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Caution:
The functions and solutions described in this article confine themselves to the
realization of the automation task predominantly. Please also take into account that
corresponding protective measures have to be taken in the context of Industrial
Security when connecting your equipment to other parts of the plant, the enterprise
network or the Internet. For more information, please refer to Entry ID 50203404.
http://support.automation.siemens.com/WW/view/en/50203404
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Fermenter
2 V1.0, Entry ID: 68098270
Task Description and
s Solution 1
Fundamentals Process
Engineering 2
Structure and Function
Principle 3
Integrating the Unit
Template 4
SIMATIC PCS 7
Starting the Unit
Template 5
Fermenter
Application Example Operating the Application 6
Related Literature 7
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History 8
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Fermenter
V1.0, Entry ID: 68098270 3
Warranty and Liability
Note The Application Examples are not binding and do not claim to be complete
regarding the circuits shown, equipping and any eventuality. The application
examples do not represent customer-specific solutions. You are responsible for
ensuring that the described products are used correctly. These application
examples do not relieve you of your responsibility to use safe practices in
application, installation, operation and maintenance. When using these
application examples, you recognize that we cannot be made liable for any
damage/claims beyond the liability clause described. We reserve the right to
make changes to these application examples at any time without prior notice. If
there are any deviations between the recommendations provided in this
application example and other Siemens publications e.g. catalogs the
contents of the other documents have priority.
We do not accept any liability for the information contained in this document.
Any claims against us based on whatever legal reason resulting from the use of
the examples, information, programs, engineering and performance data etc.,
described in this application example will be excluded. Such an exclusion will not
apply in the case of mandatory liability, e.g. under the German Product Liability Act
(Produkthaftungsgesetz), in case of intent, gross negligence, or injury of life, body
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Fermenter
4 V1.0, Entry ID: 68098270
Preface
Preface
Objective of this application
The objective of this application is to supply you with a prefabricated and unified
example project for a process engineering plant. It offers a quick introduction and
know-how acquisition, based on the appropriate equipment modules. This example
project can be adjusted flexibly to your own requirements and be integrated into
your own multi-projects.
Main contents
The following core points are discussed in this application:
Structure of a fermenter
Description of the individual functions and configurations
Handling the application example
Validity
As of SIMATIC PCS 7 V8.0 SP1
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Fermenter
V1.0, Entry ID: 68098270 5
Table of Contents
Table of Contents
Warranty and Liability .............................................................................................. 4
Preface ...................................................................................................................... 5
Table of Contents ..................................................................................................... 6
1 Task Description and Solution ...................................................................... 8
1.1 Task .................................................................................................. 8
1.2 Solution ............................................................................................. 8
1.2.1 Fermenter unit ................................................................................... 8
1.2.2 Overview of the overall solution ......................................................... 9
1.2.3 Core functionality ............................................................................. 11
1.2.1 Description of the individual functions .............................................. 12
1.2.2 Control concept ............................................................................... 14
1.2.3 P&I flow diagram ............................................................................. 15
1.3 Hardware and software components ................................................ 16
2 Fundamentals Process Engineering......................................................... 17
2.1 Fermenter........................................................................................ 17
2.2 Temperature control ........................................................................ 17
3 Structure and Function Principle................................................................. 18
3.1 Project structure .............................................................................. 18
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Fermenter
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Table of Contents
Fermenter
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1 Task Description and Solution
1.1 Task
1.2 Solution
1.2.1 Fermenter unit
This application example refers to the unit of a universal fermenter (bioreactor) for
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Fermenter
8 V1.0, Entry ID: 68098270
1 Task Description and Solution
1.2 Solution
Display
The figure below shows a possible specification of a chemical plant for the
production of bio-ethanol based on a fermenter.
Figure 1-1: Process layout of a typical chemical plant with a fermenter as a part of the bio-ethanol process
Dehydration
Bioethanol
Superheated
Bioethanol
steam
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Drying
Separation
Thin slop
Syrup
Bioethanol
Drying
Loading
DDGS DGS
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Description
The fermenter unit template includes several preconfigured, standardized and
readily interconnected equipment modules. Based on this sample solution,
numerous instances with different parameter settings can be generated and
adapted for integration into a variety of automation solutions. The hardware-
independent configuration of the PCS 7 project enables flexible integration into
existing projects.
The Fermenter unit template has been realized in the form of a PCS 7
multiproject as follows:
The Component View contains one project for the automation system (AS) and
one project for the operator station (OS).
The Plant View contains a hierarchy folder for each equipment module of the
fermenter.
All control functions are realized in the AS project in the form of CFCs (continuous
function charts). Furthermore, the AS project includes a hierarchy folder with
simulation charts for simulating processes, for example, a change in filling levels
within an equipment module.
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1 Task Description and Solution
1.2 Solution
All equipment modules are available in the master data library of the project in the
form of process tag types and include function blocks of the PCS 7 Advanced
Process Library (APL).
The OS project comprises the visualization of the fermenter with all equipment
modules and shows:
a schematic layout of the fermenter
the relevant indicators (KPI: Key Performance Indicators)
controlling a cleaning process (CIP)
controlling a discontinuous production process
Delimitation
The automation solution on hand has been developed for a fermenter in
discontinuous operation in the white biotechnology environment. "White
biotechnology" refers to industrial manufacturing of products with biotechnological
methods. Microorganisms or cells are used here to produce the desired product
naturally. Typical target branches are fine chemical industry and food technology.
The sample solution is based on fermentation processes for bio-ethanol. Other
alcohols (incl. beer) as well as biogas are manufactured in fermenters; however,
the plant instrumentation can deviate strongly from the fermenters for bio-ethanol.
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The aim of "red biotechnology", on the other hand, is to access the genome of
microorganisms to produce certain pharmaceuticals or extract DNA sequences and
proteins for diagnosis. These are products which the cell would not naturally
produce and which are therefore allocated to the pharmaceutical sector.
Fermenters in red biotechnology pose special requirements on the automation
which are not covered by the sample solutions on hand. A respective so-called
Bioreactor Control Toolbox is currently developed (see /2/ in related literature in
chapter 7).
The engineering process within the fermenter is not simulated. With an enhanced
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simulation, the unit template could also be used in an operator training system.
Required knowledge
Basic knowledge of the following subject areas is required:
Configuration with PCS 7 and APL
Knowledge in the field of control engineering
Basic process engineering knowledge
Fermenter
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1 Task Description and Solution
1.2 Solution
Process image
The process image of a fermenter comprises the following elements:
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Schematic illustration of the unit with feed components (arranged on the left of
the reactor) and discharge components (arranged on the right of the fermenter)
Faceplates to control the individual components (aggregates)
SFC for the production and cleaning process
Overview of all relevant indicators (Key Performance Indicators) and operating
duration displays
The process image provides an overview of the entire unit and allows the operator
to intervene as required.
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1 Task Description and Solution
1.2 Solution
Figure 1-3
2 5
3
4
7
8
1
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The process image of the fermenter comprises the following main components:
1. Cleaning in place (CIP) without dismantling
2. Inflow of an ingredient
3. pH value control
4. Stirrer
5. Pressure control
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Fermenter
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1 Task Description and Solution
1.2 Solution
(4) Stirrer
The motor-driven stirrer is used for mixing the added ingredient with the neutralizer
in order to obtain a homogeneous distribution of the material concentration and
temperature within the reactor. The stirrer is controlled on demand via SFC.
(7) Reactor
The fermentation takes place inside the reactor. The reactor is designed and
selected with consideration of process-specific relationships which may be quite
complex in some parts.
These include, among others, the following:
ingredients (for alternating products) and neutralizers which require a specific
design or tank property
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feed and discharge quantities and the production volume to determine the
reactor size
fermentation and neutralization in the appropriate ambient conditions required
(pH value, temperature and pressure)
Further functions
After starting the control, a production process is performed with a cleaning
process at the end. After cleaning, all controllers and actuators are enabled for the
operator.
The operator can start the production on demand or control the individual
components of the fermenter.
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1 Task Description and Solution
1.2 Solution
Note The PCS 7 project can be expanded by your own KPI, such as stand time,
space-time yield, and catalyst productivity.
For the fermenter control, the PID controllers PIDConL of the APL are used for
pH value, pressure, as well as temperature control.
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All further actions (open/close valves and activate/deactivate pumps and motor)
are controlled via SFC.
Note Physical correlations, e.g. between pressure and temperature, are not
considered for simulation.
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Fermenter
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1 Task Description and Solution
1.2 Solution
The figure below shows the individual elements of a fermenter in the form of a
piping and instrumentation flow diagram.
Figure 1-4
YC
ClP_In
CIP
YC
Feed
NS
Motor
Feed
QIC YC
PIC
pH NeutrSubst
Pressure
Neutralizer
YC
Out
TIC
Reactor
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Venting
YC
Cool
LI
Coolant Level
YC
Outflow
Product
YC
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Cooling
Product
TIC
Jacket
YC
M
CIP_Out
YC
Jacket_C CIP
Hot steam
YC
Jacket_H
Cooling water NS M
PumpReactor
NS
PumpJacket
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1 Task Description and Solution
1.3 Hardware and software components
Hardware components
Table 1-1
Component Note
SIMATIC PCS 7 ES/OS IPC547D W7 For the PCS 7 V8.0 SP1 example project
Note When using different hardware, please observe the minimum requirements for
installing the software components. The minimum requirements are available in
the PCS 7 readme file.
Fermenter
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2 Fundamentals Process Engineering
2.1 Fermenter
the inner fermenter wall. In the course of plant operation, the heat transition
properties may change due to the formation of deposit layers (fouling).
Adding a neutralizer causes an exothermal chemical reaction in the fermenter
which causes a temperature increase in the mixture. The fermentation process
itself also causes release of reaction heat. To balance these changes and for
setting a given temperature, the mixture is pumped through a cooling heat
exchanger.
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Fermenter
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3 Structure and Function Principle
3.1 Project structure
The designation of process tags follows a uniform naming convention, whereby the
function is named in compliance with the European standard EN 62424. The figure
below shows how a process tag name is composed:
Figure 3-1
TIC_Jacket
Function Designation
T = Temperature (first letter)
I = Display (following letter)
C = Control (following letter)
The following table contains all letters used in this application and their meaning:
Table 3-1
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Y Control valve
Table 3-2
Next letter Meaning
C Control
I Indication
F Fraction
S Binary control function or switching function (not
safety-relevant) (Switching)
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3 Structure and Function Principle
3.1 Project structure
In the plant view, the Fermenter unit template is realized in two hierarchy levels.
The first hierarchy level in the AS project UnitTemplate_AS is empty and the next
subordinate level includes one hierarchy folder for each equipment module of the
fermenter with the required CFC charts and the related process simulation.
The first hierarchical level in the OS project UnitTemplate_OS is empty. The next
subordinate hierarchy level includes the process image Fermenter.pdl of the
fermenter. The following figure illustrates the structure of the PCS 7 multiproject.
Figure 3-2
UnitTemplate OS Project
Fermenter
PDL
Fermenter
UnitTemplate AS Project
Fermenter
SFC CFC
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StartFermenter KPI
CIP ProcSimulation
pH
Level
ProductTemp
Pressure
JacketTemp
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3 Structure and Function Principle
3.2 Equipment modules and process tags
Note All necessary descriptions, configurations and procedures for the reference
versions are available in the documentation with the entry ID: 53843373. For
further information on individual equipment modules, please refer to chapter 5
Equipment Modules and the process tag types in chapter 4 Process Tag
Types.
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3 Structure and Function Principle
3.3 Cleaning (CIP)
3.3.1 Structure
Opening and closing the valves is performed via the SFC CLEANING.
The table below provides an overview of the individual elements and the process
tag types used.
Table 3-3
Designation Process tag type Description
YC_CIP_In Val_An_Afb1 Control valve for detergent inflow
YC_CIP_Out Val_An_Afb1 Control valve for detergent outflow
The following figure shows a simplified illustration of the structure of the feed
inflow, including any interconnections or SFC access across different CFC charts.
Figure 3-3
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YC_CIP_In Sim_CIP
SFC IN_CIP
V
In1
MV
OUT_CIP
V
In1
OpenAut
CloseAut
CIP_Flow_Sum
ModLiOp
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Out
AutModLi
ManModLi
YC_CIP_Out
V
MV
V
OpenAut
CloseAut
ModLiOp
AutModLi
ManModLi
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3 Structure and Function Principle
3.3 Cleaning (CIP)
Simulation
In simulation chart Sim_CIP, the difference is formed from YC_CIP_In and
YC_CIP_Out and transferred to simulation chart Sim_Level for calculating the
filling level.
Figure 3-4
If the valve is opened 100%, the CIP inflow and drainage correspond to 50 (factor
0.5) liters per second.
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3.3.2 Configuration
YC_CIP_In
Valve process tag YC_CIP_In is used to control the flow rate of the detergent
(acid or base) to the tank. The communication blocks (subchart A, sheet 6) in the
process tag were deleted since no controller is employed for controlling. For
opening or closing, valve block V receives an external actuating signal via SFC.
In a simulation environment, both channel blocks of subchart B (Rbk and MV)
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have the same value (control value of the valve block (subchart A, sheet 1)) via
the preceding simulation block; i.e. the delay between valve control and valve
action will not be simulated.
The following table shows how the instance of Val_An_Afb1 is configured.
Table 3-4
Block Connection Value Use
Interconnection to the simulation
V MV (Level\\Sim_Level\IN_CIP.In1)
ER_AH_En Disables the alarm message for maximum
V (hidden) 0 valve opening
ER_AL_En Disables the alarm message for minimum
V (hidden) 0 valve opening
Sim Sim1ActOp.Value 1 Activates simulation of the readback value
Interconnects with the simulation of the
readback value from the valve
Sim Sim1ValueOp (YC_CIP_In\V.MV)
Sim Sim2ActOp.Value 1 Activates simulation of the control value
Interconnection with the simulation of the
manipulated value from the valve
Sim Sim2ValueOp (YC_CIP_In\V.MV)
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3 Structure and Function Principle
3.3 Cleaning (CIP)
YC_CIP_Out
The valve process tag YC_CIP_Out is used to control the detergent drainage
from the tank. The communication blocks (subchart A, sheet 6) in the process tag
are not required since no controller is employed for controlling. For opening or
closing, valve block V receives an external actuating signal via SFC.
In a simulation environment, both channel blocks of subchart B (Rbk and MV)
have the same value (control value of the valve block (subchart A, sheet 1)) via
the preceding simulation block; i.e. the delay between valve control and valve
action will not be simulated.
The following table shows how the instance of Val_An_Afb1 is configured.
Table 3-5
Block Connection Value Use
Interconnection to the simulation
V MV (Level\\Sim_Level\IOUT_CIP.In1)
ER_AH_En Disables the alarm message for maximum
V (hidden) 0 valve opening
ER_AL_En Disables the alarm message for minimum
V (hidden) 0 valve opening
Sim Sim1ActOp.Value 1 Activates simulation of the readback value
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Fermenter
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3 Structure and Function Principle
3.4 pH value control (pH)
Note The flow rate control with equipment module Level-Control contains an
integrated behavior. Change the simulation before applying for pH value control.
In the simulation chart, all influencing variables (inflow, drainage) are acquired
across all process tags and taken into account for forming the pH value.
3.4.1 Structure
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The PID controller captures the pH value from the simulation chart and controls by
adding neutralizer depending on the specified pH value.
The table below provides an overview of the individual elements.
Table 3-6
Designation Equipment module / Description
process tag type
QIC_pH pH-Control-Std pH value control via the concentration difference
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Note A description and further information on the configuration and principle of the
equipment module pH-Control-Std is available in chapter 5 Equipment
Modules of the documentation which is available at entry ID: 53843373.
Simulation
CFC chart Sim_pH (part of the equipment module pH of the Fermenter unit
template) calculates the pH value in the reactor based on the inflow (ingredient and
neutralizer).
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3 Structure and Function Principle
3.4 pH value control (pH)
Figure 3-5
3 1
4 2
5
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Creating (5) a slight noise and adding (6) it to the process value
3.4.2 Configuration
QIC_pH
The configuration of this process tag deviates from pH value control pH-Control-
Std as follows:
Table 3-7
Block Connection Value Use
C Gain 190 Controller gain
C TI 720 Controller delay
Interconnection deleted, block renamed and
moved to sheet 6. Additionally, a conversion
block (pH -> Mol/L) was added and
pH_SP interconnected with the display block
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3 Structure and Function Principle
3.4 pH value control (pH)
Note Controller optimization for the pH-Control-Level process tag has already been
performed with the PID tuner. The controller is optimized for a fast neutralization
process. For a slow (homogenous) neutralization process you change the
controller parameter (Gain = 41, TI = 300) accordingly.
A description for performing the controller optimization is available in chapter 6
Equipment Modules of the documentation which is available under the entry ID:
53843373 and in the article How do you do a controller optimization with the PCS
7 PID Tuner? under the entry ID: 8031495.
YC_NeutrSubst
The configuration of this process tag deviates from pH value control pH-Control-
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Std as follows:
Table 3-8
Block Connection Value Use
Interconnection to the simulation
(Sim_ProductTemp\Temp_Incr_Neutr.In1)
V MV (Sim_Level\Neutr_Scale.In1)
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QI_pH_Tank
The configuration of this process tag does not deviate from pH value control
pH-Control-Std.
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3 Structure and Function Principle
3.5 Filling level (Level)
3.5.1 Structure
The filling level in the product is controlled via SFC. The respective valves and the
stirrer motor are opened/closed and started/stopped via the respective valves. In
the simulation chart, any inflow is recorded and the filling level is output in the
display process tag as a percentage. The table below provides an overview of the
individual elements.
Table 3-9
Designation Equipment module / Description
process tag type
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Figure 3-7
YC_Feed Sim_Level
SFC
V Feed_Scale
MV In1
YC_Product
V Outflow_Scale
OpenAut V In1
CloseAut MV
ModLiOp Level_Max_Percen
V
AutModLi Out
OpenAut
ManModLi
CloseAut
ModLiOp
NS_Motor AutModLi
LI_Level
U ManModLi
StartAut I
StopAut Sim1ActOp
ModLiOp
AutModLi
ManModLi
U
FbkRunOut
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3 Structure and Function Principle
3.5 Filling level (Level)
Simulation Sim_Level
In the simulation chart, the filling level is calculated from the total of any inflow and
the drainage converted as a percentage.
Figure 3-8
4
2
3
6 7
5
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1. Inflow of the ingredient (100 % valve opening correspond to 20 l/s) with a delay
of 1 second (PT1 behavior)
2. Inflow of the neutralizer (100 % valve opening correspond to 1 l/s) with a delay
of 1 second (PT1 behavior)
3. Drainage of the product (100 % valve opening correspond to 20 l/s)
4. Summarizing any inflow and drainage including CIP and forming an integral
value
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3.5.2 Configuration
LI_Level
The LI_Level display process tag uses the filling level percentage of the
Sim_Level simulation for the process value display.
The following table shows the configuration of the instance from AMON__Std.
Table 3-10
Block Connection Value Use
Sim Sim1ActOp.Value 1 Activates simulation
Interconnection to the simulated process
value
Sim Sim1ValueOp (Sim_Level\Level_Max_Percen.Out)
PV Scale 100 Maximum value of the process value
Unit of the process value as a
PV PV_InUnit 1342 percentage
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3 Structure and Function Principle
3.5 Filling level (Level)
YC_Product
The YC_Product valve process tag controls the product flow rate (opening drain
valve) from the tank. The communication blocks (subchart A, sheet 6) in the
process tag were deleted since no controller is employed for controlling. For
opening or closing, valve block V receives an external actuating signal via SFC.
In a simulation environment, both channel blocks of subchart B (Rbk and MV)
have the same value (control value of the valve block (subchart A, sheet 1)) via
the preceding simulation block; i.e. the delay between valve control and valve
action will not be simulated.
The following table shows how the instance of Val_An_Afb1 is configured.
Table 3-11
Block Connection Value Use
Interconnection to the simulation
V MV (Sim_Level\Outflow_Scale.In1)
ER_AH_En Disables the alarm message for
V (hidden) 0 maximum valve opening
ER_AL_En Disables the alarm message for
V (hidden) 0 minimum valve opening
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YC_Feed
The valve process tag YC_Feed is used to control the ingredient flow rate (by
opening the feed valve) to the tank. The communication blocks (subchart A, sheet
6) in the process tag were deleted since no controller is employed for controlling.
For opening or closing, valve block V receives an external actuating signal via
SFC.
In a simulation environment, both channel blocks of subchart B (Rbk and MV)
have the same value (control value of the valve block (subchart A, sheet 1)) via
the preceding simulation block; i.e. the delay between valve control and valve
action will not be simulated.
The following table shows how the instance of Val_An_Afb1 is configured.
Table 3-12
Block Connection Value Use
Interconnection to the simulation
V MV (Sim_Level\Feed_Scale.In1)
ER_AH_En Disables the alarm message for
V (hidden) 0 maximum valve opening
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3 Structure and Function Principle
3.5 Filling level (Level)
NS_Motor
The stirrer mixes the ingredient with the neutralizer in the reactor. Stirrer control is
performed via SFC and based on process tag type MOT_1sp_1fb_1cm__Std.
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This process tag type is included in the master data library and it is used for motors
driven at constant speed.
Configuring the instance from MOT_1sp_1fb_1cm__Std was not necessary.
Note A description and further information on the configuration and principle of the
process tag type MOT_1sp_1fb_1cm__Std can be found in chapter 4 Control
Modules of the documentation which is available under the entry ID: 53843373.
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Note The Limit block of the APL can be used for interlocking the motor, e.g. when
falling short of the filling level, and be connected to the interlock block of the
motor process tag. In this case, the stirrer interlock becomes active when falling
short of a defined filling level of the reactor and the motor cannot be started.
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3 Structure and Function Principle
3.6 Pressure control (Pressure)
3.6.1 Structure
The PID controller detects the tank pressure from the simulation chart and reduces
the pressure (venting). The table below provides an overview of the individual
elements.
Table 3-13
Designation Equipment module / Description
process tag type
PIC_Pressure Level Control Pressure control of a tank
YC_Out Level Control Control valve for venting
Note The description, configuration, and procedure for equipment module Level-
Control is available in chapter 5 Equipment Modules of the documentation at
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Simulation Sim_PressLevel
CFC chart Sim_PressLevel (which is part of the Split-Range-Pressure
equipment module) receives the manipulated variable of the venting valve
(negative value). The control valve for the inert gas was substituted by adding two
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disturbance values.
The figure below shows the structure and process of simulation.
Figure 3-9
In the Diff block (1), the fermentation volume (pressure change due to the
fermentation process) and the filling level-related inflow (pressure change due to
different filling levels) is recorded in addition to the manipulated venting variable.
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3 Structure and Function Principle
3.6 Pressure control (Pressure)
3.6.2 Configuration
PIC_Pressure
The configuration of this process tag deviates from filling level control Level-
Control as follows:
Table 3-14
Block Connection Value Use
C Gain 8.0 Controller gain
C TI 75.0 Controller delay
C SP_InHiLim 15.0 Maximum value of the internal setpoint
New interconnection to the simulation chart
Sim Sim1Value (Sim_PressLevel\PressLevel.Out)
PV Scale.High 15.0 Maximal process value
PV PV_InUnit 1138 Unit of the process value (mbar)
Note Controller optimization for the process tag has already been performed with the
PID tuner. The controller is optimized for the operating range (8 mbar).
Descriptions for performing the controller optimization are available in chapter 6
Equipment Modules of the documentation which is available under the entry ID:
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53843373 and in the article How do you do a controller optimization with the
PCS 7 PID Tuner? under the entry ID: 8031495.
YC_Out
The configuration of this process tag deviates from filling level control Level-
Control as follows:
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Table 3-15
Block Connection Value Use
Interconnection to the simulation
V MV (Sim_PressLevel\Out.In1)
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3 Structure and Function Principle
3.7 Jacket temperature control (JacketTemp)
3.7.1 Structure
The PID controller records the temperature of the fermenter jacket and increases
or reduces the jacket temperature by means of hot steam or cooling water
according to the specified temperature. The table below provides an overview of all
components.
Table 3-16
Designation Equipment module / Description
process tag type
TIC_Jacket Split-Range-Temperature Slave controller for split-range control with one
manipulated variable and two actuators
YC_Heat Split-Range-Temperature Control valve for heating steam
YC_Cool Split-Range-Temperature Control valve for cooling water
NS_PumpJacket MOT_1sp_1fb_1cm__Std Pump (e.g. stream pump) for continuous
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Note The display process tags and the process tag for master controller
TIC_Reactor of the Split-Range-Temperature equipment module are not
required and are therefore not part of this solution. Therefore, the communication
blocks to_Master and from_Master are deleted in the TIC_Jacket controller
process tag. The missing process tags and interconnections will not affect the
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Simulation Sim_JacketTemp
CFC chart Sim_JacketTemp (which is part of equipment module
Split-Range-Temperature) was reduced by the simulation part of the heat
exchanger (TempLevel block) and contains an additional disturbance signal.
The figure below shows the structure and process of simulation.
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3 Structure and Function Principle
3.7 Jacket temperature control (JacketTemp)
Figure 3-10
NS_PumpJacket
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The pump is controlled in the CFC NS_PumpJacket on the basis of the process
tag type MOT_1sp_1fb_1cm__Std. This process tag type is part of the master
data library.
Note A description and further information on the configuration and principle of the
process tag type MOT_1sp_1fb_1cm__Std can be found in chapter 4 Control
Modules of the documentation which is available under the entry ID: 53843373.
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Note For the following cases, a pump interlock can be performed (configured):
3.7.2 Configuration
Temperature control via the reactor jacket is configured for independent operation.
Since, in this example, the system is not influenced by other plant units and the
controllers react very quickly, no further modifications are required.
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3 Structure and Function Principle
3.8 Product temperature control (ProductTemp)
In the following figure the entire structure of the product temperature control,
including all interconnections across all CFC charts, are represented in a simplified
format.
Figure 3-11
Sim V Temp_HeatExchang
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Sim1ValueOp MV In1
from_Valve to_CTRL
In Out
SFC
YC_Cooling NS_PumpReactor
V U
OpenAut StartAut
CloseAut StopAut
ModLiOp ModLiOp
AutModLi AutModLi
ManModLi ManModLi
The controller process tag TIC_ Reactor captures the product temperature
(simulation chart Sim_ProductTemp) and controls it with the help of the control
valve YC_Cool.
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3 Structure and Function Principle
3.8 Product temperature control (ProductTemp)
Simulation
In the simulation chart, the product temperature is calculated based on the flow
rate of the neutralizer, the flow rate of cooling water to the heat exchanger, and the
influence from jacket temperature control.
Figure 3-12
1 3 4
6
5
3.8.1 Configuration
TIC_Reactor
The following table shows the configuration of the instance from the CTRL_
Std4Valve process tag type.
Table 3-18
Block Connection Value Use
C NegGain.Value 1 Negative controller gain
C Gain.Value 8.5 Controller gain
C TI.Value 4 Controller delay
C SP_InHiLim 100.0 Maximum value of the internal setpoint
C PropFacSP 0.8 Applying the P-action to the feedback
Inverts the hardware error signal from
Intlock InvIn02 1 the valve process tag
Inverts the out of service signal from
Intlock InvIn03 1 the valve process tag
Interconnection to the valve (control)
to_Valve Out (YC_Cool\from_CTRL.In)
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3 Structure and Function Principle
3.8 Product temperature control (ProductTemp)
Note Controller optimization for the process tag TIC_Reactor already performed with
the PID tuner. Descriptions for performing the controller optimization are
available in chapter 6 Equipment Modules of the documentation which is
available under the entry ID: 53843373 and in the article How do you do a
controller optimization with the PCS 7 PID Tuner? under the entry ID: 8031495.
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YC_Cool
The valve process tag YC_Cool controls the flow rate (opening feed valve) of the
cooling water to the heat exchanger. The process tag includes communication
blocks for data exchange (control signals and control commands) with the
controller process tag.
The valve block V includes an external control value (via a communication block)
from the controller process tag. In a simulation environment, both channel blocks of
subchart B (Rbk and MV) have the same value (control value of the valve block
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(subchart A, sheet 1)) via the preceding simulation block; i.e. the delay between
valve control and valve action will not be simulated.
The following table shows how the instance of Val_An_Afb1 is configured.
Table 3-19
Block Connection Value Use
Interconnecting to the simulation
V MV (Sim_ProductTemp\Temp_HeadExchang.In1)
ER_AH_En Disables the alarm message for maximum
V (hidden) 0 valve opening
ER_AL_En Disables the alarm message for minimum
V (hidden) 0 valve opening
Interconnection to the controller
from_CTRL In (TIC_Reactor\to_Valve.Out)
Interconnection to the controller
to_CTRL Out (TIC_Reactor\from_Valve.In)
Sim Sim1ActOp.Value 1 Activates simulation of the readback value
Interconnecting with the simulation of the
readback value from the valve
Sim Sim1ValueOp (YC_Cool\V.MV)
Sim Sim2ActOp.Value 1 Activates simulation of the control value
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3 Structure and Function Principle
3.8 Product temperature control (ProductTemp)
YC_Cooling
The valve process tag YC_Cooling controls the flow rate (opening feed valve) of
the product through the heat exchanger.
Note An alternative is using an on/off valve. In this case, a new process tag must be
configured for an on/off valve
The communication blocks (subchart A, sheet 6) in the process tag were deleted
since no controller is employed for controlling. For opening or closing, valve block
V receives an external actuating signal via SFC.
In a simulation environment, both channel blocks of subchart B (Rbk and MV)
have the same value (control value of the valve block (subchart A, sheet 1)) via
the preceding simulation block; i.e. the delay between valve control and valve
action will not be simulated.
The following table shows how the instance of Val_An_Afb1 is configured.
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Table 3-20
Block Connection Value Use
ER_AH_En Disables the alarm message for max. valve
V (hidden) 0 opening
ER_AL_En Disables the alarm message for min. valve
V (hidden) 0 opening
from_CTRL Block deleted
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NS_PumpReactor
The pump is used for pumping the product through the heat exchanger, as well as
for pumping the product out. The pump is controlled via SFC and based on process
tag type MOT_1sp_1fb_1cm__Std. This process tag type is included in the
master data library and it is used for motors/pumps driven at constant speed.
Configuring the instance from MOT_1sp_1fb_1cm__Std was not necessary.
Note A description and further information on the configuration and principle of the
process tag type MOT_1sp_1fb_1cm__Std can be found in chapter 4 Control
Modules of the documentation which is available under the entry ID: 53843373.
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3 Structure and Function Principle
3.9 Sequential function charts (SFC)
Note The parameter assignment for the selection of setpoints and operating modes,
including the schematic illustrations, are taken from the function manual
SIMATIC Process Control System PCS 7 PCS 7 Advanced Process Library
V8.0. This function manual is available under the entry ID 57265842 and
includes information on operating modes and setpoint selection, as well as
further detailed information about all parameters of the APL blocks.
Create and use SFC types, SFC instances for recurring sequences. Continuing
information on SFC configuration and on creating SFC types is available in the
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PREPARING
When starting the fermenter, the PREPARING sequence will be executed to bring
the unit into a non-production mode of operation. For this reason, all valves and
controllers are prepared for automatic mode with specified SFC value. Then, any
inflow is stopped and the fermenter is drained via the CIP outflow. Additionally, the
process simulation is reset.
The flowchart below shows a simplified scheme of all sequential steps and
transitions of the SFC operations. Selection of the operating mode and the type of
default setpoint are not considered.
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3 Structure and Function Principle
3.9 Sequential function charts (SFC)
Figure 3-13
Start
Drainage
no
Filling level
0.0
yes
CIP outlet closed
End
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PRODUCTION
The PRODUCTION sequence is followed by the PREPARING sequence and
comprises the discontinuous fermentation process. For the production (batch), the
unit is filled with an ingredient at plant shutdown (no production). The valve of the
ingredient is opened until a defined filling level has been reached. Neutralizing is
performed after filling and during the fermentation process. The pH value controller
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controls the addition of the neutralizer using the pH value in the tank. Drainage is
performed after neutralization has been completed.
All controllers obtain the setpoint values relevant for the production process, such
as temperature (reactor jacket and product temperature), tank pressure and pH
value, from the sequencer. The sequence of steps includes some further queries
so the devices (pump and stirrer) for the production process will only start after a
filling level of, for example, 20 % has been reached and the pressure controllers
have been activated. After the production has been completed (drainage), the
process simulation is reset.
The flowchart below shows a simplified scheme of all sequential steps and
transitions of the SFC operations.
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3.9 Sequential function charts (SFC)
Figure 3-14
Start
temperature control
pH setpoint = 7.0
Jacket temperature = 21.0
Inlet open,
Filling
no
Temperature 20.0
Filling level 20.0
yes
no
Fermentation
Ingredient inlet closed
pH value control
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no
Stirrer active
pH 6.9* 7.1
Temperature 20.0* 22.0
Press. 10.0
yes
Drainage
End
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3 Structure and Function Principle
3.9 Sequential function charts (SFC)
CLEANING
In the CLEANING sequence chain the cleaning of the tank interior is performed
by rinsing with a detergent. A lower jacket temperature is set, the YC_CIP_Out
drain valve is closed and the feed valve YC_CIP_In is opened until a defined
reactor filling level has been reached. The detergent liquid is stirred in the tank for
a given period of time and pumped through the heat exchanger. Afterwards, the
liquid is pumped out via the YC_CIP_Out valve. All controllers, valves and pumps
are enabled for the operator and the simulation is reset.
Note The cleaning process was shortened for this example so none of the multiple
rinsing (detergent and water) typical for the process, possibly with a specific
resting time, is performed.
The flowchart below shows a simplified scheme of all sequential steps and
transitions of the SFC operations.
Figure 3-15
Start
yes
CIP intlet open
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no
yes
yes
CIP outlet closed and simulation
reset
End
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3 Structure and Function Principle
3.9 Sequential function charts (SFC)
ABORTINGSTOPPING
In the ABORTINGSTOPPING sequence chain, all controllers, valves and
motors/pumps of the fermenter are stopped and enabled for the operator.
Additionally, the process simulation is reset. In the same way as after the cleaning
process, the operator has the option to operate all plant units as follows:
controlling all of the valves
controlling the motor and both pumps
changing the setpoint specification (internal setpoint) of the controllers and
monitoring the process
performing controller optimization (changing individual controller parameters or
using the PID tuners)
Note The simulation values for the pH value are based on the respective totals of
ingredient and neutralizer. After emptying the tank, these values are not reset
automatically but only after a renewed SFC run.
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3 Structure and Function Principle
3.10 Process simulation (ProcSimulation)
2
1
1 2
Delayed transfer of the ingredient inflow (corresponds to 0.12 mbar at 60% valve
opening) to simulation chart Sim_PressLevel of the pressure control.
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3.11 Process characteristics (KPI)
Production volume
Figure 3-19
1 2 3
3. Forming the integral value by totaling the product outflow and displaying the
integral value by means of display block MonSumProduction.
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4 Integrating the Unit Template
4.1 Preparation
Note In order to use the example project in your own project, the function blocks
Titr_pH, TitrDeltaC and TitrLimDeltaC must be copied for pH value
conversion. Additionally, an update of the attributes must be performed when
copying the functions and function blocks.
Table 4-1
No. Action
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4.2 Implementation
The following instructions describe how you can integrate the unit template into
your project. Not described are the interconnection of each individual signal and
the settings for each individual parameter.
The unit template and the target project must be open in the plant view.
Table 4-2
No. Action
1. Open the plant view of the fermenter, select the hierarchy folder Fermenter in the AS project
and click Edit > Copy.
2. Change over to the target project.
In the AS project, select the hierarchy folder where the fermenter shall be added, then select
Edit > Paste from the menu bar.
Note
All charts including interconnections and simulations will be copied.
3. In the target project, select the AS project and select Options > Plant View > Update in the
Multiproject from the menu bar.
A dialog for the export of the Plant hierarchy opens.
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4 Integrating the Unit Template
4.2 Implementation
No. Action
4. Click OK in this dialog and also confirm the next dialog with OK. The Plant hierarchy in the
OS project of the target project will be matched accordingly.
5. Compile and download the AS project and then compile the OS project.
Note You may use the process image of the reactor from the sample project. This
project is available at
< ProjectPath>\UT_Ferm\Ferm_OS\wincproj\OS\GraCS\Fermenter.Pdl>.
In chapter 6 of the application description Equipment Modules for PC7 Using the
Example of the Chemical Industry under the entry ID 53843373 you will find
detailed instructions and notes on the following subjects:
Integration of equipment modules
Adjusting the parameters of an equipment module
Interconnecting an equipment module
Integrating a color palette into the OS
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Note Please take note of the modified project path when integrating the color palette in
the OS. The project path valid for the stirred tank reactor unit template is
<ProjectPath>\UT_Ferm\Ferm_OS\wincproj\OS\GraCS\UnitTemplates.xml>.
Process connection
Configuration of the PID controllers
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5 Starting the Unit Template
5.1 Preparation
7. Use the WinCC Explorer and open the properties window for your computer; click on the Use
local computer name button in the Computer properties dialog.
Confirm the Change computer name prompt with OK.
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8. Click File > Exit to close the WinCC Explorer and select Close project and exit WinCC
Explorer in the next dialog.
Then click OK to confirm.
9. Open the WinCC Explorer again as described in step 5.
10. Double-click to open the Tag Management. In the WinCC Configuration Studio, right-click on
Tag Management > SIMATIC S7 Protocol Suite > Industrial Ethernet and select the menu
command System parameters.
11. Use the Unit tab to check the defined Logical device name. When using the S7-PLCSIM
program, the device name PLCSIM(ISO) will be selected. If the device name has been
changed, the program must be restarted. Open the WinCC Explorer again as described in
step 5.
Note
If the OS cannot create a connection with the AS (grayed faceplates), select the logic device
name CP_H1_1: and restart the OS.
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5 Starting the Unit Template
5.2 Commissioning
5.2 Commissioning
The following instructions describe how the unit template fermenter can be set to
initialization mode.
Initialization requires that the SIMATIC Manager has been opened and the project
has been selected in the components view.
6. Click PLC >Download in the menu bar and confirm the Download dialog with Yes.
Confirm the Stop Target Module dialog with OK and then the Download dialog with Yes.
1. Click the UnitTemplate_OS > SVE20E > WinCC Appl. > OS with your right mouse button
and then select the menu command Open object.
2. Select File > Activate from the WinCC Explorer menu to activate the OS (WinCC Runtime).
3. In the System Login dialog, enter Unit as user name and Template as password and then
confirm with OK.
4. In the picture section, select the unit template Fermenter.
Note
The fermenter is already in the production/cleaning process, since the AS program processing
(PLCSIM) has already been started.
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6 Operating the Application
6.1 Overview
6.2 Scenario A
Description
After activating the OS, the fermenter is either in the production/cleaning process
or has already completed this process. The operator can decide between the
following options:
Operating the motor, the actuators, pumps and controllers (cleaning
completed)
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No. Action
1. Go to Plant View and click on the hierarchy folder Fermenter_MP > UnitTemplate_AS >
Fermenter. The contents of the folder are displayed in the right window pane.
2. Double-click to open the SFC StartFermenter.
3. The SFC description in chapter 3.9 tells us that the filling level is polled in sequence chain
PRODUCTION (Transition).
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6 Operating the Application
6.3 Scenario B
No. Action
4. In the SFC you select the PRODUCTION sequence chain and enter the new filling level 39 in
the Condition tab of the object properties of the Filling_Complete (Transition) query. Click on
the Accept button and close the Properties window of the condition.
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5. Compile and load the AS user program via menu item PLC > Download .
Note
Perform a delta download without parameter readback.
6. Go to the OS and monitor the renewed production process.
Notice
In the OS, the production is performed with the new filling level. In the SFC, the original filling level
is still displayed. To update the SFC display, the OS must be recompiled.
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Note The scope of the necessary SFC adjustments increases depending on the
change request. If you wish to change the pressure, for example, you need to
enter the new setpoint value in the step of the setpoint specification and adjust
the step enabling condition in the subsequent (polling) transition.
6.3 Scenario B
This scenario discusses running the plant in non-production mode. In this mode
you have the option to operate the individual components of the fermenter and
perform a controller optimization, for example.
In the following scenario, a production ( 30%) is performed without specific
temperature and pressure control with a pH value of 5 pH. All required changes
(valves and controller) are made by the operator.
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6 Operating the Application
6.3 Scenario B
Table 6-2
No. Action
1. Go to the OS and wait until the production and cleaning process has been terminated or terminate
SFC processing by pressing the Stop or Abort button in MANUAL mode.
2. Click on the block icon of the valve of the ingredient, YC_Feed, and change the command in the
faceplate to Open.
3. Watch the filling level of the tank and close the valve for the ingredient, YC_Feed, after reaching
the filling level of approximately 30 %.
4. Use the conversion block to calculate the concentration difference of 5 pH.
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5. Click on the block icon of the QIC_pH and change the operating mode of the controller to
Automatic in the faceplate.
6. Click on the Setpoint input field and enter the calculated concentration difference -208.0 into
the input field of the expansion and click on the OK button.
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Note
The controller of the pH value control is active and reacts to a pH value smaller than 5 pH.
7. After controlling the pH value, the controller reacts to the process changes, e.g: by reopening the
valve for the ingredient, YC_Feed.
Note In order to obtain a precise pH value, the simulation must be reset prior to a
renewed filling. In the SFC you press the Stop or Abort button or restart a
production and cleaning process.
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7 Related Literature
7 Related Literature
7.1 Bibliography
This list is not complete and only represents a selection of relevant literature.
Table 7-1
Topic Title
/1/ Practice book for SIMATIC S7 and Controlling with SIMATC
SIMATIC PCS7 control systems Mller, Jrgen / Pfeiffer, Bernd-Markus /
Wieser, Roland
Publicis Kommunikationsag
ISBN 978-3895783401
/2/ Fermenter in red biotechnology Pfeiffer, B-M., Grieb, H., Rougoor, J.:
PLS-Toolbox zur Automatisierung von
Bioreaktoren.
(PLS Toolbox for automation of bioreactors)
VDI-Kongress Automation 2011, Baden-
Baden. VDI-Berichte 2143, S. 217-221,
VDI-Verlag, Dsseldorf.
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68098270
\2\ Siemens Industry Online http://support.automation.siemens.com
Support
\3\ Controller Optimization with the http://support.automation.siemens.com/WW/view/en/
PID Tuner 8031495
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8 History
8 History
Table 8-1
Version Date Modifications
V1.0 07/2013 First version
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