Specifically, both the US
Food and Drug Administration (FDA)
and the European Medicines Agency
(EMA) have published guidelines that
specify how to create and manage
quality production records in an electronic system to provide an electronic
record that precisely details how a
drug has been produced. An electronic
12
batch record (eBR) system for paper- pharmaceutical product. The MBR conless manufacturing must encompass tains the product specification (what is
three steps: design, execution, and re- produced); the work procedures, con
view. To facilitate the review and re- ditional framework, equipment, and
lease process and reduce the workload workflow (how to produce); the critical
for quality assurance teams, reviews quality attributes (how the product and
should be exception based.
process is verified); and the necessary
In principle, the eBR adopts the tradi- tests for ensuring product quality (how
tional paper-based production proce- to prove product quality).
dures established by the manufacturers The eBR approach in its most basic
in the pharmaceutical industry. Produc- form can be an electronic representation processes are specified in an easy- tion of previously paper-based proto-use and flexible master batch record cesses (paper-to-glass). However, eBR
(MBR) that serves as a template for a can also help streamline workflows
general recipe for how to produce a and eliminate errors and deviations by
Technical features
Simatic IT eBR enables paperless manufacturing and
gathers critical data in an electronic format, offering
a comprehensive set of out-of-the-box features:
• Vertical integration from the enterprise resource
planning (ERP) level to the automation level
• Batch and operations management
(including operator guidance and production steps)
• Materials and inventory management
(weighing, dispensing, mixing) at the container level
(with ERP integration)
• Equipment management over the complete lifecycle
of the plant
• Sample management (with laboratory information
management system [LIMS] integration)
• Deviations/alarms/alerts management
• Batch reporting
• Full batch and materials genealogy
• Batch release by exception
Simatic IT eBR enables complete paperless manufacturing
using the capabilities of state-of-theart IT systems and by networking the
electronic batch information with
other production systems, such as laboratory information management systems (LIMS), distributed control systems (DCS), and building automation
systems. Such integration enables
higher production quality (Right First
Time) and facilitates batch review and
release.
Minimizing risks, exploiting
opportunities
While pharmaceutical companies have
long been aware that introducing
p aperless manufacturing will provide
substantial benefits, they have been
hesitant to introduce such systems on
a large scale due to concerns regarding
the actual costs, risks, and benefits of
paperless manufacturing.
An eBR solution covers the processes
and requirements of both the production of active pharmaceutical ingredients and the secondary processes and
must be capable of handling very complex operations. A given plant will execute as many as 300 recipes that can
involve several thousand process parameters and several hundred production steps.
Integration provides added benefits the Simatic IT R&D Suite, which covers
Until recently, there were no truly typical R&D activities such as developintegrated solutions for paperless ment of new products, product mainmanufacturing that could encompass tenance, and product enhancement, as
the manufacturing execution system well as quality information with the
(MES), production, and automation LIMS component Unilab. There is also
levels and that could integrate both an integration with the Preactor APS
manual and automated processes. software for production planning and
With Simatic IT eBR, Siemens now pre- scheduling. This helps streamline opersents a solution that can bridge the ations across the entire product life
gap between ISA-95 and ISA-88 stan- cycle.
dards for interfacing MES and automation, batch control, and manufacturing Streamlining processes
IT. The solution helps guide manufac- With Simatic IT eBR, companies can
turing operations, whether manual or more easily introduce paperless manuautomated, via seamless interaction facturing based on electronic MBRs and
between the MES, automation system, become more efficient in their ope
and enterprise resource planning (ERP) rations without compromising quality
system. Siemens’ solution for eBR man- and product safety – in both manual
agement offers native integration be- and highly automated environments.
tween the MES and the DCS layer. This Thanks to the seamless integration
expedites the design, execution, and between batch processing in the DCS
review steps of eBR and provides real and workflow management in the MES,
flexibility in the MBR design. In the DCS, Simatic IT eBR can streamline and
a robust and powerful batch engine significantly accelerate the implemenmanages complex low-level S88.01 re tation of a solution for paperless manucipes related to automatic control of facturing, reducing typical implementathe process, while the selection of the tion times from one year to only months
master recipe name and version makes for one recipe. all master recipe information available
for use in the MES design tool. Additionally, Simatic IT eBR integrates with siemens.com/pharma
13
LIMS Simatic IT Unilab
Cloud solution for even
greater ease of use
With the Simatic IT Unilab 7.0 laboratory information management system (LIMS),
Siemens offers a complete redesign of the previous Siemens LIMS for laboratory
automation. The new version of the proven and comprehensive software can now
also be accessed via mobile devices.
T
he new Simatic IT Unilab LIMS offers not only increased ease of use and simplified implementation
and operation but also reduced costs. As a cloud
solution, the latest version of the software is completely
web-based and runs with any standard HTML5 browser, thus
eliminating regular system updates and installation costs.
The flexible web design of Simatic IT Unilab 7.0 enables the
user to quickly change between using the software on a PC
and a tablet. With the “comfort” and “compact” display
options, the user can choose how extensively the data
should be displayed, with “comfort” being especially suitable for touchscreens and “compact” working well on regular PCs with a keyboard and mouse. To address the size and
detail of the displays as well as the desire for customized
displays, Version 7.0 allows users to choose between “novice”
and “expert”.
“Expert” shows all the details for the desired sample, while
only the necessary data are displayed in the beginner mode.
In addition, each user specifies his or her desktop and designs a customized work environment using what is known
as the docking manager. The software also features a completely redesigned search function with autocomplete, results filtering, full-text search, and a time stamp. In addition,
14
summaries and graphs can be generated directly from the
results window. The launch pad, which is identical for Simatic
IT Unilab and all the other modules in the Simatic IT R&D
Suite, can be individually configured with access rights for
each user. In this way, the user can define which documents
are linked on the desktop and whether an Internet search engine should be displayed, for example.
siemens.com/lims
Technical features
of Simatic IT Unilab LIMS 7.0
•
•
•
•
Increased ease of use
Simplified implementation and operation
Reduced costs
Completely web-based software (cloud solution)
that runs with any standard HTML5 browser
• Flexible web design that enables the user to
quickly change between running the software
on a PC and a tablet
Continuous bio processing
On the way to production scale
Biological production in the pharmaceutical industry is currently dominated by batch processes.
However, a continuous process offers substantial benefits. Key factors for implementing such
concepts in an actual production environment are integrated automation solutions and process
analytical technology (PAT) systems for in-line quality control.
C
ontinuous processing is a very promising
concept to make production in the pharmaceutical industry more agile, flexible,
and efficient. At present, several companies are
advancing concepts for continuous processes
towards the production scale, and experts
e xpect that continuous processes will grow
significantly over the next 10 years, from
5 p ercent of business today to as much as
30 percent.
Concepts for an integrated process
However, continuous manufacturing requires a
shift in mind-set on different levels within the
pharmaceutical industry. It creates the need for
a tighter integration between process, PAT, and
control systems. Siemens is capable of providing such an integration with its Simatic PCS 7
process control system and the PAT software
Simatic Sipat. This native integration capability
is complemented by collaborations with pharmaceutical companies and original equipment
manufacturers to develop what is still required
in terms of standardization of interfaces and
analyzer solutions for in-process control.
Biological APIs are
typically produced in
batch processes, but the
industry is currently
evaluating continuous
processes as a more
efficient approach
Technical features
The PAT software Sipat and the process control system
Simatic PCS 7 can provide:
• A multidisciplinary PAT implementation combining
analytical, mathematical, process, control, and IT expertise
• An improved process understanding
• An approach to implement quality-by-design and
realtime product release
From proof to production
Although a large amount of research and development is still needed, in terms of both technology and mind-set, continuous manufacturing is an essential part of meeting the growing
need for agile, efficient, local, and high-quality
biological production in the pharmaceutical
industry. It will help the industry achieve operational excellence through a higher degree of
automation, streamline drug development by
offering a uniform platform for clinical development and commercial production, and significantly reduce production footprint and
c apital expenditures. siemens.com/pharma
15
Simit Simulation Framework Version 8.1
Efficiency through simulation
Simulation for virtual commissioning and operator training is an important approach
for improving the efficiency of process plants throughout their entire lifecycle.
Operator Training System (OTS)
Trainer
station
Simulated
processes
OTS training stations
Operator station
(server)
Simit SF (Simulation Framework)
• Simulation design
• OTS runtime management
• Trainer dialogue
Simit VC (Virtual Controller)
• Configuration of emulation manager
Simulated
IO and
devices
DCS
Training
scenarios
Operator
station
OTS virtual automation
Simit Virtual
Controller
Engineering
system
• Runtime simulation
• Synchronization
• Virtual time management
• Remote control interface
• Internal communication
• External communication (OPC, shared memory)
Simit Virtual Controller (configuration)
Simulated
automation
Simit Virtual Controller software (runtime)
Simit Simulation Framework
D
uring the commissioning and start-up of a plant,
correcting errors in automation configuration
requires great effort. These time-consuming and
costly changes can be prevented through virtual commissioning, in which the engineering is tested from the desk,
so to speak. Nearly all design-specific and functional errors
can be detected and corrected before the actual commissioning. With the Simit software family, Siemens offers a
sophisticated range of products for virtual commissioning
(V.C.) of automation systems.
Training capabilities included
With the new version, V8.1, Siemens is expanding its range
of V.C. and Operator Training Systems. The Simit product line
has been extended to include the Simit Virtual Controller
software, with which the Simatic S7-300, S7-400, and S7-410
controllers can be emulated. The new interface to the Simit
Virtual Controller V3.0 is consistent with existing couplings.
Simit Simulation Framework and Virtual Controller are coordinated and can be synchronized both in real time and in virtual time (for faster or slower simulation runs). The Virtual
Controller software allows an unlimited number of emulated
controllers, which can be distributed across multiple computers. It thus offers the flexibility, scalability, and performance
necessary especially for large projects or training systems.
The modeling defined for V.C. can be re-used almost directly
as a model for planned training scenarios.
16
Technical features
• Single simulation environment:
– for virtual commissioning and operator training
– for real and virtual automation
(real CPU or Simit Virtual Controller)
• Synchronized execution of simulation and emulation
in real time or virtual time (faster/slower)
• Improved ease of use and efficiency (in the coupling,
routing, and scaling of signals in the simulation
models, for example)
With the software offering and close integration of all the
tools, the Simit Simulation Framework serves as a link between engineering, simulation design, virtual and real commissioning, the operator training system, and plant operation. With the ability to model process behavior in Simit,
users can realistically represent and test the full interplay of
the processes, automation program, and equipment.
siemens.com/simit
Multimedia presentation:
siemens.com/discover-simit-simulation
Process automation | process news ACHEMA special 2015
Control module type for engineering
Efficient engineering
A new type concept offers plant operators and constructors even more
efficient engineering, greater standardization, and enhanced security.
S
Recurring functions can be defined as control
module types (CMTs) in Simatic PCS 7 and are
therefore easy to duplicate
iemens has adopted an integrated engineering process
to enable more efficient configuration workflows
when sharing data from planning tools with other systems, for example, in automation. Part of this approach involves bringing the plant planning system and the automation and process control systems closer together by reducing interfaces. Standardization creates a common basis so
that all the plant engineers, operators, and process and automation engineers can communicate effectively. This saves
time, simplifies engineering, and reduces costs. Recurring
automation jobs can be rapidly implemented by duplicating
standardized software modules for recurrent functions or
functional units in control module types (CMTs). Any number of test points can be derived from the CMT. Using the
type instance concept, central modifications to the CMT also
impact the instances (derivatives). This allows types to be
modified centrally for all projects in Simatic PCS 7 engineering.
siemens.com/pcs7-engineering-system
Simatic HMI Comfort Outdoor Panels
Extremely flexible for
all outdoor uses
The new Simatic HMI Comfort Outdoor
Panels were specially developed for
demanding HMI tasks in extreme ambient
conditions. Monitoring and control are
exceptionally flexible – in any outdoor area.
and are particularly durable thanks to a UV-protected device
front with IP65 protection. Excellent antiglare properties, automatic dimming, and a wide reading angle enable reliable
and fatigue-free monitoring and control in any light. With
extensive planned certifications, a wide temperature range,
and suitability for environments with up to 90% humidity,
the devices can be used in almost any industry.
siemens.com/comfort-outdoor
W
hether they are used in the oil and gas industry, on
ships, or in refrigerated warehouses, the Simatic
HMI Comfort Outdoor Panels with 7- or 15-inch
daylight-readable widescreen displays offer everything required for monitoring and control in outdoor areas. The robust Comfort Panels are easy to use, offer high-end f unctions,
17
process news ACHEMA special 2015 | Process automation
Simatic PCS 7 / Open OS
Central process control
Simatic PCS 7 / Open OS supports efficient process control
with intelligent integration of system components.
O
ver time, process plants grow into system landscapes
made up of heterogeneous automation technologies
with components from various manufacturers. The
Simatic PCS 7 / Open OS V.8.0 option enables controllers that
are not Simatic PCS 7–compliant to be integrated into the
process control of Simatic PCS 7. Centralizing control rooms
and integrating any number of different controllers into
PCS 7 thus becomes a quick and easy task.
Data are exchanged between the PCS 7 operator station and
various automation systems via existing WinCC channels or
the OLE for Process Control (OPC) channel. External systems,
which can only be integrated with the latter, simply require
an OPC server matching the controller type. Simatic S7‑1200
and S7‑1500 controllers can be integrated into the process
control of the operator station using the base functionality
of Simatic PCS 7 / Open OS. The Simatic S7‑1200 or S7‑1500
channel of the PCS 7 operator station is used for integration.
This allows the operator to control and monitor the entire
plant, including package units, with S7‑1500 controllers
from a single operator station.
siemens.com/pcs7
Simatic S7‑400 long-term/lifetime support
A strong foundation
Simatic S7‑400 automation systems providing
various levels of safety and availability will
be offered up to and beyond the year 2030.
Siemens ensures the smooth operation and
long-term availability and scalability of the
components over the entire lifetime of the
system.
PCS 7
operator station
OPC channel
Simatic S7 Protocol Suite
Simatic S7‑1500 channel
OPC server
Channel for
additional systems
Simatic
S7‑300
S7‑1500
18
Controller Y
Integration of low-level components
using Simatic PCS 7 / Open OS
s tandard and high-availability to safety-related controllers.
Innovations such as the S7‑410 controller, currently the fastest and most powerful CPU for process automation, are
optimized for use in challenging environments with an
e xtended temperature range of up to +70°C, and for G3
environmental specifications with a new paint coating.

Siemens will guarantee the smooth operation and long-term
availability and scalability of the components up to and
b eyond 2030 for the entire lifetime of the system.
siemens.com/s7‑400
T
he guarantee of availability we offer plant operators
and manufacturers in all branches of industry is based
on the robustness, flexibility, and long-term viability
of our modular systems. The key issues we focus on are spare
part supplies, compatibility, and availability of components,
as well as innovation and services. Access to automation
components is ensured over the coming decades for the
entire line of Simatic S7‑400 automation systems, from
Controller X
Future-proof:
Simatic S7‑400
Process automation | process news ACHEMA special 2015
The preconfigured faceplate for the Sinamics G180 inverter
Sinamics G180
Specific drive solution
The Sinamics G180 drive solution is specifically designed for
potentially explosive areas. A special tool makes it easy to integrate
the drive into Simatic PCS 7.
T
he Sinamics G180 series can be used in applications
ranging from simple pumps and fans to demanding
drive solutions in the 2.2 to 6,600 kW power range –
for example, for centrifuges, presses, extruders, or compressors. A further development of the Dynavert-T frequency inverter, the Sinamics G180 is specially designed for use in potentially explosive areas. Whether implemented as compact
devices, cabinet systems, or cabinet devices (air-cooled and
liquid-cooled), the frequency inverters are adapted to the requirements of drives with square-law and constant-load
characteristics.
The Sinamics G180 can be integrated, configured, operated,
and monitored in Simatic PCS 7 using the Inverter Management Software (IMS). With the Advanced Process Library
(APL), the drives can be integrated efficiently and with
greatly reduced engineering work as a fully configured continuous function chart (CFC) plan using the preconfigured
Sinag180 solution template. The FbDrive channel driver
module of the APL is already logically configured with the
function and logic modules. An APL faceplate is available for
monitoring and control in the operator station and is used
to control the Sinamics G180 via Profibus DP. Required data
on the motor condition and measured values such as torque,
power, and feedback are shown clearly and concisely. Faults
are readily identified and can be prevented or, in the event
of their occurrence, quickly cleared.
siemens.com/sinamics
Technical features
• Drive solutions in the 2.2 to 6,600 kW
power range
• Design that enables use in potentially
explosive areas
• Minimal engineering work thanks to
preconfigured solution template
19
process news ACHEMA special 2015 | Services
Simatic PCS 7 Lifecycle Services
With Lifecycle Services, plants never look old
The update management included in Simatic PCS 7 Lifecycle Services
ensures continuous adaptation to keep process plants on the cutting
edge of technology throughout their lifecycle.
T
he lifecycle of process plants is currently at least 20 possible obsolescence risks, such as aging of the equipment.
years. That is a very long time. And this length has To maintain their increasingly complex control systems, comconsequences, as the plant must be continually up- panies in the chemical industry rely on extensive long-term
dated during this period. Simatic PCS 7 Lifecycle Services, lifecycle contracts. In some cases, these contracts have a
which provide maximum transparency and efficiency, en- term of 15 years or more.
able plants to stay up to date. The service contracts are individually tailored to the requirements of the customer, ensur- “Design for lifecycle” ensures sustainability of plants
ing system and plant availability as well as long-term in Another important element within lifecycle management is
vestment protection.
the serviceability of process control solutions. What is known
To protect the plant owner’s investment, the control func- as “design for lifecycle” plays a crucial role here. In a sys
tions must be maintained for a long period, and the provi- tem audit, the experts from Siemens inspect the installed
sion of spare parts and corresponding support services must solution using checklists and analysis tools and then define
be ensured. This is not always easy, because the innovation an action plan with which the required serviceability and upcycles in the basic technology – including, for example, PCs gradability can be achieved. The professional global service
infrastructure with local and central service resources, spare
and operating systems – are becoming ever shorter.
The same is true for the innovation of process control sys- parts logistics, and modern service tools allows plant opertems based on PC systems. New features help increase the ators to focus on their core business and rely on their plant
quality and productivity of a plant, which is something that at all times.
plant operators naturally want to benefit from. Systematic
management of upgrades ensures that the plant is always
operating according to the latest technology and prevents siemens.com/pcs7lcs
Cumulative
Lifecycle
Services costs
Cumulative
Lifecycle
Services costs
Obsolescence
risk
Lifecycle
Service costs
per year
Service costs
per year
Year
1
2
3
4
5
6
7
8
9 10 11 12 13 14 15 16 17
With a reactive approach to service (i.e. without a Lifecycle
Services contract), the obsolescence risk increases greatly.
Expenses for maintenance and risk coverage fluctuate and
are difficult to predict.
20
...
1
2
3
4
5
6
7
8
Obsolescence
risk
9 10 11 12 13 14 15 16 17
...
The preventive service approach (i.e. with a Lifecycle Services
contract) stands in contrast to the reactive approach. Continuous
support of the plants keeps the obsolescence risk low and ensures
a constant and predictable optimized cost of maintenance and
modernization.
Services | process news ACHEMA special 2015
Siemens Engineering & Consulting
Well thought out from the very beginning
Siemens Engineering & Consulting (EC) experts support
the chemical and pharmaceutical industries in estimating
planning and investment costs. These services also
ensure greater transparency
and efficiency in the
operation of a plant.
T
he chemical and pharmaceutical
industries are highly competitive,
with more and more new products constantly coming onto the market. Sales are growing rapidly, especially
in Asia and Latin America. Companies
that wish to keep up with the changing
market landscape need to continuously
focus on innovation and efficiency. Production plants are
central to the planning from the very beginning. “Manage
project costs before they occur” is not just an empty slogan;
behind this is a business plan that covers the entire lifecycle
of a plant. Siemens EC services begin as early as the design
phase, providing support to the customer through to the
final implementation of pilot and production plants.
The Siemens engineers and chemists develop the appro
priate production processes for specific chemical and pharmaceutical products, and these processes are then reflected
in the plant design. Customers can also rely on EC experts
in the optimization of existing plants. If necessary, they
can provide full project management for basic and detailed engineering, construction, and commissioning. The
Competence Center Cost Engineering within Siemens EC
provides transparency regarding the expected investment
costs.
Realistic investment cost estimates
The Cost Engineering staff can estimate the expected investment costs early in the project. The Competence Center has
an extensive collection of data for investment cost estimates,
coupled with current methods and suitable IT tools.
Drawing on the evaluation of completed projects, the team
members estimate the costs of other units based on their
share of the whole and on the plant type – basic chemical
plant, polymer plant, or pharmaceutical plant, for example.
Another method is based on the generation of quantity
Competence Center Cost Engineering
• Ensuring transparency in investment costs
• Monitoring the entire lifecycle of a plant
• Creation of a basis for business decisions
• Stochastic analysis of likely cost variance based
on project-specific factors
structures for each unit, which allows the cost of all the
equipment and the required units to be evaluated.
Engineering effort, procurement including inflation rates,
and additional expenses for contingencies are also taken into
account.
EC uses a stochastic analysis to indicate the quality of
the investment cost estimation. This risk analysis provides
the mathematical probability of a cost variance based on
project-specific factors. From this analysis, the value of the
contingency can be derived, along with the elements that
have the greatest impact on under- or overestimating the investment costs. This analysis supports project management
in the identification of units associated with risks.
siemens.com/ec
21
process news ACHEMA special 2015 | Services
Center of Competence (CoC) Pharma
End-to-end service
Consistently high product quality and plant availability are the
top priorities in the pharmaceutical industry. This calls for the
fastest possible service from plant manufacturers and suppliers,
even beyond a pure fault incident.
M
any pharmaceutical manufacturers rely on multilevel on-call and service models to meet the high
demands of continuous production and high product quality. Depending on the incident, different specialists
are needed. These experts must have specific expertise in
highly automated process plants with intelligent sensors,
various bus systems, virtualized client/server systems, and
other modern technologies, and their skills must always be
kept up to date. The software solutions in networked plants
also address various components of small programmable
logic controllers (PLCs) via HMI / Supervisory Control and
Data Acquisition (SCADA) solutions, distributed control systems (DCS), and the manufacturing execution system (MES)
and enterprise resource planning (ERP) level. In the Center
of Competence (CoC) Pharma in Marburg, Germany, Siemens
has handled pharmaceutical projects involving process and
automation technology throughout the entire lifecycle of
plants for more than 15 years. This experience has resulted
in a broad and coordinated portfolio of specialized services,
allowing plant faults to be resolved quickly, for example.
If a fault occurs in a plant, trained staff from the pharmaceutical manufacturer will usually restore functionality of the
plant with their own on-call service technicians. In cases in
which the plant operator is not able to find an appropriate
solution, other specialists must be called upon – but this may
take several hours or even days. In order to prevent production downtime or even the loss of entire batches, the CoC
also offers its customers in the pharmaceutical industry oncall service specifically for the support of production plants
22
»I n GxP projects, the
economic Key Performance
Indicators (KPIs) can only
be achieved if processes
are successfully integrated
and the respective
necessary decisions are
made promptly.«
Peter Hess, Siemens Certified Project
Manager and Quality Assurance Manager,
Siemens CoC Pharma, Marburg
Services | process news ACHEMA special 2015
using the Simatic S7, Simatic PCS 7, and Simatic Batch products. Through constant dialogue during and after the service
deployments, but also through customer support for plant
alterations, extensions, and improvements, the CoC keeps
its pharmaceutical expertise up to date and enables the customer to receive optimal support. The expertise of CoC
Pharma is also available throughout the country by means of
remote services.
Expertise throughout the entire lifecycle of the plant
To secure the expertise of suppliers beyond the construction,
upgrading, or migration of production plants, customers are
often eager to integrate system suppliers into the plant
maintenance processes. Service activities performed by system suppliers after a plant modification are frequently contractually agreed. Cooperation in the event of a fault is necessary not least due to the regulatory requirements that
must be met in order to keep the system valid throughout
the entire lifecycle. Consistent engineering in accordance
with GMP (good manufacturing practice) and maintenance
of equipment and qualification documents in accordance
CoC service modules
Preventive system
maintenance
Emergency spare
parts service
On-call service
Qualification /
validation
Lifecycle
management /
consulting
with GDP (good distribution practice) are essential and are
usually carried out through the revision and versioning of
existing applications and documentation. The GAMP 5 directive calls for the inclusion of suppliers in the plant maintenance process. Options for the integration of external services in the lifecycle of the plant are described under supplier management.
Service after project completion
For Siemens as a system supplier, the three basic pillars of
projects in the pharmaceutical environment – engineering
in accordance with GxP, validation and qualification in accordance with GAMP 5, and structured project management
using PM@Siemens – are well established in the company’s
business processes. Additional modules can be implemented
during the process, complementing a service contract. The
customer can choose from various service modules.
In addition to offering the desired accessibility, on-call service also ensures that previous project staff members who
are familiar with the plant will be involved as service personnel. This minimizes the time needed for clarification and familiarization with the plant. The emergency spare parts service includes contractually prepared ordering methods for
all relevant and plant-critical components, so that repair can
be carried out as quickly as possible. In lifecycle management / consulting, the customer’s requirements are matched
with the experience at Siemens during the preparation of a
project or during the implementation of plant modifications.
Optimization and preventive maintenance
When required, or at specified time intervals, essential
optimizations such as standardization, realization of
potential for savings and improvement, installation of
new technologies, or proactively advising plant personnel are initiated on the customer or supplier
side. To detect faults early, regular analysis of the
systems and their diagnostic files is carried out as
a form of preventive maintenance. For qualification and validation services in accordance with
GAMP 5, system and plant knowledge facilitate
analysis and management of changes in the lifecycle of the plant. This allows plant owners to
minimize risks during operation and meet compliance requirements.
For many years, the CoC Pharma in Marburg has
been providing technology and industry expertise to
pharmaceutical customers throughout the lifecycle of
their plants. Thanks to a reliable and ongoing service
with system suppliers, customers are able to achieve their
project goals and maintain the required quality at low risk
with high reliability, safety, and efficiency. siemens.com/pharma
23
process news ACHEMA special 2015 | Process analytics
Siprocess GA700
More modules – more possibilities
Since 2012, Siprocess GA700 has been the
modular device concept for extractive gas
analysis in Siemens’ portfolio. After a
successful start with the Oxymat module,
two additional modules now follow with
the Ultramat 7 and Calomat 7. For the
user, this increases flexibility with the
same simple and consistent operation.
The base unit is
available as a version
for wall mounting
(above) and as a
built-in unit (left)
T
he platform approach separates the housing, includ- Two new teammates
ing the operator interfaces, and the actual analyzer. A The measurement principles of the modules have not
base unit accommodates the individual modules. It is changed from the previous series 6, and the new devices
available as a plug-in and as a wall-mounted version and in- meet the same technical specifications as their predecessors.
cludes the local user interface with a high-resolution graph- The extended temperature range, allowing for use in hot enics display, as well as a protected keypad, communication in- vironments (up to 50°C), even makes air-conditioning unnecterfaces, power supply, and basic electronics and software. essary in some areas. The first module released, Oxymat 7,
It is possible to install up to two insertable analysis modules reliably performs oxygen measurements. Calomat 7, which
– which include the near-sensor electronics, evaluation soft- is now available, allows for quantitative determinations of
ware, and the necessary electronic interfaces and process hydrogen and noble gases in binary or quasi-binary gas
connections – into this base unit. The modules can be in- mixtures. To determine the concentration, the Calomat 7
stalled and removed at any time; the base unit remains in modules use the specific thermal conductivity of the binary
place. This allows for easy retrofitting or modification in case sample mixture. The modules have high measurement range
of changing analytics requirements and also facilitates main- dynamics. Calomat 7 modules can be used in pure gas contenance and repair measures. The modules can be easily trols as well as in inert gas or hydrogen determinations in
combined, which ensures the configuration is perfectly furnace and converter gas and in monitoring devices for
matched to the measurement task.
hydrogen-cooled turbogenerators.
24
Process analytics | process news ACHEMA special 2015
The Ultramat 7 module can measure up to four infrared-
active components with high selectivity. The most important gases, carbon monoxide and carbon dioxide, are covered
in the first stage; other components will follow. The module
operates according to the nondispersive infrared (NDIR)
two-beam principle and uses molecule-specific absorption
of spectral bands in the infrared range. Thanks to the doublelayer detector and optical coupler, reliable measurement
results can be achieved even in complex gas mixtures.
Enhanced flexibility – simplified operation
Oxymat 7, Ultramat 7, and Calomat 7 modules can be used
in many combinations. Cross gas effects can be measured in
a single device and offset against each other. Because it is
also possible to use two modules of the same type, higher
availability of relevant analytics applications can be achieved.
The rapid exchange of modules, which can be performed onsite without removing the platform, also increases availability. The exchange is possible without special expertise; the
modules are automatically detected and configured. Even repairs can be carried out by in-house staff after training by
Siemens.
The Simatic process device manager (PDM), the universal,
manufacturer-independent tool for configuration, parameter assignment, commissioning, diagnostics, and maintenance of intelligent process devices and automation components from Siemens, can be used for parameter assignment
and retrieval of diagnostic information. Operation on the device itself is based on the series 6 menu structure, which has
now been standardized across all modules. This considerably
shortens the learning process. The fully graphic display
shows detailed and contextual help texts in 10 languages.
These messages help during commissioning and in everyday
work and are complemented by NAMUR-compliant operating symbols. Siprocess GA700 stores maintenance information and other notes in a logbook over 24 hours. The device
also outputs preventive maintenance instructions and allows
the creation of 16 freely configurable maintenance intervals
with an early warning function. The Oxymat module also
monitors measurement value drift.
Proven quality, new functionality
The seventh-generation Siemens process gas analyzers combine technological innovation with the familiar reliability
and robustness of the predecessor series, which remains
available. In addition, for optimal adaptability to various
measurement tasks, the insertion devices of the two series
can also be combined with each other.
siemens.com/cga
Ultramat 7 can measure up to four infrared-active
components with high selectivity
Oxymat 7 reliably performs oxygen measurements
Calomat 7 quantitatively determines hydrogen and
noble gases in binary or quasi-binary gas mixtures
Technical features
• High measurement range dynamics for versatile
application possibilities with the Calomat 7
• Use of molecule-specific absorption of spectral bands
in the infrared range with the Ultramat 7
• Ability to combine many modules
• Fast module replacement and automatic configuration
• Data access via Industrial Ethernet, with support for
Profibus DP, Modbus, Profinet, and Foundation Fieldbus
planned
25
process news ACHEMA special 2015 | Process analytics
Analyzer System Manager
Reliably monitoring process analytics
Analyzer
Intelligent
sampling
Analyzer house
The Analyzer System Manager records the information
of distributed analyzers in the control room
Fieldbus
such as Profibus DP
Hardwired
connection
IO module
Simatic
ET200M
ASM Server
Industrial Ethernet
interface
Y-Link
To ensure efficient plant operation, accurate
information on equipment reliability and
data quality is very important. The Analyzer
System Manager (ASM) is a manufacturerindependent system for monitoring
analyzers, making it possible to draw
reliable and robust conclusions about data
quality and device status in process plants.
A
nalyzers have high requirements in terms of selection,
commissioning, and maintenance. For this reason,
skilled personnel perform analyzer maintenance, calibration, and validation in process plants. To support these
experts, Siemens, in close cooperation with one of the largest
chemical companies in the world, developed ASM, which
allows the plant operator to assess the status of analyzers
and data quality from the control room. ASM is based on
standard Simatic components and can be optimally adapted
to all plant sizes and requirements.
Customized reports
In addition to reports related to basic process control, customized reports for specific analyzers can be created in the
form of clear charts and tables using previously calculated
key performance indicators (KPIs). ASM can record process
data from virtually all commercially available analyzers,
which can be integrated in many different ways – either via
an existing process control system, directly via fieldbus
(Modbus RTU, Profibus DP/PA, HART, etc.), or via Industrial
Ethernet. For products such as the Siemens Maxum edition
II or MicroSAM process gas chromatograph, the connection
26
Simatic
S7-410
is established via the Maxum OPC Server. Using the globally
established ASTM D3764 industry standard, ASM calculates
key data about the reliability and performance of the analyzers from the collected status information.
Efficient maintenance strategies
ASM also provides plant operators with a foundation for
planned, condition-based maintenance, because the online
monitoring of the devices allows the regular calibration cycles and maintenance intervals to be extended. Using automatically generated trends, operators can predict with high
probability when a component will fail. Another advantage:
all the information necessary for maintenance can be stored
centrally. This makes maintenance operations more efficient
and minimizes maintenance-related downtimes.
siemens.com/analyzersystemmanager
Technical features
• Acquisition of process data from all commercially
available analyzers
• Adaptation to all plant sizes and requirements
• Versatile integration of process data via fieldbus
(Modbus RTU, Profibus DP/PA, HART), Industrial
Ethernet, or Maxum OPC Server
• Extension of maintenance intervals through online
monitoring
• Shortening of maintenance-related shutdowns through
central storage of information related to maintenance
(repair instructions, manuals, etc.)
Process instrumentation | process news ACHEMA special 2015
Sitrans Library
Farewell to ad hoc
solutions
The Sitrans Library supports optimum use of Sipart and Sitrans
devices in Simatic PCS 7 applications
The integration of field devices into control systems supports users in
completing their tasks. The Sitrans Library makes function and control
modules available for optimum use of Sitrans and Sipart field devices,
both in the engineering phase and in process control.
M
odern field devices provide a range of add-on features to support operators. Siemens has developed
a new library specifically for the process instruments in the Sipart and Sitrans lines, enabling easy and safe
use of their functions via the control system.
New library for easy engineering
The Sitrans Library provides function and control modules
for both device lines and ensures their optimal use in Simatic
PCS 7 applications. To make engineering even simpler and
more reliable, the device-specific functions for Sitrans and
Sipart field devices have been added to the standard functions bundled in the Advanced Process Library (APL). The
new library, as an engineering component, is configured via
Simatic PCS 7 engineering stations in CFCs (continuous function charts). With the same look and feel as the APL, the
Sitrans Library ensures a standardized control environment
for the operator. The Simatic PDM process device manager
is used for commissioning, diagnostics, and maintenance.
Specific functions can be activated using faceplates; to avoid
duplications in the new library, standard functions already
covered by the APL have not been reimplemented.
Sipart PS2 features extensive diagnostics options
The intelligent Sipart PS2 positioner, featuring a wide range
of functions and extensive diagnostics options, is easy to
integrate into automation solutions using the new library
modules. With just one configured technological module, for
example, a valve can be opened or closed from the control
center. Switching from automatic to manual mode and modifying the positioning value are also possible with the Sitrans
Library. The states of the binary inputs and outputs in the
positioner are visualized in the same faceplate without any
additional peripherals. The combined display of positioning
value and position indication on one diagram ensures transparency of information. This same transparency can be provided for other process-related diagnostics data.
Device-specific functions available
via the control system
As with the standard APL modules, module symbols, faceplates, and function modules are both function and system
tested and are a fixed part of the Simatic PCS 7 development
cycle. After updates, all functions are retained without the
need for any correction. Device-specific functions can be
used in the control system with no special project configuration – enabling simplified engineering, shorter configuration times, and lower error rates. The Sitrans Library can generally be used for all automation projects with Simatic PCS 7
from Version 8. Project-based, upgradable solutions can be
implemented for lower version numbers. Additional desired
functions can be reported to the development team and, following evaluation, may be made available in future versions
of the Sitrans Library.
siemens.com/sitrans
27
process news ACHEMA special 2015 | Process instrumentation
Sipart PS2 Positioner
One that controls
everything
The Sipart PS2 positioner has been enhanced
to include many new diagnostic functions. The
aluminum housing for double-acting actuators
is certified to protection type Ex t.
S
iemens has added numerous new features to the Sipart
PS2, which has proven itself in practice for more than
20 years. Deployable in a wide variety of process industries, the positioner now offers the latest HART 7 communication standard.
In addition to the existing housing versions for single- and
double-acting actuators, there is now also a rugged aluminum housing with an inspection window for double-acting
actuators. This aluminum housing is certified to protection
type Ex t (dust protection provided by housing). The advantages of this protection type include the fact that it is based
solely on the housing and does not require any complex
power supply, which is directly reflected in the reduced investment costs.
In addition to safe failure behavior, the Sipart PS2 now offers
the “fail in place” function, which ensures that the valve remains in the last known position before failure of the electrical power supply, as is required in power plants in particular.
The compact Sipart PS2 booster provides rapid control of
large actuators. Directly mounted on the positioner, it minimizes manual pipe-laying work. To further simplify installation, the booster can be attached to the positioner already at
the factory. The booster increases the air-moving capacity of
the Sipart PS2 to a Cv value of 2.0 (air volume per time), allowing it to easily perform dynamic control tasks on actuators with large volumes.
The diagnostic cockpit enables the user to get started quickly
and easily using HART communication. All the relevant information for the valve (set point, actual value, deviation, status of the performance and partial stroke test, valve characteristics) is visible at a glance. Other facts and details are just
a few clicks away from the diagnostic cockpit. siemens.com/sipartps2
28
Technical features
• Deployable in a wide variety of
process industries
• A luminum housing certified to
protection type Ex t
• D iagnostic cockpit that enables
the user to get started quickly and
easily using HART communication
For 20 years, the Sipart PS2 has impressed users
with its versatility and reliability
Industrial communication | process news ACHEMA special 2015
Industrial remote communication
Easily integrating distributed stations
Comprehensive system solutions for Simatic
S7-based telecontrol technology ensure that
widely distributed automation systems can
be reliably controlled and monitored from a
central control center.
O
ne of the key challenges in plant engineering for
water/wastewater, gas, and district heating supply
systems is the increasing decentralization of energy
production. The corresponding systems must be designed
to be more extensive and flexible. To ensure that the supply
quality remains high, outstations (remote terminal units =
RTUs) need to be reliably connected to the control center.
From PLC to RTU
Using Simatic S7 control technology, RTUs can be easily and
flexibly integrated into the control center, and extensive
telecontrol systems can be set up with networked structures.
A core component is the Simatic S7-1200. This controller’s
modular design allows it to effectively meet the specific requirements of telecontrol technology.
An integral part of the implementation of a telecontrol
solution is the transfer of data from the RTU to the control
center. Due to the high demands regarding data consistency,
caching in case of connection failure, and chronological classification of values, such a solution requires great effort to
program conventionally. The CP1243-1 communication module for the Simatic S7-1200 can be simply plugged into the
controller and the programmable logic controller (PLC) transforms into an RTU: all the relevant measured values or inputs
and outputs in the controller can be directly transferred to
the control center. These values are defined once in the configuration using the “Data point configuration” function. In
this way, cyclic or event-controlled transmission of measured
values, set points, or alarms can be implemented with just a
few simple steps and without programming. Standards such
as DNP3 and IEC 60870 can be used as communication protocols, along with proven protocols such as Sinaut ST7.
Fit for cellular networks
The Simatic S7 automation system can also be equipped for
communication via cellular network, with special variants
such as the CP 1243-7 LTE, or via externally connected industrial routers such as Scalance M – an option that must be
The communications processors
connect outstations to the control
center via a Simatic S7-1200
Technical features
• Uniform hardware platform for automation
and telecontrol technology: by plugging the
CP1243-1 module into the Simatic S7-1200,
the controller is transformed into an RTU
• Simple engineering of data transmission
using the “Data point configuration” function
in Step 7
• Modules for communication via cellular
network using established standards such as
DNP3 or IEC 60870, or proven protocols such
as Sinaut ST7
used in places where there is no possibility of connecting the
RTU via cable. This enables telecontrol protocols, the appropriate transmission path (DSL Internet, cellular, etc.), and
measures to safeguard against failure to be implemented
without further programming effort.
siemens.com/industrial-remote-communication
29
process news ACHEMA special 2015 | Power supply
Sitop for 24 V nonstop
Reliable
power supply
Production interruptions and
downtime due to power failure are
costly. The modular Sitop power
supplies reliably supply critical
process components with 24 volts
and ensure continuous operation.
Sitop power supplies meet the process industry’s high requirements
for availability of electrical components
A
s the world’s best-selling industrial power supply
solution, the efficient Sitop power supply units, with
high MTBF (mean time between failures) of up to
1,000,000 hours at 40°C ambient temperature around the
clock, ensure the high product quality that is particularly critical in process automation.
Redundancy and selective protection for added security
With one-, two-, or three-phase connections for load currents of up to 40 A and with various additional modules,
Sitop power supplies are suitable for virtually any plant configuration. The wide temperature range of -25°C to +70°C
and extensive certifications enable nearly universal use. For
critical processes requiring a highly available 24-V supply,
additional modules provide the desired security. For example, a redundancy module isolates two power supply units
of the same type and prevents a short circuit in a faulty device from having an effect on the intact power supply.
The Sitop PSE200U selectivity module protects against short
circuits or overloads in a 24-V circuit. It divides the 24 V
across four branches and reliably switches off only the faulty
load branch.
Uninterruptible power supply in Simatic PCS 7
For the implementation of uninterruptible power supplies,
the Sitop DC UPS modules with various energy storage
o ptions offer a cost-effective and efficient solution.

Maintenance-free double-layer capacitors as in the Sitop
UPS500 allow 24-V buffering in the minute range, for example, for data storage and for safe shutdown of PC-based
30
Technical features
• 1-, 2-, or 3-phase connection in extremely
slimline designs
• Wide temperature range, from –25°C to +70°C
• MTBF of up to 1,000,000 hours
• Comprehensive certifications, such as ATEX,
IECEx, and for shipbuilding
• Scalable expansion of protection levels to meet
the highest requirements
• Sitop library for integrating the DC UPS into
Simatic PCS 7
s ystems. Battery solutions such as the Sitop UPS1600 enable
a network bridge of up to several hours for continuous
operation of automation systems or sensor technology. The
DC UPS module can communicate via Industrial Ethernet and
Profinet and can be directly integrated into the Simatic PCS 7
process control system using the free Sitop library. A faceplate in the user interface is supplied with operational
and diagnostic data. The module generates messages and
ensures the connection to the PCS 7 maintenance system.
Buffer operation in case of power failure, required battery
changes, or other critical plant states are quickly identified,
increasing plant availability.
With its modular design, Sitop enables reliable 24-V supply
of process applications with the highest requirements.
siemens.com/sitop
Industrial identification | process news ACHEMA special 2015
Simatic RFID
Identification facilitates optimization
For the process industry, radio-frequency identification (RFID)
offers interesting possibilities for process optimization, such as
the management of liquid transport containers.
Efficient container management with RFID: Aleris saves energy
and reduces costs through needs-based container cleaning
Devices in the Simatic RF600 UHF system portfolio enable
detection ranges of more than 3 m and include transponders for
special applications in harsh environments
F
rom small 20-liter beer kegs to aluminum crucibles be transferred directly to the inventory management sysweighing several tons, containers are used in the food, tems. Transponders such as the new Simatic RF622T conpharmaceutical, and chemical industries for transport- tainer tag with 4 KB memory can record a great deal of dising liquids and molten material. The transport takes place tributed data. For special applications, heat-resistant tranbetween individual process steps, between work sites, or to sponders such as the Simatic RF680T are available, which
the end customer, and in some cases results in high costs. In can be used reliably in harsh environments. The transponaddition to the high procurement costs (with the corre- ders remain permanently on the containers and are durable
sponding capital commitment), there is also the cost of enough to withstand cleaning.
cleaning and maintenance.
The aluminum recycler Aleris uses such a system for its liquid
An automatic container history, including current location metal crucibles. To save energy, the customized aluminum
and usage information, can be of assistance, as all transac- alloy produced is transported to the customer in the liquid
tion data and status information for the container (for exam- state. Because the metal gradually cools, automatic proof of
ple, filling with precise material property data) are recorded the precise time of delivery is important. The transported
seamlessly and automatically. The data collected allow man- alloys have different melting points. Thanks to the “knowlufacturers to better plan inventories, increase the handling edge” about the current use of the transport crucibles, they
rate, and optimize and better plan service and cleaning do not need to be heated to the highest temperature for
intervals.
cleaning. In this way, Aleris reduces costs and can determine
An automatic history can be implemented with RFID sys the optimal inventory of crucibles from the precise inventory
tems such as the Simatic RF600. At ranges of more than 3 m, and circulation data.
labeled containers can be detected during transport with a
forklift, for example. The system connects to Simatic S7 via
Profinet. Using a clearly structured XML protocol, data can siemens.com/rfid
31
process news ACHEMA special 2015 | Energy efficiency
Silyzer electrolysis system
Pure “green” hydrogen
The chemical and pharmaceutical industries use hydrogen as a synthesis gas,
but it has now also been gaining importance as a “green” energy carrier.
Surplus electricity from photovoltaic systems and wind turbines is increasingly
being used for the production of hydrogen by electrolysis.
W
ith the Silyzer electrolysis system, Siemens offers great deal to offer for pure consumers of hydrogen, which is
a solution based on proton exchange membrane used, for example, in the manufacture of flat glass as a pro(PEM) technology that offers significant advan- tective gas and in the chemical industry as a synthesis gas.
tages over the conventional alkaline process. Whenever elec- Metalworking companies use it as a reducing agent and the
tricity is available – for example when generated through re- food industry uses it for the hardening of fats. On-site hynewable energy –Silyzer can break down distilled water into drogen production not only reduces transport and logistics
oxygen and hydrogen using the electrical current. It can re- costs; it also provides maximum operating safety and high
spond within milliseconds to large peaks in electricity pro- availability.
duction from wind turbines and solar power systems. Even
with these high dynamics, the electrolyzers do not need to Efficient production with PEM
be maintained at a specific operating temperature. They can The PEM high-pressure electrolysis of the Silyzer 200 uses a
also be switched off completely and need no preheating be- proton exchange membrane. This is a relatively new techfore being switched on.
nology for hydrogen production – and a clear improvement
on conventional electrolysis both in terms of efficiency and
Production and consumption for industry
environmental sustainability. In addition, the PEM technolFrom optimization of the power demand profile to dynamic ogy is low maintenance, it works without any hazardous subproduction of hydrogen, Silyzer is a clean and efficient stances, and the recovered hydrogen is very pure, without
solution for modern industrial operations. With Silyzer, even sulfur, nitrogen, or carbon residues.
surpluses produced from in-house energy production are not
wasted but can be put to efficient use. Silyzer also has a siemens.com/hydrogen-electrolyzer
Technical features
The Silyzer
electrolysis system
converts electrical
power into
hydrogen using
PEM technology
32
• CO2-free on-site production,
with no transportation or
logistics costs
• High availability and faster
on/off operation without
preheating
• Maximum operating safety and
elimination of caustic alkalis
• Virtually maintenance-free
operation with proven
components
• Energy savings in standby
mode
• Easy integration with existing
control systems
Integrated Drive Systems | process news ACHEMA special 2015
Flexible N-Bipex couplings
Increased
service life of
the drivetrain
The elastomers for the N-Bipex couplings are available in three
Shore hardnesses
As reliable connection elements between
motors and transmissions, couplings
contribute significantly to extending the
life of the drivetrain. In addition to
equalizing offsets, they absorb shocks and
enable force transmission that dampens
torsional oscillation.
W
ith the Flender N-Bipex coupling, Siemens is
e xpanding its product portfolio to include a

new elastic claw coupling. The coupling, made of
high-quality ductile iron, is manufactured in 10 sizes ranging from 19 to 90. The cams are cast rather than milled, enabling them to be optimally shaped. Ductile iron couplings
allow much higher rotational speeds than gray cast-iron
products and offer protection against forced rupture that is
comparable with steel.
The newly developed elastomer material for the N-Bipex
coupling is designed for peak performance and is available
in three Shore hardnesses. The material achieved maximum
values for the key performance criteria of pressure strength,
abrasion resistance, dimensional stability, and deformability.
Together with the optimized curved design, this material
enables torque that is 10% to 20% higher at lower restoring
forces than in previous solutions, depending on the size. This
allows use for dynamic loads with high operating safety. The
elastomers can be used without any temperature limitations
for the rated torque in the range of -50°C to +100°C. The
N-Bipex couplings with their modified standard geometry
and the high-quality material properties of the elastomers
offer a longer service life than conventional solutions.
Compared to milled cams, the casting method offers a greater
degree of freedom for optimally shaping the cams
siemens.com/couplings
33
process news ACHEMA special 2015 | Integrated Drive Systems
IDS for hazardous area applications
Efficiency and safety in
hazardous environments
With minimal engineering effort, Integrated Drive Systems (IDS) for use in
hazardous areas enables maximum safety with the highest level of efficiency.
B
ased on efficient and reliable drive components, IDS
combines proven and standardized products with industry-specific solutions. The offering has now been
extended to include applications in explosion protection
zones. IDS for hazardous areas consists of a Sinamics G180
frequency inverter and a Simotics XP explosion-proof motor.
Perfectly matched components minimize the engineering
effort and eliminate the need for the usual certification. The
high energy-efficiency class (IE2) and inverter operation also
keep operating costs low.
Complies with the requirements of EN 50598
In accordance with the horizontal, vertical, and complete
lifecycle integration of IDS, the explosion protection drives
are optimized in all three dimensions. To achieve horizontal
integration in the drivetrain, the components meet the
energy-efficiency requirements of the new IES standard
EN 50598 and achieve maximum energy-saving potential
through their high efficiency. The power losses of the entire
Product features
• Perfectly matched Sinamics G180 frequency
inverter and Simotics XP explosion-proof motor
• Minimal installation and certification effort
• Integrated system mechanisms that support
interaction with the controller, HMI, and
Simatic PCS 7
• Easy engineering using Sizer for Siemens
Drives and DT Configurator
• Compliance with energy-efficiency requirements of IES standard EN 50598
drive system are reduced. For this purpose, the Sinamics
G180 has optimized pulse frequencies for effective motor
utilization, and the converter output currents are matched
to the rated motor currents (from 2.2 kW).
For vertical integration in the automation environment, the
drive system features integrated system mechanisms that
perfectly support interaction with the controller, the HMI,
and also the Simatic PCS 7 process control system. The standardized system configuration of the motor and converter
allows easy engineering using Sizer for Siemens Drives and
DT Configurator.
IDS for hazardous areas also offers what is known as lifecycle integration – services throughout the lifecycle of the
plant. The ability to achieve guaranteed performance values
and create customized documentation ensures high efficiency in plant engineering. Integrated diagnostics and
maintenance as well as worldwide after-sales support ensure
high availability during operation of the plant. Finally, during
modernization plant operators benefit from retrofit solutions, including specific adaptations such as plug and play,
and energy-efficiency services. Optimized components and
coordinated drivetrains from a single source increase the
productivity, reliability, and energy efficiency of the overall
plant.
siemens.com/ids
34
Integrated Drive Systems | process news ACHEMA special 2015
Energy-efficiency standard EN 50598
Energy-efficient drive systems
The new European EN 50598 standard goes into effect this year, which will
make it possible for users of drive systems to determine the energy demand
based on application-specific load profiles.
T
he new EN 50598 standard, “Ecodesign for power
drive systems, motor starters, power electronics, and
their driven equipment,” published in December 2014,
focuses on the individual components and the overall system, taking the application into consideration. The standard
applies to drive components and motor systems in the
low-voltage range of 100 V to 1,000 V and in the power
range of 0.12 kW to 1,000 kW.
Energy-efficiency requirements for the motor system
For loss determination, the standard defines a total of eight
operating points, which are to be documented by the manufacturers of motor systems and CDMs. This information will
allow users to determine the energy requirements of their
machines with the respective drives. For the CDM, the standard defines the efficiency classes IE0, IE1, and IE2. The values for class IE1 can be found as a CDM reference. A CDM
with 25% lower losses achieves efficiency class IE2; a CDM
with 25% higher losses achieves efficiency class IE0. As with
existing motor classes, higher numbers stand for lower
losses and higher energy efficiency. In the future, the motor
systems will be labeled with the efficiency classes IES0, IES1,
and IES2 (see figure).
The three parts of the standard
The first two parts of the standard address the issue of energy
efficiency and enable users to match the energy needs of their
machines with the appropriate drive, based on applicationspecific load profiles. The first part contains the general approach for determining the losses of electrically powered machines and describes the responsibilities and requirements, Profitable for manufacturers and users
as well as the necessary data flow, for component manufac- The implementation of EN 50598 allows users to determine
turers, machine builders, and systems integrators. The sec- the power losses of the individual components and their
ond part describes the methods used to determine losses in interaction in the motor system at a reasonable cost, as well
partial-load operation of the motor system (motor with con- as to compare their energy efficiency. This provides the basis
verter or motor starter) and its components, and specifies the for determining energy demand in actual operation in the
efficiency classes for the motor system and converter (de- application.
fined in the standard as the complete drive module, or CDM). Siemens offers its customers optimally matched drive
The measurement and calculation methods for the CDMs are components for efficient optimization of their electrically
also described and defined. The third part of the standard powered machines at all relevant operating points. Energy
deals with ecodesign and environmental declarations, which efficiency is one of the many advantages offered by IDS.
enable the uniform creation of product-specific lifecycle assessments, taking into account the essential environmental
siemens.com/legislation-and-standards
aspect by defining product category rules.
Efficiency classes for Power Drive System (PDS*) – motor system
Determining efficiency
classes IE 0 – IE 2
PDS relative
torque current / %
100
50
25
P L, PDS
(0; 100)
P L, PDS
(50; 100)
P L, PDSM
(0; 50)
P L, PDS
(50; 50)
P L, PDS
(0; 25)
P L, PDS
(50; 25)
50
P L, PDS
(100; 100)
P L, PDSM
(100; 50)
P L, PDS (100; 100)
P L, RPDS (100; 100)
Reference value
(Reference system =
Reference converter +
reference motor)
IES 0
20 % higher losses
than reference value
IES 1
Reference value
± 20 %
IES 2
20 % lower losses
than reference value
120 %
100 %
80 %
50 %
0%
100
PDS relative
speed / %
PDS = Motor with converter
* Motor system = Motor with converter or motor starter
35
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