trends in process automation - siemens · 2011-08-10/11 industry sector trends in process...
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© Siemens AG 2011. All Rights Reserved.
Industry Sector2011-08-10/11
Trends in Process Automation
Prof. Dr. Michael Bruns
Vice PresidentProcess AutomationIndustrial Automation Systems
SRAES @ Goa 2011
© Siemens AG 2011. All Rights Reserved.
Industry Sector2011-08-10/11
Indu
strie
sIndustrial Automation Systems stands for…
...products and solutions with highest level of customer valueSo
lutio
nsPr
oduc
ts
Design & execution of plants
Ener
gy
Ref
iner
y
Wat
er
Che
mic
als
Oil
& G
as
Pulp
& P
aper
Cem
ent &
Gla
s
Met
al /
Min
ing
Sola
r
Phar
ma
Food
& B
ev
Aut
omot
ive
Elec
tron
ics
Process Discrete
Plant Engineering Software
MES SIMATIC IT
SIMATIC Automation Designer, COMOS
SIMATIC PCS 7SIPAT, Batch,
Asset Management,Redundancy, Ex(i)
SIMATIC WinCC, SIMATIC Panels,Panel PC
SIMATIC S7PC-based, LOGO!Remote I/O, Safety
DCS HMI PLC/ IPC
© Siemens AG 2011. All Rights Reserved.
Industry Sector2011-08-10/11
Global Trends in Verticals
Chemical&
BioFuels
Chemical Industry will grow around 6% per year
New plants especially in China, Near Middle East, India, Brazil
Modernization/specialization of plants in North America, Europe
Food&
Beverages
Continuous market growth especially in developing countries
Increased demand in tracking & tracing and product safety
Global Standardization of production
India: Non Alcoholic Drinks grow fastest (15% CAGR)
Pharma-
ceutical
Biggest market growth is expected in India (over 15%)
India will be in the top 10 of biggest pharmaceutical markets
Regional regulators will become increasingly important
© Siemens AG 2011. All Rights Reserved.
Industry Sector2011-08-10/11
Global Trends in Verticals
Glass &
Solar
Water&
Wastew.
Environmental protection (carbon emissions)
Energy efficiency
Capital efficiency TCO (total cost of ownership)
Cement
Water scarcity (mega cities, e.g. in Asia Pacific)
High degree of industrialization on a global base
Major growth in APAC/India –
evolution from M3 to M1
High economic pressure and complex value chain
Solar: Rapid Growth and evolving technology
Glass: Environmental protection and product innovation
© Siemens AG 2011. All Rights Reserved.
Industry Sector2011-08-10/11
Customers are driven by life cycle costs
and operational efficiency
Customer Requirements Solutions
Lower Project costs
Increase flexibility
Decrease life cycle costs
Reduce resource consumption
Digital enterprise and optimized en-
gineering
workflow
Comprehensive Fieldbus
solutions
Life cycle services
Operational efficiency
1
2
3
4
Global Trends
New plants especially in Brazil, China, India, NME
"Brown fields" in EU / NAM
India with biggest market growth in pharmaceutical
Global standardization of products
Regional regulators will become increas-
ingly
important
Environmental protection
Energy efficiency
Capital efficiency TCO
© Siemens AG 2011. All Rights Reserved.
Industry Sector2011-08-10/11
Solutions
2 Comprehensive Fieldbus
solutions
3 Life cycle services
1 Integrated Engineering
©
Siemens AG 2011. All Rights Reserved.
4 Operational Efficiency
© Siemens AG 2011. All Rights Reserved.
Industry Sector2011-08-10/11
Only an integrated view across all levels of production enables faster time to market!
Process serial serial, shortened by tools
parallel
Further optimization
by individual tools is widely exhausted
time time time
ProductProcessMechanicalElectricalAutomation
Level
yesterday today tomorrow
Integration of Process Planning and Automation Engineering…
enables parallel Planning Process …
© Siemens AG 2011. All Rights Reserved.
Industry Sector2011-08-10/11
… save valuable time
… based on a new engineering workflow
Engineering workflow on the basis of one engineering model for configuration of plant-, electrical-
and automation aspects
parallel
time
tomorrow
Electrical Design
Piping 3D
design
P&ID Instrument
ation
•
Assembly•
Commissioning•
SOP
Document-Mgmt.
DCSConfigu-
ration
Function-
oriented engineering
model
I&C planning:
Plant & Process related planning:
© Siemens AG 2011. All Rights Reserved.
Industry Sector2011-08-10/11
Integrated Engineering with COMOS and PCS 7 Today's Situation Using a Motor as an Example
P&ID
3-D model
Circuit diagram
PCS 7 Software Configuration
PCS 7 Hardware ConfigurationSingle-pole representation
COMOS SIMATIC PCS 7Object,
e.g., motor
Configurations and structures are transferred as objects between COMOS and SIMATIC PCS 7
© Siemens AG 2011. All Rights Reserved.
Industry Sector2011-08-10/11
Trends in Process Automation
2 Comprehensive Fieldbus
solutions
3 Life cycle services
1 Integrated Engineering
4 Operational Efficiency
©
Siemens AG 2011. All Rights Reserved.
© Siemens AG 2011. All Rights Reserved.
Industry Sector2011-08-10/11
Short-circuit or wire break on trunk line
AFD
PROFIBUS PA
/
FOUNDATION Fieldbus
H1
bus termination
Active
Field
Distributor (AFD)
Link
(redundant)Field Device Coupler, redundant (M = master)
Higher availability and robustness
due to intelligent fieldbus
Infrastructure
© Siemens AG 2011. All Rights Reserved.
Industry Sector2011-08-10/11
Foundation
Field
Bus
All required configuration with one Foundation Field bus Link for a scalable availability
PROFIBUS PA and FOUNDATION Field bus FF Use the same Physical Layer
FF-H1 ring redundancy
No 3rd party components required
No interoperability issues
PRO
FIB
US
DP
back
bone
FF Link
FF-H1
FF Link
FF-H1
FF Link
FF-H1
FF Link
FF-H1
Ideal Link with Highest availability !!! Only at Siemens
© Siemens AG 2011. All Rights Reserved.
Industry Sector2011-08-10/11
Trends in Process Automation
2 Comprehensive Fieldbus
solutions
3 Life cycle services
1 Integrated Engineering
4 Operational Efficiency
©
Siemens AG 2011. All Rights Reserved.
© Siemens AG 2011. All Rights Reserved.
Industry Sector2011-08-10/11
Life Cycle Services (LCS) for SIMATIC PCS 7
Life Cycle Service
For Operation and Serviceability of plants
Are maintaining the existing functions of DCS for minimized costs
As per Standards & Recommendations
© Siemens AG 2011. All Rights Reserved.
Industry Sector2011-08-10/11
Life Cycle Services (LCS) for SIMATIC PCS 7
Specific Characteristics
Planning and management of Product Obsolescence in-house
PCS 7 components ~100% by Siemens
Integrated in PCS 7 PLM (Product Life-Cycle Management)
Siemens = OEM for MS –
delivery of PCs w. MS operating sys.
Worldwide Product Service Infrastructure (SIMATIC)
Regional Service Organization
Common Remote Service Platform
Benefits
Increased plant availability
Modernization and service costs can be planned –
over years
Investment protection & securing of serviceability
Ensuring the delivery capacity of spare parts
Reduction of the Total Cost of Ownership (TCO)
© Siemens AG 2011. All Rights Reserved.
Industry Sector2011-08-10/11
Trends in Process Automation
2 Comprehensive Fieldbus
solutions
3 Life cycle services
1 Integrated Engineering
4 Operational Efficiency
©
Siemens AG 2011. All Rights Reserved.
© Siemens AG 2011. All Rights Reserved.
Industry Sector2011-08-10/11
Optimization
Advanced Process Control (APC)
Intelligent and energy efficient maintenance of electronic and mechanical plant components
SIMATIC PCS 7 offers not only corrective but also preventive Plant Asset management
Reduction of the decision and reaction time -
high plant availability, cost effective
Energy Management acc. to Standards Advanced Process Analytics
Model based predictive control (MPC)Typical applications:
Two component distillation (2x2)
Cement mill (3x4)Benefits
Less process deviations
Increased yield
Higher throughput
Plant Asset Management Advanced Process Control
SIMATIC
PCS 7
Electrical
EnergySteam
Cooling
HeatCompressed
Air
Gas
Water
SIPAT -
key Enabler for Continuous Manufacturing & Real Time Releases
© Siemens AG 2011. All Rights Reserved.
Industry Sector2011-08-10/11
Thank you for your attention!
©
Siemens AG 2011. All Rights Reserved.