Siemens Process Automation End-user Summit- 2011 ... · PDF fileSiemens Process Automation End-user Summit-2011 ... Q3. Q4. Q1. Q2. 2012. ... Siemens Process Automation End-user Summit-

SPAES 2011 Goa, India / © Siemens AG 2011. All Rights Reserved.

Siemens Process Automation End-user Summit-

2011

Experience. Technology. Community

SPAES 2011 Goa, India / © Siemens AG 2011. All Rights Reserved.Industry Sector2011-07-31

Cost ReductionIntegrated control

strategyIntegrated

engineeringEfficient use of

resourcesConsistent

quality

Energy EfficiencyEfficient motors

& equipmentAlternative fuel

sourcesProcess

optimizationHeat recovery

Environmental Protection

Regulations Emission

reduction Worker safetyCO2 reduction

Capital EfficiencyHigh production

availabilityFlexible

operationsGlobal

partneringInventory

control

Key Trends

in the Cement & Construction Material Industry


A Unique Portfolio to Support

the Cement Value Chain + Extension for Construction Material

Asphalt Plants

Concrete Plants

Aggregates


Controller & IOs

Motors and drives

Pressure transmitters

Temperature

transmitters

Flow metering

Level measurement

High and medium voltage

Safety productsMotor control centers

Operator stationsAdvanced process

control& Energy

Management

Solutions, Products and Services with Highest

Customer Benefits Along the Entire Value Chain

Low voltage switch gears and motor starters

Mechanical gear boxes

Gas analyzers

Weight measurement

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Totally Integrated Automation &

Totally Integrated Power for the Cement Industry

Energy flow

Data flow

BMS Building

Management Systems

ERP

Enterprise Resource Planning

Auto-

ma-

tion

CommunicationCommunication

Auto-

ma-

tion

MES

Manufacturing Execution Systems

ERP Enterprise Resource Planning

Low voltage

Totally

Integrated Power

Totally Integrated

Automation

Total Building

Solutions

Medium voltage


From the Field …

… to the Management

… as powerful as you need it to be!

Totally

Integrated Automation from the Field to the Management Level


U p g r a d eU p g r a d e

Cemat -

A success story! Upgrade of the Cemat versions

1976 1981 1987 1992 1996 2000 2003Cemat

withSIMATIC S32

Cemat V1.8- Cemat V2

MIS WIN3.11LS_C

SIMATIC S5

Cemat V1.6

DISITSIMATIC S5

150A/K

Cemat V3

MIS WIN3.11LS_B

SIMATIC S5

Cemat V4

MIS WIN3.5NT4.0

SIMATIC S5SIMATIC S7

Cemat V5

PCS7 V5SIMATIC S7

Cemat V6

PCS7 V6SIMATIC S7

2005Cemat V6.1

20072007Cemat V7Cemat V7

PCS7 V7 SP1PCS7 V7 SP1SIMATIC S7SIMATIC S7

PCS7 V6SIMATIC S7

More than 11000 Simatic PCS7

installations since 1996

More than 700 CEMAT700 CEMAT

installations since 1971

20102010Cemat V7.1Cemat V7.1

PCS7 V7.1 SP1PCS7 V7.1 SP1SIMATIC S7SIMATIC S7

NewNewSPSP

August 2011August 2011


Tailored to the cement requirements

CEMAT functionality

Comprehensive diagnosticComprehensive diagnostic Interface and Interlock condition Status information Detailed fault information Process parameter setting

Comprehensive information MCC data, I/O addresses, location ,… Sound and video files CAD drawings PDF descriptions

Maintenance dialog Operation hours Equipment down time Maintenance information Devices description


Tailored to the cement requirements

CEMAT functionality

Group and Route FunctionGroup and Route Function Start & Stop of complete process units Status call of groups objects Object list Operation mode

Messages SystemMessages System Object related Fault class (e.g. elec., mech.) Alarm selection

Trend ControlTrend Control Online configuration On-/Off-Line values Time selection


Continuous Development NEW version: Cemat V7.1 SP1

Storage module for silo management Storage module for silo management

Polygon with 3 outputsfor kiln start-up and shut-down

Polygon with 3 outputsfor kiln start-up and shut-down

NewNewAugust 2011August 2011


Parameter Management

Material Management

Silo Management

Usecase

-

Raw MillRaw Material and Silo

Management

Material and Silo Management

Parameter Management

NewNewAddAdd--OnOn

Based on Advanced Process Function (APF)


Some Cement relevant new features of Simatic PCS 7 V8


Further Cement relevant new features of Simatic PCS 7 V8


Cemat Engineering with Comos

PCS7 with Cemat COMOSCOMOS

COMOS database

with Cemat Typicals

COMOS database

with Cemat Typicals

Cemat Typical “Belt zyx”

MMD2

D1 D1

R2

Cemat Typical “Belt xzy”

MMD2

D1 D1

R2

Cemat Typical “Belt xyz”

MMD2

D1 R1

R2

~ 45 Cemat Typicals

Process Tag TypeCemat Typical “Belt zyx”

MMD2

D1 D1

R2

Cemat Typical “Belt zyx”

MMD2

D1 D1

R2


MMD2

D1 D1

R2


MMD2

D1 D1

R2


MMD2

D1 R1

R2


MMD2

D1 R1

R2

~ 45 Cemat Typicals

Process Tag Type

Automation Interface

Typical “Belt xyz”Flow SheetP&ID

Flow SheetP&ID

Strom-laufplanStrom-laufplan

Funktions-beschrei-

bung

Funktions-beschrei-

bung


Flow SheetP&ID

Elect. circuit

diagram

Elect. circuit

diagramFunction-

descriptionFunction-

description

Target system-neutral


Flow SheetP&ID


Funktions-beschrei-

bung

Funktions-beschrei-

bung


Flow SheetP&ID


Funktions-beschrei-

bung

Funktions-beschrei-

bung


Flow SheetP&ID

Elect. circuit

diagram

Elect. circuit

diagramFunction-


description


Flow SheetP&ID

Elect. circuit

diagram

Elect. circuit

diagramFunction-


description

Target system-neutral

Konzern-Datenbank

Konzern-Datenbank

CFC Project“Belt 216-BC3”



Project with Belt 216-BC3Project with Belt 216-BC3Project with Belt 216-BC3


Roadmap for CEMAT based on PCS 7

PCS7 V7.1 SP2

PCS7 V8.0

CEMAT V7.1Incl. Project Standards

Documentation: English / German

CEMAT V7.1

Special languages (Russian/Chinese)

2010Q1 Q2 Q3 Q4

2011Q1 Q2 Q3 Q4 Q1 Q2

2012

CEMAT V7.1 SP1

CEMAT V8.0

PCS7 V7.1 SP3

New Version planned Service Pack

CEM

AT

PCS

7


Integration of Technological Modules


Laboratory Automation

Quality Control System

Operator station X

Operator station Y

Operator Process Control

PX-LAB server

PLC controllaboratory

analyzers material preparationpress mill

transport tube system

Sample taker

receiving

station

sample handling

field bus

Profibus

Ethernet via TCP/IP

Intra / Extranet

Remote Access

Sample taker

ARL, Bruker, Panalytical

Sympatec, Malvern,

Plant Control System


Siemens Answers

Energy Portfolio for the Cement Industry

Advanced Process Control & Optimization

Power Monitoring & Management

Energy Efficiency Motors

& Equipment

Waste Heat Recovery

Innovated Motor & Drive Concepts

Emission Monitoring


Energy saving Economic and ecological significance

Low-loss drive technology

Optimum process

n

•

In General: Electric drive systems

represent ≈

70 % of industrial power consumption

•

In Cement Plants:Electric drive systems

represent ≈

90 %

of industrial power consumption

High energy costs have direct impact on the operating costs. To reduce operating costs means to produce in more environmentally friendly fashion and more economically.

Power Management

Energy-saving motors

High potential for Energie

saving in Cement


Energy Management

Siemens offers solutions for all steps

Three steps to Energy Efficiency

Accompanied Consulting

Energy Monitoring System Measurement

display

energy

flow, quantities Cost

center

allocation, energy

costs

per production

unit SIMATIC PCS 7 / WinCC

& SIMATIC powerrate

& b.data

Energy Management System Cost

Transparency, Monitoring

& Reporting Show reserve

of energy

(oversizing) Interface to ERP

Products, Systems and Solutions Drive Systems Peak Load management with SIMATIC powerrate Energy planning with b.data

Preparation / Consulting Energy Check / Analysis Energy Optimization

Services Documentation

and action

plan

Continuous Process


Integrated Energy Management Energy data acquisition and handling

Data Compression

Limit Monitoring

Visualization

Trends, Energy Data

SENTRON PAC

Separate Acquisition of Energy Data

Integrated Acquisition of Energy Data

Operating Level

(Monitoring & Control)

Bus System

e. g. Ethernet

Control Level

Bus System

e. g. PROFIBUS

Field Level

(Data acquisition)


Intelligent Motor Control Center (iMCC) Transparent Detection and Evaluation

An intelligent Power Management system ensures continuous

data recording and evaluation to achieve maximum transparencyfrom the infeed

to the individual consumer.

Profibus DPProfibus DP Industrial EthernetIndustrial Ethernet


Energy Management

for the Management Level

Emission Energy balancing

Energy billing

Batch related balancing

Energy planning

€ / $

CO2 kWh kWh

kWh/kW


Energy Management and Advanced Process Control (APC)

Tools embedded in PCS 7 & Cemat

embedded

OS-LAN Ethernet

OS Clients

Engineering

Station ES

Industrial Ethernet / Fast Ethernet

OS-Server

(redundant)

APC Engineering Tool Modeling & Test

APC OS Faceplates Operation & Control

APC Runtime Function Blocks Runtime Calculations


Advanced Process Control (APC) Tools

high

APC Method

low APC Complexity

GainScheduling

3rd party tools

in PCS 7

OverrideControl PID

Tuning

SmithPredictor

OperatorTraining

Simulator

FuzzyControl

ControlPerformanceMonitoring

Lead-LagFeed-Forward

Control

in the Standard Add-On

lean

MPC

Soft Sensor

lean large

MPC

Embedded

Interfaced


Advanced Process Control for the cement industry

Integrated and modular Concept

Gas Analysis System at kiln for gas concentration measurement.

Finished Material

Raw Material

Return Material

Mill

Separator

MCONeuro-

Softsensor

MCOMPC

2x2 System

Grain size (quality)

Reject[t/h]

Mixed raw materials

[t/h]

Separaor fan speed

[rpm]

.

.

.

mea

sure

men

ts

MCOLaboratory

valueacceptance

Forecast of grain size

Setpoint for fuel calculation

Primary Fuel Secondary Fuels

Set points for the controllers

Setpoint for fuel calculation

Primary Fuel Secondary Fuels

Set points for the controllers


Energy Saving in the Clinker Production

Cemat Fuel Manager

Reduced primary Energy

consumption.Calorific Value

for the Kiln

Primary FuelSecondary

Fuels

Set points for the controller


Gas

con

cent

ratio

n

Excess of AirDeficiency of Air

CO O2

Stack Loss

λ

= 1

(complete combustion of O2

)

Cost Saving by optimizing burning process

Combustion AirO

ptim

al w

orki

ng a

rea

Incomplete Combustion Waste of Energy

Optimal working area:

O2: 0,5 ... 2%

CO: < 200ppm

Gas Analysis at kiln inlet for gas concentration measurement of O2 and CO


Process Instrumentation & Analytics

Energy Saving in the Clinker Production

Improved Clinker Burning

Gas Analysis System at kiln for gas concentration measurement.


Energy Consumption of Cement Plants

(Source: ECRA –

European Cement Research Academy 01/2010)

45% of the electrical energy consumption is being caused by the cement mills and reflects itself in the consumption per ton.


Overview of SICEMENT IT MCO

actual values: Separator drive speed [rpm] Mixed clinker [t/h] Gate position (constant per grade) Mill filling level based on:

Recirculation bucket elevator power [A]

Power consumption. of the mill drive [MW]

Electronically ear chamber 1 [%] Electronically ear chamber 2 [%]

Mill temperature [°C]

Finished Material

Clinker

Mill

Separator

Neuro-

Softsensor

Grain size (quality)Reject

[t/h]

raw material

[t/h]

Separator fan speed

[rpm]

Forecast of grain size

MPC 2x2 System

SICEMENT IT MCOIntegrated in CEMAT /

PCS7

Return Material

Model Predictive Controller

Model development based on historical data's.

The MPC uses the impulse response for continuous learning

Controller detects future deviations and change the set points

Laboratoryvalue

acceptance


Summary Energy saving solutions

High Efficiency Motors (Eff1/Eff2)

Fix speed drive vs. variable speed drive (Drives concept)

Process Optimization

Advanced Process Control (Expert System)

Gas Analyser

Systems

Fuel Manager for Secondary Fuels (integrated in Cemat)

Energy Management

Energy consumption measurement and display

Power Management System

Solutions for Electrostatic Precipitators

Emission Management and Process Gas Analyzer Systems

Up to 10%Up to 10%

Up to 40%Up to 40%

Up to 70%Up to 70%

Up to 80%Up to 80%

Up to 20%Up to 20%

Electrical EnergyFossil Energy


VISION -

“The Green Cement Plant”

Energy Saving Solution from SiemensEnergy Saving Solution from SiemensEnergy Saving Solution from Siemens

SPAES 2011 Goa, India / © Siemens AG 2011. All Rights Reserved.

Thank you for your attention!

Thomas Walther

Director

Competence

Center Cement

& Construction Material

Phone

+49 9131 18 3468

Cellular: +49 173 9665 389

Fax

+49 9131 18 3444

E-Mail: [email protected]

Siemens Process Automation End-user Summit- 2011 ... · PDF fileSiemens Process Automation End-user Summit-2011 ... Q3. Q4. Q1. Q2. 2012. ... Siemens Process Automation End-user Summit-

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