PCS7 Global Solutions en

Global Solutions based on
SIMATIC PCS 7
Nur für internen Gebrauch / © Siemens AG 2011. Alle Rechte vorbehalten.

Global Solutions based on SIMATIC PCS 7

Seite 2 01.08.2011 Industry Sector
Benefits for You
Siemens manages your projects professionally.

Peter Löscher, CEO Siemens:
“Our values – excellent, innovate and responsible – are our guiding principles
in doing so.”
Project Management is a vital component of our joint success

More than 50% of Siemens global sales in 2009/10 was project business
15,000 project managers work for our customers, worldwide everyday

Our Strategy
PCS 7 PA, global in vision, capabilities and performance, the most

competitive source for comprehensive systems, solutions and services
Industry expertise in Chemical, Oil & Gas, Glas & Solar, Life Sciences,
Pulp & Paper, Food & Beverage, Metals & Mining, Cement, Power,
Water, based on:
Best-in-class Project Management
MAV, single source Full scope automation solutions
one stop Product & Systems & Applications
Leading DCS System PCS 7
Proven process optimization applications
Enterprise-wide information-to-knowledge processing
Services, LCS
A division which enhances financial performance
Solution Portfolio for Industries
IT Security and Services Building Security

Consulting and
and Fire Protection
Project Services
Integrated Safety Instrumentation

and Analytics
Energy Supply,
Distribution and Management
Integrated Automation
Control Components
Plant Engineering Software
Motors and Drives

Industrial Water
Gas Compression
and Distribution Asset Management

Siemens in Process Control with SIMATIC:
Our Customers Benefit of a worldwide PCS 7 Installed Base
Europe: 4.254 Over 11.300 projects* in all sectors of the process industry with Simatic PCS 7 Asia Pacific: 3.121
46,7% 34,2%
Over 42.300 PCS 7 Controllers shipped since PCS 7 Market Lauch.
Austria 198 China 2.258
Azerbaijan 1 Taiwan 104
Bulgaria 12
Croatia 13 Japan 108
Czech Rep. 36
Hungary 18 Australia 72
Israel 13 Finland 163
Kazakhstan 10 New Zealand 3
Russian Fed. 237
Romania 14 Sweden 176
Serbia 2 Netherlands 284 India 266
Germany 1547
Slovakia 37 UK 184 Poland 134 Bangladesh 2
Slovenia 47 France 232
Turkey 136 Canada 38 Belgium 152 Austria 197 Vietnam 28
Ukraine 10 Switzerland 151 Indonesia 56
China 2258 Malaysia 34
Germany 1.547 Italy 203 Slovakia 37
USA 723 Spain 338 Turkey 136 Myanmar 1
Japan 108
Saudi Philippines 22
Denmark 34 Arabia 20
Singapore 17
Estonia 1 Mexico 121
Egypt 31 Thailand 82
Finland 163 Taiwan 104
UAE 29
Iceland 5 Americas: 1.142 India 266
Ireland 18 Korea 68
12,6%
Latvia 6
Lithuania 12 Canada 38
Netherlands 284 USA 723 Africa: 137 Russia & Central Asia, RoW: 261 Middle-East: 188
Norway 33 1,5% 2,9% 2,1%
Poland 134 Argentina 44
Sweden 176 Chile 30 Brazil 134
Algeria 8 Belarus 2 Bahrain 2
UK 184 Colombia 15 Angola 9 Russian Fed. 237 Iran 98
Australia 72
Ecuador 2 Egypt 31 South Iraq 1
Belgium 152 Peru 10 Chile 30 Africa 65 Turkmenistan 3
Kenya 2 Kuwait 1
Cyprus 1 Venezuela 6 Mauritius 1 Uzbekistan 5
Lebanon 3
France 232
Greece 5 Brazil 134
Argentina Morocco 7 Lybia 11
44
Italy 203 Mozambique 1 Rest of World 14 Oman 3
Luxemburg 2 Costa Rica 6 Namibia 2 Pakistan 4
Macedonia 2 El Salvador 2 Qatar 14
Nigeria 7
Malta 2 Guatemala 3
Portugal 22 Honduras 4 South Africa 65 Saudi Arabia 20
*: Estimation based
Spain 338 Mexico 121 Swaziland 2 on reported orders UAE 29
Switzerland 151 Trinidad 4 Uganda 1 May 05, 2011 (9.103) Yemen 2

Overview of Project Execution Man Power and Locations
in Process Automation
Americas Europe + Africa Asia

210 Siemens 475 Siemens 432 Siemens
120 Solution Partners 540 Solution Partners 255 Solution Partners
Manchester Copenhagen
Den Haag Stockholm

Brussels HQ Karlsruhe Vienna
Budapest
Moscow Seoul
Paris, Lyon, Lille
Kiev
Tokyo
Springhouse Madrid
Shanghai
Barcelona Milano/Genua
Cairo Taipei
Mexico City Caracas Istanbul Dubai
Manila
Bogota Kuwait Mumbai Pune
Bangkok
Santiago Sao Paulo
Kuala Lumpur
Singapore
Dhahran
Buenos Aires Johannesburg Jedda Jakarta Melbourne

Complete Automation / Electrical / Instrumentation solution

Complete Automation / Electrical / Instrumentation solution

Strategic Vendor Selection for
Integrated Control & Safety Systems 20 years w.o. Stop

Operator Training Systems Technology leaders, not followers
Process Simulation Broad scope of supply with > 80% of required
discipline
Real-Time Process Optimization
Significant experience, capabilities & references
Remote Operations
Project delivery excellence
Embedded Advanced Process Control
Strong global and local presence
Integrated Plant Asset Management
Relailable invest
Measurement, Valves, and Machinery
Comprehensive longterm lifecycle support
Performance and Equipment Health Monitoring
Industry-Specific Application Packages

PCS 7 the Difference, Chemical Industry
Managers Procurement
PCS 7 provides the best performance and offers the fastest and largest CPU on the market. This is We expect that the PCS 7 Concept will help you to achieve cost savings of about 30%
what you need for success. PCS 7 is freely sellable, and published prices exist.
PCS 7 empowers your users to do their jobs better, faster, more efficiently and cost effectively Siemens offers 3 business models for solutions: Siemens, Siemens with partners, or partner alone.
With Siemens you have access to the Industry-leading Know-How Siemens has a hotline service free of charge.
PCS 7 allows quickly production changes for better meet of market demands SIMATIC PCS 7 reduces the TCO and provids better plant availability
“Normally, changing over from one system to another takes months. With Siemens the operation The power of PCS 7 produces a highly functional, cost-effective Control & MCC Solution
simply involved pressing a button. In addition to complying with all of our specifications, Siemens Advanced control is free of charge and has never been easier
technology enabled us to keep our operations running in order to meet the needs of our customers.
Significant reduction in engineering and commissioning costs
We are proud of that.”
PCS 7 supports beginning with a new version six languages as standard, and the language can be
PCS 7 is the technology you need, the platform your application demand
switched over on every operator station.
With PCS 7 you get higher productivity and quality over the whole life cycle
PCS 7 is based on SIMATIC and is developed and manufactured by Siemens itself. ABB, Emerson,
We offer the greatest variety of DCS configuration options, the lowest automation life cycle costs and Honeywell use 3rd party
the most powerful engineering tools to keep your total enterprise a step ahead of your competition
Operator Eng./Maint.
Information always at the right time and the right place with User-friendly operator navigation PCS 7 process I/O, the right solution for every requirement
Advanced Alarm Management minimizes the no. of alarms by 80% The world‘s first truly integrated safety controller, Absolute Integrity between Control and Safety
PCS 7 is multilingual, clearly structured, ergonomic and easy to understand. PCS 7 bietet die bis heute nicht gekannte Möglichkeit CFC, SFC und Objectview.
PCS 7 reduces the work load of the operating personnel. Intuitive view provides situational awareness PCS 7 ist das erste System, bei dem das HMI mit Hierarchie projektiert werden kann
and better decision support. “The Simatic Route Control software helped us to reduce the configuration overhead in this project by
Getting the right information to the right people at the right time about 25% and to trim 20% off the normal commissioning time"
Geographically super-distributed system with Telecontrol wide area network The Safety Matrix enables automatic program generation from the Cause & Effect matrix and automatic
PCS 7 basiert auf SIMATIC dem mit Abstand am meisten eingesetzten System auf der Welt visualization in PCS 7 with operator functionality.
“We can change over our production faster, which brings us great advantages, especially considering SIMATIC Batch is seamlessly integrated in PCS 7, and can be executed as an OS-based or AS-based
the constantly changing fashions and trends in the industry.” process, as a single or redundant batch.
“We have to supply power round-the-clock, 365 days a year, because when the power station fails, the PCS 7 CFC: Customers can create their own blocks using SCL or chart-in-chart functionality.
entire operation comes to a standstill.” PCS 7 offers better networking possibilities and supports hybrid applications, coupling of package
SIMATIC offers the highest availability and reliability in the industrial automation market units in the engineering, e.g. via HW-Config. SIMATIC is the better approach to Digital Factory
Customers want a simple method for accessing process graphics via intranet/browser. PCS 7 Web Easy to learn, easy to use, easy to maintain, and easy to connect to your existing automation
clients allow operation to different projects with different versions at the same time. PCS 7 is rugged, PCS 7 with APL, pre-configured profiles, faceplates and tools. Faster engineering of large systems by
stable and redundant in all levels. powerful bulk tools

Success Factors
Change Management Process

Focus on supervision
Structured Delivery
Tool Based Engineering
Procurement Successes
Standardized SW Typicals (Control Modules, HMI)
Standardized HW Typicals (Cabinets, Termination Solutions)
Tool Based Document Management
Process Know How Hand Over to Service
Well known partners
Template Documents & Checklists
Operation closing
Project
Hardware design
Software design
Sub contractors
Project opening
Commissioning
Site acceptance
Implementation
Manufacturing
Construction
Purchasing &
Organization
specification
Quality plan
acceptance
Installation
Functional
Delivery
Factory
Training
support
Benefits, The Difference
How do I start up faster and more efficiently?
How do I minimize my energy and materials costs?
How do I maximize throughput and improve quality?
How do I reduce unplanned shutdowns and prolong the time between shutdowns?
How do I capture the knowledge of retiring staff?
How do I significantly reduce my maintenance cost?
How do I "hot cutover" to newer equipment?

Solution
Project Management: Project Execution:

Project Controlling Sales support
Supervision Detailed specification
Consulting Engineering Support
Contracting Scheduling &Tracking
Concepts
Detail Engineering:
Hardware Planning
Software Engineering
Factory Acceptance Test
Products&Systems Construction
SIMATIC PCS 7 Commissioning
LV Switchgear Site Acceptance Test
MV Switchgear Training
Field devices System Upgrades
Drives System Migration
Cabinets Documentation
Tool based engineering & Document Management
Software Module Library Definitions

CFC Templates Software Modules & Process Tags
Block Icons HMI Data Rules
Software Module Design / Test Specification Field Terminations
Use Use
Functionality
Customer Data Advanced ES (new)
I/O List
Database Tool
Import & CORE
Interlock diagrams
Clarify Consistency Management RATIO
Sequence diagrams Check of changes
HMI sketches etc. COMOS
Generate Generate
Documents PCS 7
SW & HW FAT Result Sheets Loop Check Result Sheets AS OS
Hardware Configuration Consistent Process Displays
Field Termination Schedules Validation Documentation Symbol Table Picture Hierarchy
CFC Archiving
Project Documentation Plant Hierarchy

Typical Project Organization
Customer
Project team
Steering Committee
Customer
Siemens
Customer Customer
Siemens AG
Project Manager Commercial Manager
Headquarters Support
N.N N.N Customer
R&D
Service & Support
Siemens Siemens Siemens
Industry Specifics
Sales Region xxx Project Manager Commercial Manager Siemens
N.N. N.N. N.N.
Siemens AG Siemens Siemens Siemens

Siemens
MES Interface Lead Engineering Lead Engineering Lead Engineering
Quality Management
Application-Software HW + Erection SAT + Commissioning
Siemens Siemens Siemens Siemens

SW Design Spec. HW Design Spec. Software-Integration QPP, Audits, SOPs
Coding Standards Project engineering Training Risk evaluation
Solution Partner Sub supplier

Solution Partner
Application-Engineering Hardware Manufact.
Commissioning support
Test execution Erection

Document landscape for Process Control
General Process Functional Control

Quality / Test
Specifications Specifications Specifications System Specification
Overall Project Plant structure, Technological Master Quality &

DCS User Requirement Specification
Description Hierarchy, Functional units Test Requirements
Black-Box / Third Party

Master Process-Flowcharts Specification of
Controls Project Quality Plan
Time Schedule Process Description Recipes and Operations
Data Exchange
Project Structuring, P&I Diagrams Specification of Interlocks, Hardware Design Test Planning (FAT / SAT)
Organisation Responsibilities (Design approved) Closed loop controls Specification incl. Terms of Acceptance
List of Codes and Standards, Instrumentation Safety & Emergency Software Design DCS System
Eviromental Conditions & Control List Shutdown functions Specification Test Specification & Reports
Site Plan Hazardous Area Control Modules Responsibility:

Specification of
Classification, Equip. Modules Units DCS Application Built
Field Instrumentation
Main cable routes S88 Model Customer Siemens

Proposal
Technical Part Commercial Part

Reference to tender (specification) Cover Letter to customer
Scope of Supply Hardware Price Schedule
Scope of Supply Services (Engineering) Payment Terms, Milestones
Description of solution Commercial Conditions
Architecture Drawing
Project Schedule
Project Organization
Place of delivery, FAT
List of Exclusions / Deviations
Documentation requested from customer
Documentation delivered
Technical Data (e.g. Heat Dissipation)
Functional design
closing
Project
Hardware design
Software design
Site acceptance
Sub contractors
Project opening
Commissioning
Process design
Implementation
Manufacturing
Cost estimate
Purchasing &
Construction
Organization
specification
Quality plan
acceptance
Proposal
Installation
Feasibility
Delivery
Factory
study
Operation
Training
support
Delivery Service execution
Project opening / Quality plan
Project Quality Plan to ensure qualified project execution according to a signed standard
Project Description
Project Organization (Customer & Siemens)
Roles & Responsibilities (customer & Siemens)
Codes & Standards
Document Management
Communication in Project
Change Management
Working Procedures
Key Milestones, Quality Gates
Test & Approval Procedures
Safety & Security
Sub contractors
Project opening
Functional design
closing
Project
Hardware design
Software design
Site acceptance
Organization
Commissioning
Process design
Implementation
Quality plan
Manufacturing
Cost estimate
Purchasing &
Construction
specification
acceptance
Installation
Feasibility
Proposal
Delivery
Factory
study
Operation
Training
support
Functional specification
FS Control Modules Control Modules (Conti & Batch)

S88 Model - Equipment Modules with Control Strategies (Batch)
S88 Model - Batch Strategies (Recipes, Unit allocations) (Batch)
Interlock & Safety Functions (Conti & Batch)
The Functional Specifications FS Equipment Test Specifications
are the basis for Modules (FAT)
Factory Acceptance Test
closing
Project
Hardware design
Software design
Site acceptance
Sub contractors
Project opening
Commissioning
Process design
Implementation
specification
Manufacturing
Cost estimate
Purchasing &
Construction
Organization
Quality plan
Functional
acceptance
Installation
Feasibility
Proposal
Delivery
design
Factory
study
Operation
Training
support
Hardware design
PCS 7 Architecture (Bus, HMI, Controller, I/O) Earthing Scheme

Cabinet Assignment Power Supply / Power Distribution
Cabinet Layout Basic Hardware Typicals (Sensor to I/O)
Cable Specification Bill of Material
Functional design
closing
Project
Software design
Site acceptance
Sub contractors
Project opening
Commissioning
Process design
Implementation
Manufacturing
Cost estimate
Purchasing &
Construction
Organization
specification
Quality plan
acceptance
Hardware
Installation
Feasibility
Proposal
Delivery
design
Factory
study
Operation
Training
support
Software design
PCS 7 Project Specific Settings

Controller conventions
HMI naming convention
HMI graphic definitions
Alarm management
Historical, trending and reporting
Security
Device interfaces
Functional design
closing
Project
Site acceptance
Sub contractors
Project opening
Commissioning
Process design
Implementation
Manufacturing
Cost estimate
Purchasing &
Construction
Organization
specification
Quality plan
acceptance
Software
Installation
Feasibility
Hardware
Proposal
Delivery
design
design
Factory
study
Operation
Training
support
Seite 24
Feasibility
study
Process design
Cost estimate
Proposal
01.08.2011
Project opening
Quality plan
Organization
Sub contractors
Purchasing & Manufacturing
Functional design
specification
Hardware
design
Software design
Purchasing &
Manufacturing
Implementation
Cabinets
Factory
acceptance
Delivery
Third Party Components
Construction
Installation
Operating & Monitoring Components
Commissioning
Site acceptance
Project
Operation closing
support
Training
Industry Sector
Seite 25
Feasibility
study
Process design
Cost estimate
Proposal
01.08.2011
Project opening
Quality plan
Implementation Hardware
Organization
Sub contractors
Functional design
specification
Hardware
design
Software design
Purchasing &
Manufacturing
Implementation
Factory
acceptance
Delivery
Construction
Installation
Commissioning
Loop Diagrams
Site acceptance
Detailed Cabinet Layout
Project
Operation closing
support
Cable List with termination schedule
Training
Industry Sector
Implementation Software
1.) PCS 7 Engineering using Mass Engineering Tools

Control Functions (CFC, SFC, Batch)
Hardware (e.g. I/O Ranges)
HMI (e.g. OS Screens)
2.) Project Specific Adjustments according to Specification

Adjustments of Instances (Interlocks)
Connections between Control Modules (Logical Conditions)
Group Control Strategies, Complex Loops
Sequences, Batch
Implementation
Functional design
closing
Project
Software design
Site acceptance
Sub contractors
Project opening
Commissioning
Process design
Manufacturing
Cost estimate
Purchasing &
Construction
Organization
specification
Quality plan
acceptance
Installation
Feasibility
Hardware
Proposal
Delivery
design
Factory
study
Operation
Training
support
Implementation – Automated Hardware Configuration
Step 1:
Lead Engineer preselects HW components in central list
Step 2:
Engineers easily design system architecture EXCEL Based
(AS’s, DP’s, Profibus lines) and distribute the I/O’s to the DP’s. Configuration Tool
Automatic name generation for AS’s, DP’s, I/O modules, MTA’s
Step 3:
Export HW Config to PCS7 & Generate I/O List
PCS 7
Implementation
Functional design
closing
Project
Software design
Site acceptance
Sub contractors
Project opening
Commissioning
Process design
Manufacturing
Cost estimate
Purchasing &
Construction
Organization
specification
Quality plan
acceptance
Installation
Feasibility
Hardware
Proposal
Delivery
design
Factory
study
Operation
Training
support
Factory acceptance test FAT
Overview
FAT Matrix Simulation Cases for SW-FAT

DCS HW/SW Field System Control Equipment
Intelligent Field Cabinets (CPU/I/O) Modules Modules
Devices HMI
Test Type Bus
HW FAT (Integration) x x
Type HW
HW FAT x
All DCS HW
SW FAT x x
Typicals
SW FAT x x
Instances
Functional design
closing
Project
Software design
Site acceptance
Sub contractors
Project opening
Commissioning
Process design
Implementation
Manufacturing
acceptance
Cost estimate
Purchasing &
Construction
Organization
specification
Quality plan
Installation
Feasibility
Hardware
Proposal
Delivery
Factory
design
study
Operation
Training
support
FAT:
Seite 29
Feasibility
study
Examples
Process design
Cost estimate
Proposal
01.08.2011
Project opening
Quality plan
Organization
Sub contractors
Functional design
specification
Hardware
System
design
HW FAT PCS 7
Software design
Purchasing &
Manufacturing
Implementation
Factory
acceptance
Delivery
Construction
Installation
Commissioning
Site acceptance
SW FAT
Typicals
Project
Operation closing
support
Training
Industry Sector
FAT:
Seite 30
Feasibility
study
Process design
Cost estimate
Proposal
01.08.2011
Project opening
Quality plan
Automated Test Software
Organization
Measuring Point List (Customer)
Sub contractors
Functional design
specification
Hardware
design
Software design
compare
Database
Purchasing &
Manufacturing
Access
Delta Report
Implementation
Export
Factory
T15499 Alarm HH 50 °C 100 °C
acceptance
P167543 Range 0 ... 100 bar 0…. 200 bar
Delivery
Construction
PCS 7
Installation
Commissioning
Site acceptance
Project
Operation closing
support
Training
Industry Sector
Seite 31
Feasibility
study
Delivery
Process design
Cost estimate
Proposal
01.08.2011
Project opening
Quality plan
Organization
Sub contractors
Packaging
Functional design
specification
Customs Clearance
Shipment Documents
Hardware
design
Software design
Purchasing &
Manufacturing
Delivery of Hardware Components to Site
Implementation
Factory
acceptance
Delivery
Construction
Installation
Commissioning
Site acceptance
Project
Operation closing
support
Training
Industry Sector
Construction / Installation
DCS Installation (w/o field)

Installation of Cabinets and HMI Components on Site
Interpanel Wiring (Bus System, Power Supply)
System Wiring between locations (Control Room, Electronic Room)
Power Up of PCS 7 System
Loading of all System Components
FAT End Conditions
Site Acceptance of Control System

Warranty Start – depending on contract
Functional design
closing
Project
Software design
Site acceptance
Sub contractors
Construction
Project opening
Commissioning
Process design
Implementation
Manufacturing
Cost estimate
Installation
Purchasing &
Organization
specification
Quality plan
acceptance
Feasibility
Hardware
Proposal
Delivery
design
Factory
study
Operation
Training
support
Commissioning
Loop Check Assistance (from I/O to OS)

Monitoring with PCS 7 Engineering System
Assistance for Process Test

Implement changes on PCS 7 Software
Implement changes on PCS 7 Hardware
Typically on daily rate basis
Commissioning
Functional design
closing
Project
Software design
Site acceptance
Sub contractors
Project opening
Process design
Implementation
Manufacturing
Cost estimate
Purchasing &
Construction
Organization
specification
Quality plan
acceptance
Installation
Feasibility
Hardware
Proposal
Delivery
design
Factory
study
Operation
Training
support
Seite 34
Feasibility
study
Process design
Cost estimate
Proposal
01.08.2011
Project opening
Final Site acceptance
Quality plan
Organization
Sub contractors
Functional design
specification
Hardware
design
Software design
Warranty Start
Purchasing &
Manufacturing
Hand over of the system
Implementation
Factory
acceptance
Delivery
Acceptance Certificate (can be with open points)
Construction
Installation
Commissioning
Typically after operation without errors of a certain duration
Site
acceptance
Project
Operation closing
support
Training
Industry Sector
Project closing
Customer Satisfaction Report

Lessons Learnt
Final Cost Calculation
Accruals for Warranty Phase
Project Archiving (Documentation)
Hand over to Service & Support (List of Open Points)
Project
closing
Functional design
Software design
Site acceptance
Sub contractors
Project opening
Commissioning
Process design
Implementation
Manufacturing
Cost estimate
Purchasing &
Construction
Organization
specification
Quality plan
acceptance
Installation
Feasibility
Hardware
Proposal
Delivery
design
Factory
study
Operation
Training
support
Project management
The DCS project manager is the contact person for the complete engineering process. He is supported by sub-
project managers depending on size of the project. These positions are filled with experienced project managers.
They are continuously monitoring quality, costs, deadlines and resources:
Sub-project Detailed Coordination

Project management,
Project plan project customer
management HW/SW lead
engineering schedule suppliers
Detailed
Resource Information
Status reports Project plan project
management management
schedule

DCS Realization
The DCS plays a central role in the automation of the production process.
A modular concept is the key for a successful realization of the process and automation requirements.
Preparation Factory System

Cost
of the tender Procurement Acceptance Test specification
estimation
documents FAT and topology
Detailed
Definition Cooperation
Monitoring, Creation of scheduling
of user on process
delivery, function charts aligned
requirements engineering,
assembly S88.01structures to the process
in SW and HW descriptions
engineering

Qualification
Following the relevant norms and guidelines of the industry in all phases of a project, we define the resulting
requirements in close co-operation with our customers:
Qualification
plan Realization of
Risk analysis SOP creation
for validation supplier audits
master plan
Realization Support
Monitoring of DQ, IQ, OQ IQ, OQ, PQ
Document
according to for the together with
management
GAMP DCS, MES, process
PIMS engineering

HW planning
The hardware is planed in a close coordination with the DCS realization, the instrumentation and other parts of the
plant construction. In the context of this module we prepare the assembly documentation so executing enterprises
can work according to it. The hardware is planed by modern CAE systems, we adapt to your specifications:
Control and Panel,

Cabinet Installation
instrumet room Remote I/O
design documentation
design design
Wiring diagrams Circuit diagrams Process tag list Wiring design

Fail-Safe-Control
In the process industry Fail-safe is an important topic.

The know-how, the installation and configuration is our unique selling point.
Safety dialog Procurement

Safety Hardware
with the and
classification specification
customer installation
Factory Training
Software Assembly and
Acceptance Test maintenance
application start up
FAT staff

Instrumentation
In the instrumentation phase the field controllers for the plant are specified, purchased and the assembly taken
care of. Our services for the hardware are:
Specification, Data interchange

Selection of Cost Service
definition of with process
Instruments estimation Support
the standards engineering
Installation Supervision Commissioning,

design and Procurement and logistics of Site Acceptance
calculation assembly Test

Energy Concept
We create an energy supply concept for your production plant in the areas of low and small voltage. This concept,
the purchasing of the components and the FAT is part of our standard offer as well as the supervision of the
assembly.
Creation of the Detailed

Assembly
energy supply planning of MCCs, VFDs Procurement
supervision
concept energy supply

Function Charts S88.01
This service module is our interface to the process engineering. With our process know-how and experiences in
the requirements of the chemical, petrochemical and pharmaceutical industries we represent the process in
software structures according to ISA S88.01. The resulting function plans are the basis for the DCS software:
Function charts
Consulting in Module
Software according to
process specification /
planning IEC61512-1
engineering typicals
S88.01
Continuous Sequential
Batch, phases, Version
Function Function
receipes management
Charts CFC Charts SFC

Qualification GAMP
Following the relevant norms and guidelines of the industry in all phases of a project, we define the resulting
requirements in close co-operation with our customers:
Support
GAMP training
for IQ, OQ, PQ
and Design
Risk analysis SOP definition together with
Project specifications
process
specification
engineering
Implementation
Test Tests, Traceability Document
according
specifications Test reports Matrix management
to GAMP

Migration
Conception and implementation of migration or renewal of old systems
Detailed Planning of
Inventory in Cost
Concept study planning of assembly and
SW and HW estimation
rewiring disassembly
Delivery, Actualization
DCS Internal Test,
assembly and of the
Realization FAT, SIT, SAT
commissioning documentation

Definition of DCS – MAV – MAC solution
Service DCS MAV MAC

Functional design specification
Hardware/ software design guide and specification
Unit application design guide/ manual
Delivery of DCS/ SIS cabinets incl. FAT, basic documentation (controller, I/O, PC, network etc.)
Delivery of DCS/ SIS application incl. FAT
Installation of cabinets on site
Loop Check assistance
Loop Check
Commissioning support
Commissioning
Package unit/ 3rd party interface
Package unit/ 3rd party integration
Delivery of instrumentation (pressure, temp., flow, level, weighing etc.)
Delivery of valve positioners
Delivery of valves
Delivery of analytics (gas chromatographs, analytics containers etc.)
Delivery of MCCs, drives
Delivery of fire & gas monitoring equipment (cabinet, sensors etc.)
Delivery of 3rd party equipment and software
Supervise installation of delivered equipment
Installation of delivered equipment incl. required cables, auxiliaries etc.
As built documentation of cabinets and application
As built documentation of field installation (loop sheets, cable lists, cable routing, install locations etc)
MAV objectives
The Main Automation Vendor approach has the following objectives:

Minimize coordination of multiple vendors
Minimize project management resources
Receiving a single point of contact for automation matters with clear responsibilities
Plant start-up within schedule and budget
Utilization of the MAV’s experience, expertise and skilled resources in order to design a state-of-the-art system
Reduction of interfaces to be coordinated
Smooth integration of 3rd party equipment
Uniformity of equipment
Delivery of a safe, operational, maintainable and reliable automation platform
Implementation of a life cycle strategy
…
Cost savings during project execution and over the total plant life cycle
Influence of MAV (Early Vendor Involvement)
+ Integrated Engineering on Project Lifecycle
Project Organizing Carrrying out the work Closing

start and the
preparing project
classical
approach
Cost and Staffing level
MAV
(early vendor
Involvement)
MAV
+ Integrated
Engineering
Time

Benefits
Reduce risk, Increase project effectiveness
Current Practice Design

Start of Mfg Start up
Specifications
Bidding
Negotiations
Manufacturing
Installation
Commissioning
Concept Training
Basic
Detailed Engineering
Construction
Concept Operation
Risk Savings
Early Involvement Start of Mfg Start up
Design
Specifications
Bidding
Negotiations
Manufacturing
Installation
Commissioning
Concept Training
Basic
Detailed Engineering
Construction
Concept Operation

Integrated Automation, Electrical and Power Management - in summary
100 %
Examples of
Commissioning, start up, training cost saving potentials
Installation Reduce spare parts and training

Reduced Client issues
80%
Expediting inspection
Reduced Installation due to less wiring and type
tested products
Trusted performance on-time delivery –

Single source supply
Engineering costs
Type tested solutions using
Industrial IT enabled products, proven interfaces,
InTools generated db
Elimination enquiry, bidding and negotiation, reduced

sales & Admin.
Procurement
Early standardisation, reduced cost to bid and
FEED, Bid phase reduced bid price

Benefit – Cost Efficient Knowledge and Bundling
Pre-defined solutions allow completion of detail design in a cost

efficient manner
Access to latest technology solutions reduces cost of overall project
Single point of responsibility reduces contractual interfaces:

procurement, project management, engineering, and installation
costs
Engineering and fabrication off-site reduces manpower costs
Optimization of engineering design reduces equipment, space, and

rework

Typical Savings by MAV projects
Project phase Classical % Eng MAV approach Effect by MAV relative typ. relative typ.
acc. to NAMUR approach acc. to Effect absol. Effect €/$ absol.
NAMUR Effect Effect
Conc. Engineer. general Definition 7% general definition +/- Time reduction due to Inetgrated +/- 0% +/- 0% +/- 0% +/- 0%
engineering
FEED Basic generic tender 11% MAV partner involvement more effort by MAV selection +10 … +70% +3,3% +20 … 70% + 3,9%
Engineering typ. +30% typ. +35%
EPC Bidding EPC engineering 12% EPC quote with predefined much shorter clarification and -20 … -70% - 4,8% -20 … -70% - 4,8%
vendor quotations prices and specs bidding phase, typ. -40% typ. -40%
technical clarifications
Detail Engineering Approval phase, FEED – 24% approval based on predefined shorter and easier engineering and -15 … -60% - 8,4% -15 … -60% - 8,4%
EPC - vendors clarifications specifications approval phase typ. -35% typ. -35%
Procurement negociations with several 3% Procurement based on predefined easier and shorter procurement -20 … -70% - 1,2% -20 … -70% - 1,2%
vendors specs, prices, Terms&Conditions typ. -40 % typ. -40 %
Construction construction, QM, Factory 28% automatic software generation more tests in factory possible, as all +20 … -40% - 2,8% +20… -40% - 2,8%
Acceptance tests additional integration tests in factory automation equipment is available typ. -10% typ. - 10%
possible -> more cost
Installation Installation of equipm. of 10% installation of equipment of one less equipment types, ratio effect -10 … -50% - 2,5% -10 … -50% - 2,5%
several vendors vendor for installation staff typ. -25% typ. -25%
Commissioning Integration tests on site, 5% Commissioning of pretested systems much less effort on site -15 … -60% - 2,3% -15 … -60% - 2,3%
Commissioning typ. -45% typ. -45%
100% - 18,7% - 18,1%

Typical Savings by MAV projects
during Operating Phase
Subject Classical approach MAV / MIV approach Typical effort Typical Effect Typical
cost rel. % cost
min/typ/max effect
Operator & Operator training and Training for one system family with 15 manweeks - 20%... -50%
Maintenance maintenance training for unique Human Machine Interface (HMI) trainers and trainees typ. - 30 %
Training equipment of multiple Use of Integrated Engineering for
vendors training
Service / Service / maintenace for the service only for one equipment brand 4 manyears -15% … -50%
Maintenance equipment of several vendors (24/7, if required) typ. - 30 %
Spare parts Spare part storage and management reduced spare part capacity necessary, in total typically 2,5% of Hardware cost / a -20% … -80%
for the equipment of multiple less part handling, less fixed capital typ. - 40 %
vendors
Operation different HMIs of different vendors same "look and feel" in the total plant one total plant shutdown less per year savings depend on
in use reduces operating errors with 1 day production loss means ~ 0,27% training status,
risk of operating errors less plant failures more productivity skills, operating
philosophy, etc.
Modernization Modernization of plant involves the Only the equipment of one vendor Less engineering, as only one equipment savings depend on
equipment of multiple vendors involved brand has to be modernized plant
structure,degree od
modernization, etc.
Savings sum up to ~ 1 … 2% of DCS CAPEX/year, i.e. ~ 10 … 20% savings of DCS OPEX / year
Solutions from Siemens
We provide not just the technology but also the know-how and expertise you need to maximize the
profitability of your business
Maximizing the return on equipment investments and continuous lifecycle support
New ways to extend the life of your systems and maximize the value of installed equipment
Modular Siemens solutions… free to select any combination of products and professional services you need
Lifetime services: Commitment of Siemens to ensure the long term value of your plant
We just do not improve the performance of isolated areas in your plant. We deliver measurable performance
improvements across your entire operation, including all of its processes and assets

Vielen Dank für Ihre Aufmerksamkeit!

SIMATIC PCS 7 Reference Example Special Chemicals
Rhodia – Cellulose acetate tow plant in Freiburg
Customer: Rhodia Freiburg

Worldwide market-leader in the manufacture of cellulose acetate fiber, used extensively in
the manufacture of cigarette filters - supplying 18 percent of the global market
Plant: Cellulose acetate plant – PCS3

Location: Freiburg, Germany
Manufacture of Acetate tow, which is derived from the physical transformation of cellulose
acetate flakes, in which the cellulose acetate is dissolved in acetone, and then spun into
tow
Replacement of Foxboro Videospec 4 (VS4) with UCM/UIO
Project characteristics:
Decision for Siemens: Replacement of legacy DCS (Foxboro, HIMA, Intouch) to
Best price- / performance ratio Simatic PCS 7 including Failsafe integrated
Failsafe integrated solution Application code engineered in-house by RD I IS Freiburg
MODBUS TCP- Communication to subordinated controllers
PCS 7 – quantity: (Schneider TSX Quantum)
2 redundant server Results:
Red. Webserver Integration from different 3 systems into 1 real DCS
OPC server, Archivserver Improvement of system availability to > 99,9%
9 Controller (414-1H, 417-1H)
SIPART DR21

SIMATIC PCS 7 Reference Example Glass
GOMELGLASS – 2nd line at Float Glass Plant in Belarus
Customer: GOMELGLASS at Gomel in Belarus

GOMELGLASS is the well equipped modern enterprise in Europe and the unique
manufacturer of glass on float technologies in Belarus.
Plant: Green Field Float line

Line2 startup 12/2009 – 700 t/d
Decision for Siemens:

State-of-the-art DCS based on TIA
Providing a Turnkey solution Project characteristics:
Comprehensive Scope of supply (MV / LV Distributions, Transformers, Turnkey solution with:
UPS, MCC´s, Process Control System PCS 7; Energy Management System) Electrical Equipment (power supply, power distribution,
transformers, MCC, UPS)
Good experience with Siemens technology
Automation (DCS, PLC, Engineering System, EMS)
Field Instrumentation (measuring transmitters, analytic devices,
PCS 7 – quantity: single loop controllers)
4 Controller (S7-416) with ~1,300 I/O Flexible redundancy concept

1 Redundant server redundant controller for fire reversal
7 OS clients important loops by SIPART controller
8 SIPART DR24 Monitoring of critical areas via CCTV

SIMATIC PCS 7 Reference Example Glass
AGC Klin – 2nd line at Float Glass Plant in Russia
Customer: AGC Flat Glass Europe Former Glaverbel S.A.Belgium

AGC Flat Glass Europe belongs to ASAHI GLASS Business
AGC is one of five divisions of ASAHI Group
Plant: New Green Field Float line

Line2 startup 04/2009 – 1000 t/d

Good experience with the Siemens Turn-Key solution for Klin Line 1.
State-of-the-art DCS based on TIA Project characteristics:
Providing a Turnkey solution
Siemens works as E-EPC:
Comprehensive Scope of supply (MV / LV Distributions, Transformers, UPS, Back-up
Diesel, MCC´s, Process Control System PCS 7, Instrumentation, Control Room, Drives, Electrical Equipment (power supply, power distribution,
Automation of Process Auxiliaries with Simatic S7) transformers, MCC, UPS)
Good experience with Siemens technology Automation (DCS, PLC, Engineering System)
Field Instrumentation (measuring transmitters, analytic
PCS 7 – quantity: devices, single loop controllers)
4 Controller (S7-416) with ~1,500 I/O Site Installation and Supervision
1 Redundant server
1 Engineering Station / 1 OS clients
22 SIPART DR24

SIMATIC PCS 7 Reference Example Poly Silicon
PV Silicon – PS for Solar Cell Production
Customer: PV Crystalox in Bitterfeld, Germany

PV Silicon Forschungs- und Produktions AG, is a daughter of PV Crystalox Solar AG. PV
Crystalox Solar is one of the world's leading producers of multi crystalline silicon materials
for the global solar cell industry.

13 Silicon Deposition Reactors, 5 H-Reactors for TCS Production (1800 t/a)

PCS 7 set by vendor Project characteristics:
Turnkey solution with:
PCS 7 – quantity: PCS 7 Hardware & Engineering:
22 Controller (S7-417 and S7-414) with ~4,200 I/O, 800 PA High Power Bus bar for Connection of H- and D-Reactors
2 Redundant server, 1 CAS Medium Voltage Switchgear:
13 OS clients Simatic IT Historian
PROFIBUS connection to: Gas Analytics:
68 Simocode Solution by Controlmatic, Rösberg
32 VSD’s

TPSI Project Overview Main Figures
Customer: Taiwan Polysilicon Corp. (TPSI)

Taiwan Polysilicon Corp. is a JV of Lee Chang Yung Chemical Industry Corporation and Everlight
Electronic Co, LTD (LED Maker).
Plant: Polysilicon Production Plant

Location: Ping Tung, Taiwan
5000 t/a Polisilicon
Plant comprising of
32 Deposition Reactors (Centrotherm)
16 Converter Reactors (Centrotherm)
Decision for Siemens/Competitors:

Siemens scope of supply:
Track record of similar Polysilicon projects worldwide
HW/SW Integration of ~6000HW and ~4000 “Soft-IO’s”
Availability of German expert as Lead Engineer
Won against ABB, Honeywell and Yokogawa 55 DCS Cabinets
Implementing of ~70 package units
Technicals/PCS 7 – quantity:
Commissioning and Pre-Production
~6000HW-IO’s + 4000 “Soft-IO’s”
6 AS 417H , 2 AS417FH, 1 AS414FH
2 Redundant OS-Server Siemens field devices of BU “SC”:
2 Central Archive Server
9 OS Clients 3 MAXUM II Gas Chromatographs
~70 package units 128 POINTEK CLS300
PCS7 V7.1 and APL

SIMATIC PCS 7 Reference Example Food & Beverage
Cargill-Botlek Edible oil factory in The Netherlands
Customer: Cargill
Location: Botlek – Rotterdam, The Netherlands
Plant: Edible oils

Production capacity one million tons of edible oils (palm and coconut) p.a.
Load out capacity up to 150 trucks a day
One of the biggest edible oil factories in Europe

Totally integrated automation solution Project characteristics:
MES solution with Simatic IT for truck load out and process control Replacement of existing Erdmann PLC with PCS7
Two MES installations with Simatic IT
PCS 7 – quantity: Upgrade of the plant while in full
production. Max. shutdown time
32 Controllers (S7 416/417) ~ 10,000 I/O 1 shift (=8 hours)
3 redundant OS-Servers
Project runtime > 3 years
Simatic IT for process control
Simatic IT for load out execution
17 Clients
2 Engineering Systems

SIMATIC PCS 7 Reference Example Marine Terminal
EQUATE, Olefins ship loading in Al Shuaiba Kuwait
Customer: Equate – Al Shuaiba, Kuwait (initiated by FLUOR and DOW)
EQUATE Petrochemical Company is a state-of-the-art petrochemical complex located in

Kuwait supporting markets in the Middle East, North Africa, the Far East and Europe with
the following range of products: Polyethylene, Ethylene Glycol and Polypropylene
Plant: Marine Terminal for loading of Olefins

Production Shutdown-Console and control equipment for 2 loading terminals

n/a Project characteristics:
12 Months EX-WORKS after PO
Scope of supply: Order value 1.500.000,- € (complete with commissioning)
PCS 7 (PCS/ESD) FAT 04/2009
PCS 7 FAILSAFE (TOX-Control unit )
Hernis (CCTV)
Mauell (MIMIC & Shutdown-Console)

SIMATIC PCS 7 Reference Example Ships Loading Terminal, Mobin
Petrochemical Company, Iran
Customer: Mobin Petrochemical Company, Iran

Mobin Petrochemical Company, Iran (Subsidary of Iranian Ministry of Petroleum – National
Petrochemical Company)
Contractor Payandan Tarhandishan Consortium, Iran (EPC)
Plant: Marine Terminal for loading of Olefins

Ships Loading Terminal for Mobin Petrochemical Complex (Ammonia, Butadiene, Butane,
Diesel Oil, Ethylene, Fuel Oil, Methane, Methanol, Propane, Styrene)
Decision for Siemens: Project characteristics:

n/a PCS, ESD, F&G, CCTV for 5 berths, 2 control towers,
1 berth master
Scope of supply: Order 3.700.000,-- €
Delivery Time: 9 months EX-WORKS after technical &
PCS 7 (PCS) commercial clarification
2500 signals, 14 AS 414 H, 7 ES, 14 OS , 4 server
Options: Cable equipment for the plant, optical fibre cables,
PCS 7 FAILSAFE (ESD) Systems for 8 more berths
MINIMAX (F&G)
SBT FIRE & SECURITY PRODUCTS (CCTV)
Completion: 2006
SIMATIC PCS 7 Reference Example Gas Pipeline
AZERIGAZ, Compressor station in Karadag, Asserbaijan
Customer: Azerigaz – Karadag, Asserbaijan

Azerigaz is responsible for natural gas transmission and distribution
Initiator: IPS - Luxemburg
EPC: Toyo Engineering Corporation - Japan
Plant: Compressor station for a gas pipeline

Production Shutdown-Console and control equipment for 2 loading terminals

n/a
International FAT team
Siemens scope supply: Project team with Russian SI and Japanese EPC
Order value 550.000,- € (with engineering and training)
1 x AS417-4H
2 x AS414-4HF
2 x Single OS with TFT-Touch screen (40 screens)
1 x ES
460 I/Os - 1400 signals von MAN Turbo (2 turbines)

SIMATIC PCS 7 Reference Example Gas
Wormington Gas Compressor Station
Customer: National Grid UK

National Grid is an international electricity and gas company and one of the largest
investor-owned energy companies in the world. They play a vital role in providing energy
to millions of customers across Great Britain and the Northeast US.
Plant: Gas Compressor Station at Wormington

Location: Wormington, UK
Two Units comprising of:
Gas generator (Rolls Royce Avon engine)
Power Turbine (GEC EAS1-1) Project characteristics:
Compressor (Delaval Stork PV30/30)
Replacement of legacy TI DCS
Station Control
Includes replacement of the control system hardware,
Station is classed as “not normally manned”, i. e. remote controlled instrumentation, solenoid valves and fire & gas detection
devices
Decision for Siemens: OPC link to Compressor Performance Management Tool,
Modbus link to Remote Operations
Integration of Control- , ESD- and Fire & Gas System into single platform DCS System
Experience in in Gas Turbine driven Compressors
Completion: 2009

SIMATIC PCS 7 Reference Example Propylene
NPC RT, Demo plant for propylene production, Iran
Customer: NPC RT – IRAN Project characteristics:

NPC RT is a Petrochemical Research and Technology Company DCS/ESD-Engineering/FAT by A&D SE SH61 on lump sum
EPC: Lurgi, Frankfurt base, constructive project work, very good delivery reliability
Consultancy support: Siemens for DCS/ESD Loop Circuit Diagrams by MERING, constructive project work,
very good delivery reliability
Plant: Production propylene from methanol Very close and good cooperation with LURGI India (Field) and
LURGI Frankfurt (Process)
To get a good knowledge of the process this demo plant is build. To get the information and to Local Display Panel by BARTEC considered the challenge of
comply with the safety standards 1000 signals are processed, recorded and evaluated IS-protection and ambient temperature, tailor made solution,
bad delivery reliability (3 weeks delay)
Decision for Siemens: “Embargo-PC” SIMATIC PC Rack V2 by I&S IS E&C RM2
works as PCS 7 ES/OS (1 PC defect during IFAT – no impact)
Lurgi wanted Siemens as a consultant for DCS/ESD and involve Siemens before proposal started
Siemens scope supply:

2 x AS 417-H/FH (ET 200 M, ET 200 M FS, STAHL I.S. 1, ~ 1000 I/O, SIL 2, SIL 3)
6 x Cabinets (2 x SC, 2 x EC, 2 x MC)
2 x OS (Safety Matrix)
1 x ES
1 x MIS
1 x ESD-Console
1 x Local Display Panel (BARTEC Zone 2, Ambient T= 65°C)

SIMATIC PCS 7 Reference Example DCS Conversion
Sasol, PCS 7 conversions, Germany
Customer: Sasol, Marl, Germany

Sasol Germany is a leading producer of solvents and inorganic specialties such as high
purity alumina, as well as surfactants and surfactant intermediates.
Plant: HD-Hydrogenation / FA-Distillation

In the course of continuously improvement the hydrogenation is equipped with a modern
DCS system: PCS 7. In parallel the safety concept of the plant is brought to the latest
state.
The distillation is incorporated into the hydrogenation.
Decision for Siemens: Project characteristics:

Conversion from pneumatics to DCS (PCS7 V6.0)
Due to the integrated solution of the safety technology and the connection of distributed
cabinets and decentralized peripherals SIMATIC PCS 7 is a solid base Replacement of Yokogawa CS3000
An additional argument was the wide spread and acceptance of the Siemens technology (integrated in FA-Hydrogenation)
Done without additional down time and during regular revision
time
4x AS 417H controller
2500 I/Os partial Profibus PA
4x Clients, 2x ES, 1x red. Server
F-Technology (therefore no connection to HIMA via OPC is necessary)

SIMATIC PCS 7 Reference Example PDH / PP
EPPC, PDH/ PP Plant, Egypt
Customer: EPPC, Port Said, Egypt

Egyptian Propylene & Polypropylene Company (EPPC).
Plant: PDH / PP Plant

Greenfield plant
Utiliizing a PDH plant to produce propylene from propane
The propylene is used in the PP plant

Uhde searched for a supplier that is able to handle to the complete electrical engineering
self dependent Overall responsibility by EPC:Uhde, Dortmund Germany
Basic Engineering by Uhde Germany
Siemens scope supply: Detail Engineering by Uhde India in Mumbai
Electrical Engineering by Siemens was requested
DCS PCS 7 to be in India as well
Entire Signals approx. 7300 I/O‘s
Commissioning 05/09 until 10/10
Including 80% ex( i)
Shared in 2/3 DCS and 1/3 ESD - System.

SIMATIC PCS 7 Reference Example Ammonia & Urea
Ammonia & Urea plant, Tedjen, Turkmenistan
Customer: Türkmendökünhimiya via

Gap Insaat Yatirim ve Dis Ticaret
Turkmenian state company
The largest fertilizer plant in Turkmenistan
Plant: PDH / PP Plant complex, Tecen

600 t/day of ammonia
1,050 t/day of urea granules
Uhde’s decision for SIMATIC PCS 7: Project characteristics:

Good experience with previous project (chlorine-alkali electrolysis,Weifang,China) PCS 7 executed and engineered by Siemens Support Center
Integrated Fail Safe Technology Köln
Best price SIMATIC PDM for central configuration of instrumentation
(HART devices)
Siemens scope supply: Easy Integration of package units
via PROFIBUS-DP (SIMATIC S7 300)
5 Controllers (S7 417F/H) equipped with 6,000 I/Os (incl. HART field devices)
via MODBUS
1 redundant OS server, 13 OS clients, 1 MIS-Light Archive server (Bently Nevada, Emerson, Schneider, Woodward)
2 Engineering stations
Completion: 2004
SIMATIC PCS 7 Reference Example Chemical and power plants
Customer: Qinghai Saltlake Industry Group
Plants: Chemical and power

Ammonia/Urea plant
Potassium carbonate plant
Acetylene plant
Power plant
Solution provider:
Siemens Industry automation Ltd, Shanghai (SIAS)
Decision for Siemens: Turn-key project
DCS+ESD
Safety integrated solutions
High availability e.g.:
Competitive price
redundant controller, system bus, I/O bus, I/O modules
Good relationships with customers
Commissioning at the beginning of 2008
AS: 22 417 H ( 5 F/H)
I/O: 21,000 (1300 Failsafe)
OS: 30 OS Client, 4 ES, 4 OS servers.
SIMATIC PCS 7 Reference Example Bioethanol
Bioethanol and Sugar Plant, Klein Wanzleben, Germany
Customer: Fuel 21 GmbH & Co. KG (Nordzucker)

The start-up of fuel 21 GmbH & Co. KG in summer 2006 opened up a new market with
very promising potential for Nordzucker AG, one of the leading European sugar producers.
fuel 21 produces bioethanol from sugar beet.
Plant: Bioethanol and sugar plant

Ethanol 99,6%: 130.000m3 /a
Total plant Invest: ~100 Mio. Euro
Project Partners: Project characteristics:

Process technology provider: Maguin Interis Launching the new biofuels technology, supporting the
Planer: IPRO in Braunschweig sustainability of beet-crops in Nord-Germany
MAV / MEV: Siemens RD A&D MTE Leveraging synergies between Sugar-production and
Solution Provider on/off Engineering GmbH energy/biofuels-production
365 day production with flexible operation for raw juice and
Siemens scope supply: syrup
Processing capacity increased from 13.000 to 16.000 t/D
Automation, drives, process instrumentation Developing an alternative activity as lever for increased
Electrical distribution competitivity
Completion: 2007
SIMATIC PCS 7 Reference Example Glass Wool
Glass Wool Plant, Gliwice, Poland
Customer: Isover, Gliwice Poland (Saint-Gobaint)

SAINT GOBAIN ISOVER is producer of not flammable glass wool
Plant: Bioehtanol and sugar plant

Glass wool for the east european market
Approx 120t/day
60 million USD within 2 years for the existing Stonewool Line and the new Glass Wool Line
Project Partners:
Siemens, AGA, ACC, Raute, Scoda, Kaibel+Sieber, Martek, ABB, Valmet, Mostostal,
MIMET, PEAB
Gas/Oxygen melting furnace 120t/day
Siemens scope supply: Form giving by TEL procedure 6 fiberiser units 4 forming
drums.
20kV Medium-Voltage Switch gear
Motor Control Center Curing Oven for drying coating unit.
Simovert Masterdrive Cutting and packaging units for volls and plates
Converter units and Electrical drives Inputs: Sand, soda, feldspat, dolomit, borax .... cullets
Distributed Control System PCS 7
Uninterruptible power supply
Analysis technique, Camera system, …
Completion: 2007
SIMATIC PCS 7 Reference Example Paraffinsulfonat
Sasol, PCS 7 Replacements, Germany
Customer: Sasol, Marl, Germany

Sasol Germany is a leading producer of solvents and inorganic specialties such as high
purity alumina, as well as surfactants and surfactant intermediates. Plant picture not available
NDA
Plant: Paraffinsulfonat
Base for net- and washing good (Trade name from Sasol: Marlon PS)

SIMATIC PCS 7 as a solid base with the connection of distributed cabinets and
decentralized peripherals and integrated safety solution Project characteristics:
An additional argument was the wide spread and acceptance of the Siemens technology Replacement of ABB (Contronic P) with Siemens DCS
(PCS 7 V7.0)
Siemens scope supply: Done inside a 2 weeks time frame
1x AS 417H controller
1400 I/Os partial Profibus PA
4x Clients, 1x ES, 1x red. Server
F-Technology and connection to HIMA via PROFIBUS

SIMATIC PCS 7 Reference Example Acrylic Acid
BASF, Antwerp, Belgium
Customer: BASF, Antwerp, Belgium
Plant: Paraffinsulfonat
Site for Acrylic acid and Superabsorber polymers (SAP)
Production Startup 2001 (worldwide BASF > 1 Mio. t/yr)
New ASF7 Assapan Plant (Greenfield) to increase production site capacity up to 335.000
t/yr (there of new plant 160.000 t/yr.)
Plant startup 2008
Customer Goal:
Respond quicker the growing European market-demand from its EU-based production sites
Replacement of ABB (Contronic P) with Siemens DCS
Use of latest technology to improve its competitiveness and strengthen its global market
(PCS 7 V7.0)
leadership.
Done inside a 2 weeks time frame
Integration of Asset Management and predictive maintenance (Siemens decision)
Engineering:
Automation: Siemens Industry
Failsafe applications SIL 3 (system-integrator)

PCS 7 Reference
Human Recombinant Insulin
Customer: Julphar, Ras-Al-Khaimah (UAE)

It is the largest pharmaceutical and drug manufacturing company in the Middle East
Region. Julphar produces e.g. Vitamins, Cough and Cold Preparation and Beta-Blocker
Plant: Human Insulin Production Plant

Location: Ras Al Khaimah, UAE
Manufacture human insulin, Greenfield
Decision for Siemens / Competitor:

The customer needs a reliable partner for the overall automation concept
Project Scope:
Phase 1 (finished August 2010)
Development of URS (DCS) and FS (DCS and Process) Project characteristics:
Opener for opportunity “Phase 2” (development of quantity structure together with Julphar)
Large Greenfield project for human insulin with 1.500 kg / year
Project divided in two parts
Phase 2 (ongoing from June 2010 – November 2011)
Phase 1 was base to get Phase 2
Design, implementation, commissioning and qualification/validation of plant
More than 10 PU supplier incorporated

Cargill-Gent Biodiesel Plant
Re-Design of Semi-Refinery
Customer: Cargill
Location: Gent, Belgium
Plant: Biodiesel
Scope for Siemens:

Re-Design of Semi-Refinery plant
PCS 7 – quantity:
12 Controllers S7 417
1 redundant OS-Server Re-Design of existing Semi-Refinery
Simatic Batch Upgrade of the plant during short downtime
Route Control
7 Clients
2 Engineering Stations

Baxter Singapore SGR
No external solution provider
Customer: Baxter Bioscience Manufacturing SARL

Baxter International Inc. develops, manufactures and markets products that save and
sustain the lives of people with hemophilia, immune disorders, infectious diseases, kidney
disease, trauma, and other chronic and acute medical conditions.
Net sales 2008 12.000Mio$
Plant: Factor VIII recombinant plant

Location: Singapore
Manufacture of factor VIII from hamster cells by fermentation and purification with
chromatography columns
Batch, route control with APL library
Good relationship PM Baxter – PM Siemens, due to previous project Joint Vogelbusch, Siemens team writing FS and DS
Engineering done in Austria
Pure Siemens engineering team
Hardware: Engineering / Services: 3000 I/Os
1 redundant server PCS 7 Engineering
42 Batch units
Red. batch/route control server FAT, SAT
6 Controller (417) Qualifizierungsdocumentation 13 package units
20 WinCC clients Commissioning
Field instruments, cabling Installation

Klüber Lubrication
Klüber Lubrication is a worldwide acting enterprise in the sector of chemical industry / mineralic oil solutions. The
Headquarter is located in Munich (Bavaria). Klüber is the leading supplier of special lubricants and offers tribologic solutions
for various industries: Automotive, Food Industrie, Tool- Machine Engineering, wind energy, etc.
Sales of Klüber Group in 2009
Worldwide: 325 Mio.Euro
Share of international sales 83% (based on customer origin)
Siemens GER I IA&DT BAY S ECP received a contract of

appr. 430T€ in May 2010 for modernization
(Electrics & Automation) of the Klüber factory in Salzburg (Austria).
The project was finalized successfully in Nov. 2010.
Due to the successful implementation in Salzburg, Klüber intends
to install the PCS7 solution also in all other factories of the group.

Siemens MAV Project
Large Polymer Plant Project – Wyandotte, MI
Main Automation Vendor Responsibilities

DCS – Siemens PCS 7
SIS – HIMA
MES Integration – AspenTech
Instrumentation – Siemens & Endress+Hauser
Operator Training Simulator
Commissioning
PCS 7 Scope of Supply Project Highlights

5,800 I/O (DCS + SIS) Largest Profibus installation in North America
11 Redundant Controllers 3,000 PA Devices in a redundant configuration
2 Redundant OS Servers 300 PA Devices in a nonredundant configuration
1 Red. Batch Server 500 DP Devices
9 Client Stations (Simocodes, Micromasters, Scales)
2 Engineering Stations 1,000 ET200M Conventional IO
Engineered and executed
by Siemens DS in St. Louis, MO

Sinopec, China
SINOPEC, SPC and BP joint venture project;

Overall engineering investment is about 2.7 billion US$. Put into commercial running since June 2005.
Simultaneously build 10 plants: Ethylene, Full Density Polyethylene, Polypropylene, Styrene, Polystyrene,
Acrylonitrile, Butadiene Extraction, Aromatic Extraction, MMA, SAR etc.
Adopt automation and information system integration, to upgrade unified factory producing efficiency

Saudi Basic Industries Corporation
Polypropylene production plant
Customer: SABIC
SABIC is the Saudi Basic Industries Corporation, one of the world’s leading manufacturers
of chemicals, fertilizers, plastics and metals. They supply these materials to other
companies, who use them to make the products on which the world has come to depend.
Plant: PP-2 Extruder

Location: Al Jubail, Kingdom of Saudi Arabia
Manufacture of Polypropylenes PP
Upgrade from S5 to PCS7
Decision for Siemens / Competitor: Project characteristics:

Best price- / Invensys Upgrade from S5 to PCS7
Engineering from Germany
PP-1 Project
MODBUS RS232- Communication to Honeywell TDC3000
DCS. The Scan time must be < 1sec.
Project Volume for Siemens:
Hardware: Engineering / Services: PCS 7 HW & Engineering, Training, FAT, SAT, Commissioning:
2 redundant OS Single Station PCS 7 Engineering 390K€
ES/MS Station HW Engineering
2 Controller 417-1H Documentation Dates
Scalance Network Cabinet Project Start: 08.2009
ET200M FAT, SAT, Commissioning, PAT Project Hand Over: 02.2010

Klin 2 / New Float Line Project
AGC Flat Glass Europe - Klin (Russia)
Customer: AGC Flat Glass Europe ( = Glaverbel S.A. Belgium)

Glaverbel belongs to AGC ASAHI GLASS Business
AGC ASAHI GLASS is one of five divisions of ASAHI Group

Location: Klin, Russia (100 km north from Moscow)
Line startup April 2010, 1000 t/d max
Customer investment: ~ 130 M’ Euro
EPC: Glaverbel / Tebodin
Decision for Siemens: New Build of a Flat Glass Production Line
Good experience with the Siemens Turn-Key solution for Klin Line 1. Siemens delivery is Turnkey of all Electrical and Control
State-of-the-art DCS based on TIA Siemens is E-EPC for that Project
Providing a Turnkey solution (Electrical - Engineering Procurement and Engineering)
Comprehensive Scope of supply (MV / LV Distributions, Transformers,
UPS, Back-up Diesel, MCC´s, Process Control System PCS 7, Instrumentation, Control
Room, Drives, Automation of Process Auxiliaries with Simatic S7)
Customer knows Siemens through successful project in RAK, Czech, Russia, Bel

B. Braun LIFE Nutrition – Package Unit Controller
Automation of pharmaceutical secondary processes
Customer: B. Braun AG Melsungen

B. Braun supplies the global healthcare market with products for anesthesia, intensive
medicine, cardiology, extra corporeal blood treatment and surgery.
Plant: Leading Infusion Factory Europe (LIFE)

Location: Melsungen, Germany
Manufacture of solutions for parenteral nutrition in single-chamber-, 2-chamber-
or 3-chamber-bags. Amino acid, lipid and glucose solutions in different combinations
and recipes
New green field plant.
Decision for Siemens / Competitor: Project characteristics:

Experience from previous project System based on PCS 7 and Simatic Batch for order handling
Integrated solution for the integration of package units and the MES (Werum) and processing. Connecting MES and package units
Engineering by on/off engineering with support from Marburg
Project Scope
Interface to MES (Werum) developed by I IS SCN Cologne as
Hardware: Engineering / Services: repeatable solution
2 redundant OS server, FDS, SDDS, QV High level of standardization for the package unit equipment
1 redundant Batch server PCS 7 Engineering (Siemens products are required by the customer).
3 AS 417-4 FAT
1 ES and 15 OS Clients SAT
incl. clean room and touchscreen Commissioning (on time & material)
Server for MES connection
Schmid Silicon Technology
Pilot Production plant Polysilicon / Monosilane
Customer: Schmid Silicon Technology GmbH

Worldwide manufacture for turn-key polysilicon plants.
Plant: SPP, Schwarze Pumpe

Location: Schwarze Pumpe; Cottbus; Germany
Pilot plant for polysilicon and monosilane production

Best price
Won against ABB
Pilot production of polysilicon and monosilane bases on a new
efficient process
Project Scope
Extension of the current production capacity of 540 tonnes is
Hardware: Engineering / Services: planned.
Busbar PCS 7 Engineering High probability for follow up orders is given
Valves, Analysers, LV, Assembling FAT
Controller SAT
Field devices Commissioning (on time & material)

Centrotherm
Poly Silicon plant
Customer: Centrotherm Sitec, Burghausen Project characteristics:

Experienced OEM for Silicon reactors. One of the 1st projects, in State of the Art DCS
Simatic PCS 7 including Failsafe integrated
Plant: Vent Gas Recovery – V9200 Application code engineered in-house by EF E & SP Croatia
Ethernet/Profibus DP Communication to subordinated
Location: Zaporozhe, Ukraine
controllers (S7-315)
Manufacture of Polysilicon, which is produced from the chemical transformation
Coordination of a German and Ukrainic system integrator to get
of Silicon with HCl,
Greenfield plant

Best price- / performance ratio
Failsafe integrated solution
Experience in automating chemical plants
Project Scope
Hardware: Engineering / Services:
1 redundant server pair PCS 7 Engineering
1 Controller (417-4HF) IO Cabinets
1 Engineering Station Marshalling Cabinets
3 Clients FAT

Syabas
Water distribution
Customer: Syabas
SYABAS (Syarikat Bekalan Air Selangor) provides water supply to the state of Selangor in
Malaysia.
The raw water are sourced mostly from surface water collected by several dams,
lakes and rivers, and treated at nearby water treatment plants.
Project: Syabas Phase 1 (250 stations)

Location: Kuala-Lumpur, Germany
250 RTU’s
Central Command Center
Project Volume for “SIEMENS”:
Decision for Siemens / Competitor: Total Volume: 21 290 172 RM (100%)
Best price AS Volume: 193 417 RM ( 1%)
Time schedule Video Wall: 494 800 RM ( 2%)
E Volume: 2 939 905 RM ( 14%)
Project Scope Sites: (Road cutting, cabling,…) 13 492 073 RM (63%)
Hardware:
WinCC Dates
IDB Project Start: 2009
RTU’s
Project End (planned): End 2009!
CCTV, Video Walls, ….

Vielen Dank für Ihre Aufmerksamkeit!

Delineation between the MAV and EPC
Backup
Basic Detailed
Procurement Construction Commissioning
Engineering Engineering
Process Mech. & Loop Check As built Docu

Motor Instrument Cabinet Utilities
Description, Electrical Commis- Field
Ratings Data Sheets Locations Available
Schedule Installation sioning Installation
Supervise
Plant Cabinet/ Ineter-
HW & SW Instrument Ethernet Interfaces As built Docu
Layout & Application Operability
Spec. Specification & Fieldbus to OEM Units Cabinets
Design Prototypes FAT
Install.
Software/ OEM Proj.

Hazop
Application Cabinet Hardware Delivery Loop Check Integrated As built Docu
PIDs
Design Drawings FAT Of Equip Assistance into overall Application
PFDs
Spec. DCS
Training
User Site Commiss- Operator Cover
OEMs on MCC Software
Requirement Supervision ioning & Service Warranty Client
HW/SW Specification FAT
Spec & Mgmt. Support Training Period EPC
Spec.
EPC
Package MAV
Site
Equipment Installation Units Provisional Final
Approvals Approvals Acceptance
List Locations Commissioned Acceptence Acceptence
Test MAV
& Running

Solution Questionaire
Backup
What are the Top level KPIs of the project?
Level of automation, more / less/ reduce staff / advanced control?
Could batch/production cycle times be reduced with improved automation?
Are startup/shutdown procedures fully automated or manual, so they can be improved?
Are their any plans to increase capacity, products, processes, efficiency?
Are there any parts of the process which have significant potential for improvements?
Are there any complex processes where fuzzy logic / advanced control could improve performance?
Is there any product quality giveaway in order to ensure you meet your quality specs?
Are you close to maximumof your production yield or is there room for improvement?
Describe how system is supported i.e. locally, spares, contract, engineering support
Do you have equipment / software to simulate the process and train your employees?
Loop tuning – describe what analysis is done to examine the process performance
Is there potential to move towards predictive or proactive maintenance technologies to help reduce costs?
Solutions for Industry
Backup
Planning & Design Project Engineering and Consulting Installation & Commissioning Operation & Maintenance Modernization&Migration
Presentation Configuration Check Installation and Assembly Maintenance Plan Retrofit
Feasibility Study Interface Support Commissioning Service (contract) Feasibility Study
Specifications Application Support Project Management Maintenance (contract) Survey of I/O Signals
Conception Consulting System Startup Software update Expansion
Configuration Check Configuration Optimization Services Optimization Services Online Support
Abnormal Situation Management Design Personnel Support Online Support Site Support Specialist Technical Support
Budget Proposals Project Management Technical Support Online Support Conception
Quotation Training Training Technical Support Configuration Check
Financing Technical Support Personnel Support Spare Parts Configuration
Interface Support Simulation SAT (Site Acceptance Test) Repairs Optimization

Project Management Field Trials Field Trials Field Trials Installation and Assembly
Industry Solutions Certification Validation Support Lifecycle Management Software update
Certification Validation Support On-Site Support Simulation

Validation Support FAT Support Field Trials
Industrial Security Certification
Project Management

Global Network of Experts: Tuned to YOUR Requirements
Backup
Siemens Experienced Siemens

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Siemens
corrupted. Restart y our computer, and then open the file again. If the red x still appears, y ou may hav e to delete the image and
then insert it again.
hardware and Siemens project
software specialist management
Siemens Experienced Siemens

Siemens & Partner hardware and external project
software specialist management
Siemens Experienced
The image cannot be displayed. Your computer may not have enough memory to open the image, or the image may have been
Partner
corrupted. Restart y our computer, and then open the file again. If the red x still appears, y ou may hav e to delete the image and
then insert it again.
hardware and external
software specialist
The image cannot be displayed. Your computer may not hav e enough memory to open the image, or the image may hav e been corrupted. Restart y our computer, and then open The image cannot be displayed. Your computer may not hav e enough memory to open the image, or the image may hav e been corrupted. Restart y our computer, and then open The image cannot be displayed. Your computer may not hav e enough memory to open the image, or the image may hav e been corrupted. Restart y our computer,
System Responsibility
the file again. If the red x still appears, y ou may have to delete the image and then insert it again.
Project Execution
the file again. If the red x still appears, y ou may have to delete the image and then insert it again.
Project Responsibility
and then open the file again. If the red x still appears, y ou may have to delete the image and then insert it again.

What is Electrical Integration?
Architecture overview - The past
Backup
Control Room
Control Room
Control Room Workplace
Workplace
Electrical
System network
High integration effort
Control SCADA High project risk
Control System System Server Server
Control network High lifecycle cost
Gateway /
Automation Automation Protocol Converter
Control Controller Controller Protocol 1
Protocol 3
Fieldbus Protocol 2
Local I/O
IED IED IED
Marshalling Rack
Generator Protection, Transformer Protection
Process Fieldbus Device Drives LV Swg Motors
Process Instrumentation Process Electrification Power Distribution

What is Electrical Integration?
Architecture overview - Today
Backup
Control Room
Control Room
Control Room Workplace
Workplace
Electrical
System network
Most optimized effort
Control Lowest total cost
Control System System Server
Minimized risk
Control network
Automation
Control Controller
Fieldbus IEC61850 station bus
IED IED
Fieldbus Motor
Drives LV Swg
Process Instrument starters
Process Instrumentation Process Electrification Power Distribution

Strategy Supplier selection
Backup
Supplier Process Process Process Power Distribution & Power Distribution &
Automation Electrification Electrification Power Management Power Management
Products Products Integration products Integration
ABB
Siemens All green!

Honeywell
Motivation
Emerson ABB and Siemens are
the only one that has all
Yokogawa products.
Rockwell Honeywell, Emerson,

Yokogawa does not
have in-house electrical
GE
know-how.
Invensys
Rockwell and Schneider
are not DCS players,
Schneider
but PLC players.

PCS7 Global Solutions en

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Global Solutions based on

Nur für internen Gebrauch / © Siemens AG 2011. Alle Rechte vorbehalten.

Nur für internen Gebrauch / © Siemens AG 2011. Alle Rechte vorbehalten.

Siemens manages your projects professionally.

Project Management is a vital component of our joint success

Nur für internen Gebrauch / © Siemens AG 2011. Alle Rechte vorbehalten.

PCS 7 PA, global in vision, capabilities and performance, the most

IT Security and Services Building Security

Integrated Safety Instrumentation

Plant Engineering Software

Motors and Drives

Nur für internen Gebrauch / © Siemens AG 2011. Alle Rechte vorbehalten.

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Americas Europe + Africa Asia

Den Haag Stockholm

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Nur für internen Gebrauch / © Siemens AG 2011. Alle Rechte vorbehalten.

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Integrated Control & Safety Systems 20 years w.o. Stop

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Nur für internen Gebrauch / © Siemens AG 2011. Alle Rechte vorbehalten.

Change Management Process

How do I start up faster and more efficiently?

How do I minimize my energy and materials costs?

How do I maximize throughput and improve quality?

How do I capture the knowledge of retiring staff?

How do I significantly reduce my maintenance cost?

How do I "hot cutover" to newer equipment?

Project Management: Project Execution:

Software Module Library Definitions

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Siemens AG Siemens Siemens Siemens

Siemens Siemens Siemens Siemens

Solution Partner Sub supplier

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General Process Functional Control

Overall Project Plant structure, Technological Master Quality &

Black-Box / Third Party

Site Plan Hazardous Area Control Modules Responsibility:

Nur für internen Gebrauch / © Siemens AG 2011. Alle Rechte vorbehalten.

Technical Part Commercial Part

FS Control Modules Control Modules (Conti & Batch)

PCS 7 Architecture (Bus, HMI, Controller, I/O) Earthing Scheme

PCS 7 Project Specific Settings

1.) PCS 7 Engineering using Mass Engineering Tools

2.) Project Specific Adjustments according to Specification

FAT Matrix Simulation Cases for SW-FAT

DCS Installation (w/o field)

Site Acceptance of Control System

Loop Check Assistance (from I/O to OS)

Assistance for Process Test

Typically on daily rate basis

Customer Satisfaction Report

Sub-project Detailed Coordination

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Preparation Factory System

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Nur für internen Gebrauch / © Siemens AG 2011. Alle Rechte vorbehalten.

Control and Panel,

Wiring diagrams Circuit diagrams Process tag list Wiring design

Nur für internen Gebrauch / © Siemens AG 2011. Alle Rechte vorbehalten.

In the process industry Fail-safe is an important topic.

Safety dialog Procurement