Trends in Process Automation Prof. Dr. Michael Bruns Vice President Process Automation Industrial Automation Systems SRAES @ Goa 2011
Industrial Automation Systems stands for...products and solutions with highest level of customer value Industries Process Energy Refinery Water Chemicals Oil & Gas Pulp & Paper Cement & Glas Metal / Mining Solar Pharma Food & Bev Automotive Electronics Discrete Solutions Design & execution of plants MES SIMATIC IT Products Plant Engineering Software SIMATIC Automation Designer, COMOS DCS SIMATIC PCS 7 SIMATIC WinCC, SIPAT, Batch, HMI SIMATIC Panels, PLC/ Asset Management, Panel PC Redundancy, Ex(i) IPC SIMATIC S7 PC-based, LOGO! Remote I/O, Safety
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 Pharmaceutical 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 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)
Global Trends in Verticals Glass & Solar High economic pressure and complex value chain Solar: Rapid Growth and evolving technology Glass: Environmental protection and product innovation Water& Wastew. 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 Cement Environmental protection (carbon emissions) Energy efficiency Capital efficiency TCO (total cost of ownership)
Customers are driven by life cycle costs and operational efficiency 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 increasingly important Environmental protection Energy efficiency Capital efficiency TCO Customer Requirements Lower Project costs Increase flexibility Decrease life cycle costs Reduce resource consumption 1 2 3 4 Solutions Digital enterprise and optimized engineering workflow Comprehensive Fieldbus solutions Life cycle services Operational efficiency
Solutions 1 Integrated Engineering 2 Comprehensive Fieldbus solutions 3 Life cycle services 4 Operational Efficiency
Integration of Process Planning and Automation Engineering enables parallel Planning Process Only an integrated view across all levels of production enables faster time to market! yesterday today tomorrow Process serial serial, shortened by tools parallel Level Product Process Mechanical Electrical Automation time time time Further optimization by individual tools is widely exhausted
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 tomorrow parallel Plant & Process related planning: Piping 3D design Document- Mgmt. Electrical Design DCS Instrument Configuration 2011. All Rights ation Siemens AG Reserved. Functionoriented engineering model Assembly Commissioning SOP time I&C planning: P&ID
Integrated Engineering with COMOS and PCS 7 Today's Situation Using a Motor as an Example COMOS SIMATIC PCS 7 Object, e.g., motor 3-D model PCS 7 Software Configuration P&ID Circuit diagramsingle-pole representation PCS 7 Hardware Configuration Configurations and structures are transferred as objects between COMOS and SIMATIC PCS 7
Trends in Process Automation 1 Integrated Engineering 2 Comprehensive Fieldbus solutions 3 Life cycle services 4 Operational Efficiency
Higher availability and robustness due to intelligent fieldbus Infrastructure Link (redundant) Field Device Coupler, redundant (M = master) PROFIBUS PA / FOUNDATION Fieldbus H1 Short-circuit or wire break on trunk line Active Field Distributor (AFD) AFD bus termination
Foundation Field Bus FF-H1 FF Link All required configuration with one Foundation Field bus Link for a scalable availability PROFIBUS DP backbone FF Link FF-H1 FF Link FF-H1 PROFIBUS PA and FOUNDATION Field bus FF Use the same Physical Layer FF-H1 ring redundancy No 3rd party components required No interoperability issues FF Link FF-H1 Ideal Link with Highest availability!!! Only at Siemens
Trends in Process Automation 1 Integrated Engineering 2 Comprehensive Fieldbus solutions 3 Life cycle services 4 Operational Efficiency
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
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)
Trends in Process Automation 1 Integrated Engineering 2 Comprehensive Fieldbus solutions 3 Life cycle services 4 Operational Efficiency
Optimization Advanced Process Control (APC) Energy Management acc. to Standards Advanced Process Analytics SIPAT - key Enabler for Continuous Manufacturing & Real Time Releases Gas Water Electrical Energy Steam Compressed Air Cooling Heat Plant Asset Management 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 Advanced Process Control Model based predictive control (MPC) Typical applications: Two component distillation (2x2) Cement mill (3x4) Benefits Less process deviations Increased yield Higher throughput SIMATIC PCS 7
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