2. 2 process news | 2-2012
C o n t e n t s p r o c e s s n e w s | 2 - 2 0 1 2
p Cover
Lifecycle Management
4 A Plan for Life
Lifecycle Management
8 The Next Step
Integrated Engineering
p Industry
Chemical Industry
10 Smooth Standards
Klüber Lubrication, Germany
Pharmaceutical Industry
12 Quality of Life, Quality of Product
Julphar, United Arab Emirates
16 Clear Benefits
Curti Costruzioni Mecchaniche, Italy
18 Targeting the Supply Chain
Alcon Cusí S.A., Spain
20 Quality Medicine
ICES, Singapore
p Technology
Process Control Technology
22 Innovative Operating Concept
BASF, Germany
24 Partners for Global
Solution Expertise
Siemens Solution Partners
26 Eliminating Vulnerabilities
with Updates and Patches
Industrial Security
Energy Management
28 Energy Efficiency
as a Business Process
Spenner Zement, Germany
30 Web Exclusive
31 Dialogue
BASF benefits from a user-friendly and
efficient operating concept for plant
control systems that helps operators
react fast and appropriately to
changing process conditions
Page 22
The new AVM machine series of Curti
Costruzioni Mecchaniche can pack
vials and ampoules fast and efficiently
using a perfectly aligned automation
and drive solution
Page 16
Using Simatic technology, Klüber
Lubrication implemented a
standardized automation system
covering the requirements of various
batch processes and production plants
Page 10
Klüber
SiemensAG
BASF-SE/Hans-JuergenDoelger
3. process news | 2-2012 3
“Guiding you
through change”
Axel Lorenz
Vice President
Process Automation
Industrial Automation Division
Siemens AG
Our theme for the Achema 2012 is: “Guiding you through change –
Your trusted partner for lifecycle innovation.” Every three years, experts and
engineers from process technology, engineering, and process industry
companies visit the world’s leading event for the process industry. The Achema
has always been a trendsetting technology summit for chemical engineering,
environmental protection, and biotechnology, and we are proud that we can
make a contribution to innovation through our expertise and technology.
This year, we will showcase a complete lifecycle management portfolio to
reduce the total cost of ownership. The exhibits show how the process industry
can benefit from our products, systems, solutions, and services in research and
development, process development, plant design, production, and maintenance
as well as optimization and modernization.
In this issue of process news, we have included a special edition with some of
our technology innovations, such as the latest version of our Comos and Sipat
software.
Several case studies illustrate how our process industry partners and customers
can benefit from our solutions and services throughout their system and plant
lifecycle. For example, read an interview with Dr. Birk from BASF on how lifecycle
management can improve plant performance.
Innovative products and solutions, process know-how combined with lifecycle
services make Siemens a trusted partner for a sustainable business in dynamic
times. We work with the world’s leading chemical and pharmaceutical companies
to make sure that they get the most out of their plant and activities – and we
will continue to develop and improve our offerings to that aim.
Enjoy the read!
E d i t o r i a l
4. 4 process news | 2-2012
C o v e r L i f e c y c l e M a n a g e m e n t
Photo:BASFSE
5. process news | 2-2012 5
p Lifecycle Management
A Plan for Life
From his office window, Joachim Birk can see
several BASF SE. He is director of the Center
of Excellence for Automation Technology at
BASF in Ludwigshafen and leads a team that has
been the driving force in the development of
new concepts for process control system lifecycle
management. The Center of Excellence focuses
on the contribution of
automation to efficient,
reliable plant operation
when developing and
deploying process con-
trol systems. Birk ex-
plains: “BASF SE, with its
numerous plants and
systems in different sizes
and phases of life, is an
ideal field of application
for new concepts in pro-
cess control engineer-
ing. Together with our partners, we are constantly
evaluating novel concepts, as automation technol-
ogy is a critical component in the safety, productiv-
ity, and availability of plants. We need to ensure this
contribution with continuous system care.”
Innovation as a challenge
For Birk, one of the central tasks of lifecycle man-
agement is coordinating the different lifecycles of
plants and automation systems: “On average, we
expect a process plant to have a life of 30 years in
operation, even longer in the case of some plants
here in Ludwigshafen. In comparison, lifecycles in
Ten years ago, the Center of Excellence for Automation Technology of
BASF SE in Ludwigshafen, Germany, started to develop concepts for
effective and efficient lifecycle management of process control systems.
In this context, the general technical framework for plant operation and
system maintenance is one critical aspect. However, equally important
is communicating benefits to users and management.
automation technology are about 10 to 15 years for
hardware and just 5 years for software components.
We have to match and align these cycles, always
keeping in mind that we can only implement new
features or components when production operations
permit this. In some cases, we can migrate systems
during operation, but typically we need a plant shut-
down to perform
them efficiently.
The top priority is
not affecting plant
operation in any
negative way –
innovations must
pay off in daily pro-
duction. We expect
suppliers to respect
these cycles with
their products. This
means that we need
to develop a common understanding for those
phases in which we can carry out upgrades.”
Solutions for life
The intensive work of the last 10 years has already
paid off for Birk: “In our bids, we have succeeded in
getting our suppliers to offer not only a price for the
initial investment but also for the lifecycle costs, for
example, for 15 years. This makes the maintenance
of automation technology a plannable and above all
a calculable component of the system lifecycle. We
can assess how much a system will cost us in the
course of these 15 years; this is a major step for-
» Maintenance of automation
technology must become a
plannable and above all a
calculable part of the system
lifecycle. «
6. 6 process news | 2-2012
ward, and we were also one of the trendsetters in
the industry with this approach.”
Another aspect is standardization of automation
technology. BASF actively promotes this both in
terms of the compatibility of different systems and
within the system software. For example, BASF
uses standardized software modules for engineer-
ing Simatic PCS 7 process control systems. These
modules represent typical control system tasks that
are frequently needed. BASF has developed this
tool kit together with Siemens, one of its preferred
suppliers for process control systems. “We use the
tool kit worldwide in all the new BASF plants.
Instead of having an individually programmed
stand-alone system, we can work with a control
system that is largely composed of standard com-
ponents and uses customized functions only where
expressly needed. An additional benefit of this
approach is that it helps us migrate systems more
efficiently. We have good documentation and can
easily access all required information. This defi-
nitely reduces the project complexity that you have
with current control systems significantly,” explains
Birk. “Our teams save time during engineering, and
the tool kit makes many tasks simpler, plus we can
reap additional benefits over the system lifecycle.”
However, Birk says that it is essential to evaluate
standardization in terms of the contribution it
makes to efficient lifecycle management: “It is
important to find the right balance between stan-
dardization and customization, keeping the system
simple and efficient. And we need to talk fre-
quently with the project teams on-site to make sure
the people who have to work with the systems at
the construction site or in the plant share our
approach.”
Open exchange and common objectives
Sharing and exchanging information are important
for Birk, also to establish a good working relation-
ship with suppliers and partners. “Siemens is not just
someone who we have been working with for a long
time, building a lot of trust. Both companies share
common objectives, so we can openly discuss and
evaluate ideas and concepts in the area of process
control engineering,” Birk explains. “For example,
we can assess together which innovations – for
instance, in the area of operating concepts, IT secu-
rity, or remote maintenance – should be introduced
where and when. We also carry out beta tests
together and match development activities to
requirements. This dialogue is also important for us
as it helps us put our own concepts to the test and
remain open for new ideas. I think that our job is not
so much to predict the future but to actively shape it
– and Siemens is a partner that is already well posi-
tioned for this.”
Particularly the last point – developing joint ideas
and speaking with each other – is an integral part of
the corporate culture at BASF. “Consequently, we
have many young and well-qualified employees,
whom we train intensively,” says Birk. “We actively
promote the exchange between specialists – not
only within our BASF community for automation
technology but also with our partners. Fostering
knowledge in our teams is an important aspect
when you talk about lifecycle management.”
On a more technological level, Birk sees more
untapped potential in the area of standards: “We
collaborate actively in committees such as NAMUR
(Standards Committee for Measurement and Control
in the Chemical Industry) to improve and promote
existing standards and to define new ones. It is our
D r. J o a c h i m B i r k
D i r e c t o r o f t h e C e n t e r o f E x c e l l e n c e f o r A u t o m a t i o n
Te c h n o l o g y, B A S F S E
Joachim Birk has been working for BASF for about 20 years. Today, he is the
director of the global Center of Excellence for Automation Technology at BASF
in Ludwigshafen and is involved in many fields of control technology such as
Advanced Process Control (APC), manufacturing execution systems (MES),
control systems and security systems, robotics, and laboratory automation.
Birk started his career as an APC engineer and then worked as an electrical and
automation engineer in research facilities.
C o v e r L i f e c y c l e M a n a g e m e n t
Publicis
7. process news | 2-2012 7
(MES) to be able to compile and transform system
data into key performance indicators (KPIs) for per-
sonnel in various groups and at various levels.
“The KPI cockpit, which we are currently adapting
together with Siemens to meet our requirements in
the area of chemi-
cal production, will
help us argue our
case. With it, we
can provide opera-
tion and manage-
ment with KPIs that
enable them to
compare and evalu-
ate their plant per-
formance quickly –
and this will trigger
a request for advanced and efficient automation sys-
tems that comes from the operational level, because
they see what a benefit it offers for them and their
plants. And that is what really counts.” p
info
contact
www.siemens.com/chemicals
thomas.dieckhoff@siemens.com
firm belief that systems and products have to be
widely established in the market to be sustainable
and maintainable in the long term. As a result, we
clearly pursue a strategy of using only mainstream
products wherever possible.”
Advanced concepts
for the lifecycle
Birk is also keenly
watching another hot
topic that is much dis-
cussed in NAMUR: “In-
tegrated engineering
of process and auto-
mation technology cer-
tainly still holds enor-
mous potential for im-
proving efficiency and transparency of plant and
engineering data throughout the lifecycle. This is
definitely something that our strategic planning
will look into.”
Despite his innovative spirit, Birk’s main concern is
for the BASF plants, not only in Ludwigshafen: “The
top priority is that automation technology has to
make a contribution to plant operation. And I see
this as one of the most exciting and central ques-
tions that we have to be able to answer: what is the
operational benefit?” Therefore, BASF and Siemens
are currently developing an appropriate infrastruc-
ture within the manufacturing execution system
» The top priority is that
automation technology has to
make a contribution to plant
operation. «
BASFSE
8. 8 process news | 2-2012
p Integrated Engineering
The Next Step
The basis for the compiler development is a
migration project that is planned for a batch-
ing tank at Sanofi-Aventis in Frankfurt.
Dr. Thomas
Tauchnitz, head of engineering of the Technol-
ogy Process Group at the Frankfurt Pharma site of
Sanofi-Aventis Germany, explains the details: “The
objective is to specify the automation functions in
The integration of Comos and Simatic PCS 7 is making the next step.
Currently, a bidirectional compiler helps integrate the two systems.
This project will also provide information for another important step:
the specification of an interface in the context of a planned NAMUR
(Standards Committee for Measurement and Control Technology in
the Chemical Industry) recommendation.
Comos at our site and then to transfer them via
the compiler to Simatic PCS 7. We do not yet have
the full functionality in use, but we are already
using parts of it.” The developer teams at Sanofi-
Aventis in Frankfurt and Siemens in Karlsruhe are
working hard to improve the interface. Tauchnitz
adds: “I see an important field for more advanced
approaches here in particular, as the direct data
interchange between Comos and PCS 7 also pro-
vides critical information for improving the manu-
facturer-independent integration of process engi-
neering and automation technology.”
A NAMUR study group is working with Tauchnitz on
a recommendation that specifies a defined interface
between the two systems (see box). “NAMUR intends
to implement this interface using a data container
with a generally binding structure that is accessed
by both the process engineering planning and the
automation systems.”
An employee in quality
control at Sanofi-Aventis in
Frankfurt-Höchst. The
company is currently
developing a compiler
together with Siemens for
integrated engineering in
pharmaceutical production
Integrated
engineering in the
pharmaceutical
industry: watch
the video
C o v e r L i f e c y c l e M a n a g e m e n t
9. process news | 2-2012 9
info
contact
www.siemens.com/pharma
jan.rougoor@siemens.com
Better integration, more competition
The background is that plant operators would like to
remain flexible in their choice of engineering sys-
tems, but they would also like, above all, to have a
future-proof solution for the interface. Tauchnitz
says: “After all, we still need to be able to migrate
and maintain our engineering data in 20 years –
independent of the versions of the software and
operating system that we will have then. Since the
container specifies only a data structure and is
largely system-independent, I think the proposed
NAMUR recommendation is the right approach. Sys-
tem suppliers only need to provide a corresponding
import and export option for the data, which consid-
erably reduces the complexity.”
With Comos and Simatic PCS 7, Siemens is able to
address the interface both from the engineering
environment for the process engineering and from
the automation technology side. In the latest ver-
sions, Comos PT and Simatic PCS 7 are linked
through a bidirectional interface for transferring
hardware specifications as well as module types and
instances for the process control system. In the con-
text of the compiler development for Sanofi-Aventis,
the interface will be improved so that it also covers
types and instances for equipment modules.
T h e N A M U R c o n t a i n e r
NAMUR aims to design the integration between different systems for computer-aided engineering (CAE) to be as
open and system- and manufacturer-neutral as possible. This should not only ensure that CAE tools and process
control systems of different manufacturers can be combined with each other but also enable robust and reliable
data transfer that is validated in a pharmaceutical environment, while at the same allowing for further develop-
ments of methods and processes.
NAMUR suggests a concept for this that is based on a manufacturer-independent intermediate database for
engineering data, the so-called NAMUR container. The decisive factor here is that every supplier no longer needs to
agree on an individual interface with every manufacturer for mutual data exchange, but instead each system in
this data exchange must only provide one interface to the NAMUR data container to exchange data in both
directions with any other system.
Engineering data from the CAE system form the basis for the automation specification in the user requirements
specification and functional specification. The technology objects, such as control module types and instances, are
defined in the CAE system and linked to the functionally extended automation system modules. The container will
work bidirectionally and also enable the maintenance of the stored data across the entire lifecycle as well as
automatically synchronize changes to both sides.
DenisFélix/InterlinkImagesfürSanofi-Aventis
For this interface, the existing typicals at Sanofi-
Aventis were modernized for automation in Comos
PT. They now contain all the relevant control loops
and interlocks as well as control and signal specifica-
tions. Furthermore, corresponding basic objects in
the project database were also provided by Comos
PT. On this basis, the functions for the automation
software can be specified for the process automation
independent of the target system.
Idea generator for the container
specifications
For Tauchnitz, the direct link between Comos and
Simatic PCS 7 also serves as a kind of idea generator
for the specifications of the NAMUR container. “We
work closely together with the study group here and
invite the experts to join our discussions with
Siemens when appropriate,” he says. “My assess-
ment: if we can implement a well-defined link
between Comos and PCS 7, we will also be able to
develop a well-defined NAMUR container.” p
N A M U R
CAE system
Supplier A
CAE system
Supplier B
DCS
Manufacturer A
DCS
Manufacturer C
DCS
Manufacturer B
10. 10 process news | 2-2012
I n d u s t r y C h e m i c a l I n d u s t r y
p Klüber Lubrication, Germany
Smooth Standards
Munich-based lubrication specialist Klüber
Lubrication belongs to the Freudenberg
Group and has more than 80 years of
experience in this field. The company produces
more than 2,000 different special lubricants for all
kinds of applications.
The Klüber production system is made up of a global
network of production sites ranging from small
plants with only a few reactors to complex produc-
tion systems with tank farms. In the course of a step-
by-step modernization of its production system, the
company wanted to first bring its Salzburg plant up-
to-date and thereby create a standard that could be
applied worldwide to all other plants. They wanted
to have a uniform system with consistent process
visualization and automated recipe control. In addi-
tion, the system should be able to document the
batch processes in a simple and comprehensive way.
Scalable solution for global implementation
The company decided on a process control system
based on Simatic PCS 7. Project manager Peter
Luksch explains that the decisive factor for choosing
Siemens was the standardized automation solution
with respect to hardware and software as well as
Siemens’ worldwide solution expertise. The consis-
tently scalable architecture of Simatic PCS 7 can be
easily adapted to Klüber’s plants of different dimen-
sions. Additional functionalities such as asset man-
agement, automatic batch processes, and material
transport control as well as process data evaluation
and management can also be integrated smoothly.
How to design a globally standardized automation system to cover
the requirements of many different batch processes and production
plants of different sizes? Siemens found a convincing answer to this
question raised by Klüber Lubrication.
A particularly interesting application for Klüber was
the Simatic Batch software package for the flexible
automation of complex batch processes. Its modular
design and scalability make optimum adaptation to
every plant size possible. In addition, recipes can be
developed centrally and then exchanged across loca-
tions and modified on-site. The complete process
documentation also supports Klüber in providing
proof of quality documents such as those required
by the automobile and pharmaceutical industries.
Standardization in every detail
Klüber wanted to have a modular implementation
concept that could be deployed in large and small
production sites alike. One component of this
solution was PCS 7 with Safety Integrated. To ensure
the reproducibility of electrical equipment, a control
cabinet containing the electrical and automation
equipment was assigned directly to each reactor.
A general operating concept was also integrated into
the navigation bar of the control panel. The result
was a scalable automation solution based on stan-
dards that was, at the same time, customized to
meet the specific requirements of Klüber.
Migration with integrated investment
protection
After the conversion of the Salzburg plant to Simatic
PCS 7 in December 2010, the company is step-by-
step migrating additional plants to Simatic PCS 7.
At present, a plant located in Munich is being
upgraded. Another plant in China is about to be
commissioned. A project in Spain has just been
11. process news | 2-2012 11
info
contact
www.siemens.com/chemicals
benjamin.erschen@siemens.com
started. Siemens pursues the same migration strat-
egy in all these projects: modernization of the exist-
ing systems without plant shutdown as far as possi-
ble and investment protection through retention of
the existing hardware structure wherever possible.
The worldwide standardization of the automation
systems also forms the basis for central reporting
and system integration from the field to the enter-
prise resource planning (ERP) level. An archiving and
reporting system, PCS 7 Process Historian, is to be
introduced at Klüber Lubrication later this year. p
KlüberLubrication
»The decisive factor in favor of Siemens
was the standardized automation solution
with respect to hardware and software. «
Peter Luksch, project manager, Klüber Lubrication
The operators were trained on-site on the new system
A view into the production facility
KlüberLubrication
Backgroundphoto:Fotolia
12. 12 process news | 2-2012
I n d u s t r y P h a r m a c e u t i c a l I n d u s t r y
SiddharthSiva
13. process news | 2-2012 13
insulin crystals were imported from European
sources for the local production of Jusline. Julphar
invested $136.1 million in its new plant in Ras Al
Khaimah.
Julphar XI is one of the most modern biotechnolog-
ical plants producing recombinant human insulin
crystals and is built in accordance with EMEA (Euro-
pean Medicines Agency) regulations. Improvements
on the process are now ongoing to achieve the yield.
The fermentation facilities are designed to produce
450 batches of 10,000 l fermentation broth per year,
yielding 1,500 kg of insulin crystals, which will
enable Julphar to produce more than 40 million vials
of insulin. The plant has six operational suites. In the
media preparation area, bulk media is formulated
before inoculation and seed vessels are filled to
Julphar, United Arab Emirates
Quality of Life,
Quality of Product
Thanks to a fully automated production unit for insulin, Julphar (Gulf
Pharmaceutical Industries) in the United Arab Emirates makes a contribution
to providing affordable high-quality medicine to patients and improving
the quality of life for diabetes patients in the Middle East.q y p
Diabetes in the Middle East is rising rapidly.
Illness and healthcare are causing a financial
strain on regional governments and many
families. Offering high-quality, affordable treatment
to a growing number of patients
would help ease the burden. With this
in mind, Julphar, a pharmaceutical
manufacturer in United Arab Emira-
tes, worked with Siemens to auto-
mate its biotechnology process in its
new insulin production plant, Julphar
XI. Established in 1980, Julphar is the
first pharmaceutical manufacturer in
the Arab Gulf States and a leading
pharmaceutical producer in the region.
Julphar has 11 state-of-the-art pro-
duction facilities in UAE, which adhere
to the highest standards of manufac-
turing. Its commitment to high stan-
dards has led it to procure ISO 9001
and ISO 14001 certifications. Its pro-
ducts are marketed on five continents and
in 2011 crossed over AED 1 billion in sales.
A new facility for fighting diabetes
Julphar’s insulin production plant (Julphar XI) is its
latest facility under construction and is expected to
widen its product offerings and bolster its market
presence, especially in diabetic care. Since diabetes
afflicts sizable sections of the Middle East popula-
tion, Julphar’s foray into bulk insulin production
could not have been more timely. Julphar’s first
insulin production began eight years ago when
»Julphar recognized a gap in the market
for locally produced insulin crystals.
This production will allow us to respond
to an increasing market demand, making
insulin more affordable and accessible. «
Dr. Ayman Sahli, CEO Julphar
14. 14 process news | 2-2012
begin fermentation. In the buffers preparation area,
the bulk buffers are formulated before filling storage
vessels for chromatography purification. A buffer
hold stores formulated buffers in vessels for further
use. The fermentation suite consists of four seed
fermenters and four 5,000 l production fermenters,
which produce 10,000 l of bacterial broth per batch.
In the recovery area, the E. coli is removed and the
pre-poinsulin is harvested and treated with buffers
to assist it in attaining its tertiary structure. In the
purification suite, peptides are removed and the pre-
proinsulin is cleaved using CPB to modify its primary
structure and then separated by chromatography
and finally crystallized.
A trusted partner
Julphar was happy with previous Siemens solutions,
such as in its Julphar VI plant for liquid and semi-
solid pharmaceuticals. This plant is fully automated
with Simatic components and has minimal human
intervention in all stages of production. Siemens’
first-class biopharmaceuticals knowledge and expe-
rience, and its innovative automation products and
solutions, were the main reasons that Julphar chose
Siemens to help build its new plant, the Julphar XI.
In early 2009, Julphar and Siemens discussed coop-
eration for Julphar XI. Construction continued in
2010 and was accomplished in two phases. In
phase 1, the user requirement specifications and
process-related functional specifications were deter-
mined. In phase 2, the hardware and software for
the control systems were designed. The control sys-
tem was configured, hardware was integrated, and
the system was tested. In 2011 the control system
was delivered and the plant was completed. In
March 2012 site acceptance was performed and
operation started.
“This is the start of a long-term relationship, initially
focused on successfully completing what Julphar
considers to be one of their most strategic projects
during recent years,” said Dr. Ayman Sahli, CEO of
Julphar.
Full automation for bulk production
Siemens delivered a comprehensive process control
solution based on Simatic PCS 7, including batch and
route control. The solution includes the automation
of insulin crystal production and the affiliated tank
farm, the integration of the fermentation process,
and the communication to third-party packages.
The system comprises 11 Simatic S7-417s for the dif-
ferent suites within production, connecting remote
stations with 6,000 I/Os to operate sensors and valves.
Over 7,000 m of data cable were laid to connect the
PLCs, PCs, and cabinets with industrial Ethernet and
Profibus. Operating and monitoring can be done from
the process control room and in the field with remote
HMI panels. Every operation is logged safely and all
executed batches are archived in a central server.
Project management a crucial factor
Considering the high standards for the pharmaceuti-
cal industry, the need for bulk production, and the
desire to reduce total costs,
expert project management
and engineering was a must.
The Siemens project manage-
ment approach PM@Siemens
strictly followed the V model
and complied with the latest
GAMP regulations. From the
start, project approaches were
specified, the responsible roles
defined, and expected results
described. In addition, devia-
tions in the process were antic-
ipated and planned for. This
helped minimize project risks
and improved project transpar-
ency and control. Project inter-
faces were also standardized
to ensure easy communication
between all stakeholders. A project quality plan
served as a base for all referenced documents. This
ensured compliance with relevant standards, so proj-
ect goals could be met efficiently. Siemens developed
the quality-related documents during the early phase
of the project in cooperation with Julphar. Testing
plans and standard operations were created and used
during the entire project lifecycle. The complete set
of documentation was given to Julphar for its own
quality assurance and regulation acceptance.
»We have chosen Siemens as they are
world leaders in automation process control
systems, for both the pharmaceutical and
biopharmaceutical industry. They were
able to provide a good platform suitable
for our manufacturing needs. «
Eng. Essam Hammad, Julphar Diabetes
I n d u s t r y P h a r m a c e u t i c a l I n d u s t r y
15. process news | 2-2012 15
info
contact
www.siemens.com/pharma
sebastian.voss@siemens.com
guido.pareijn@siemens.com
ity. To ensure that Julphar can benefit from the full
performance of the system over the entire lifecycle,
Siemens will provide ongoing service for the installed
base. For Julphar, this means that Siemens solutions
and expert project management not only contributed
to completing the project on time and meeting pro-
duction goals but will also continue to improve its
manufacturing process as time goes on – to make
sure that the new plant will keep improving the lives
of diabetes patients in the Middle East. p
To create more value for customers and best fulfill
requirements, Siemens combines solutions services
from different organizational units. For this project,
a team of several experts was formed. The core proj-
ect management and engineering operations were
executed in Karlsruhe and Marburg as well as on-site
in Ras Al Khaimah. This project team delivered excel-
lent performance for the customer.
Service for life
With Simatic PCS 7, Julphar is well positioned to
serve the needs of the growing market for diabetes
medication. The process control system makes a sig-
nificant contribution to optimizing operating costs,
protecting investments, and securing plant availabil-
J u l p h a r X I : t h e k e y p o i n t s
The new facility will serve the growing
market for insulin in the Middle East
3 By choosing a fully automated bulk
process, Julphar wanted to be able to
provide high-quality, affordable products
3 A Simatic PCS 7 system with 11 S7-417s
was used to automate the plant’s six
production suites and 6,000 I/O points,
reducing production costs
3 Siemens automation, expert project
management, and customizable after-
service solutions ensure that the plant is
on target to achieve its production goal
of 40 million vials of insulin each year
“This is the start of a long-term relationship,” says Dr. Ayman Sahli, general manager of Julphar. The new plant, Julphar XI,
was completed in 2011 but Siemens will provide ongoing service for the installed base over the entire lifecycle.
allphotos:SiddharthSiva
16. 16 process news | 2-2012
Curti Costruzioni Mecchaniche was founded
in 1957 in Imola / Italy with the aim of con-
structing machines and devices for the tex-
tile and agricultural industries. During the course of
time, the company has specialized in the aerospace
industry as well as the development and manufac-
turing of packaging machines for the food process-
ing, cosmetics, and pharmaceutical industries.
With the new AVM 100 and 150 cartoning systems,
the engineers of the Curti packaging division have
developed a novel design that provides outstanding
cost-effectiveness and efficiency. The AVM machine
series makes it possible to standardize packing sizes
depending on the types of containers being pack-
aged and utilize packaging resources efficiently. The
machines are also easy to operate and service. Natu-
rally, the AVM machine series is equipped with bar-
code readers to trace products, as required for phar-
maceutical applications. The machines can option-
ally be linked with higher-level IT systems to log
production data.
All electronic system
To achieve this, the engineering department
departed from the classic machine design principles
and deployed only latest-generation automation
components using solely Siemens products and sys-
p Curti Costruzioni Mecchaniche, Italy
Clear Benefits
Lower costs, reduced variety of components, and optimum usage
of packaging materials and energy – those were the objectives of the
new AVM machine series by Curti Costruzioni Mecchaniche, which
packs vials and ampoules with high speed and high efficiency thanks
to a perfectly aligned automation and drive solution.y g
I n d u s t r y P h a r m a c e u t i c a l I n d u s t r y
17. process news | 2-2012 17
info
contact
www.siemens.com/packaging
andreas.seubert@siemens.com
tems. The AVM is a fully electronic cartoning
machine – an asynchronous motor turns the carou-
sel; servodrives synchronize the individual work sta-
tions with the main drive. The Sinamics S120 con-
verter and Simotics S-1FK7 motors are not only ide-
ally suited to performing highly dynamic movements
but can also power various drive concepts with syn-
chronous or asynchronous motors (control modes
U/f, vector with/without regeneration, servo) with
only one twin-axis module, reducing type variety.
Curti uses Simotion D as the high-level control in the
new machine series. Simotion also handles the artic-
ulated arm robots so that no additional robot con-
troller is required. The Simotion systems can com-
municate via numerous field bus interfaces and are
therefore easily integrated into a large variety of
communication architectures.
The individual motors are linked via Drive-CLiQ,
which greatly simplifies commissioning and servic-
ing, since motor parameters are automatically to the
controller using an electronic nameplate and safety
functions are immediately available. This enables the
machine operator to replace motors easily and with-
out errors. The controller matches the motor data
stored on the electronic nameplate with the
approved motor types, so that only suitable motors
can be operated.
Flexible and simple project engineering
Curti’s electronics department uses both Structured
Text (ST) and Motion Control Chart (MCC) as well as
the classic ladder diagrams (LAD) and function block
diagrams (FBD) for programming. The high-perfor-
mance Simotion Scout development environment
enables the easy creation of machine logic with LAD/
FDB, the flexible implementation of the axes coordi-
nation with ST, while creating complex coordinated
motion sequences with the predefined motion func-
tion blocks in MCC. As a result, the AVM machine
series can be adapted easily to a variety of tasks; this
flexibility makes it a perfect package with clear ben-
efits for packaging ampoules and vials. p
T h e n e w m a c h i n e s e r i e s :
p e r f o r m a n c e r i g h t d o w n t o t h e l a s t d e t a i l
The new AVM 100 and AVM 150 cartoning machines consist of a
carousel with 12 stations through which the vials and ampoules pass
during the packing. In the first work step, the vials are fed from below
into the box; then the adhesive is applied and the box is closed. The
machines can also customize the packaging by applying a quality seal
or making the box resealable.
3 Box size: 60 x 40 x 35 mm to 90 x 190 x 80 mm
3 Visualization, machine operation, and recipe management:
Simatic MP370 Touch Panel
3 Control system: Simotion D445 integrated into the control unit
of the Sinamics S120 drive system
3 8 servo axes with Simotics S-1FK7 servomotors
3 1 asynchronous motor as the main drive
3 4 asynchronous motors for the auxiliary equipment
The controller coordinates all Sinamics drives and handles not only the
motion functionality with the internal technology functions but also the
temperature control and the PLC functionality.
Fotolia–Dusk
SiemensAG
18. Fotolia–Delphimages
18 process news | 2-2012
I n d u s t r y P h a r m a c e u t i c a l I n d u s t r y
p Alcon Cusí S.A., Spain
Targeting the Supply Chain
Alcon’s serialization solution enables the traceability, integrity, and
transparency of products throughout the global supply chain and helps
the company fulfill its current and future legal requirements in various
markets and protect its brand from counterfeit products.
With the establishment of the Alcon Pre-
scription Laboratory in Texas in 1945,
two pharmacists, Robert Alexander and
William Conner, laid the foundation for one of the
most successful business stories of all time. Today,
Alcon Laboratories Inc. is number one in the world
with its pharmaceutical and surgical products for
ophthalmology, contact lenses, and eye care prod-
ucts. In 2010 the company generated sales of
US $7.2 billion. Alcon operates facilities in 75 coun-
tries, serves 180 markets, and employs 23,000
people.
Artificial tears from Spain
One of the company’s main products is lubricant
eyedrops and ointments, which Alcon sells in various
countries, especially in France and Turkey. Each
packaging unit must receive a unique ID with a serial
number as a data matrix code (2-D bar code), which
makes them fully traceable and which complies with
the legal requirements of the respective countries.
This serialization provides the products with an elec-
tronic “pedigree” and allows them to be monitored
without interruption, in accordance with the various
19. process news | 2-2012 19
Bar Code Data Matrix RFID
ERP
External Enterprise Data Exchange
ePedigree
Track/Trace
Authentication
Serialization Line System
Serialization Line System*
Code Reader/Scanner
RFID Encoder/Reader
Printer
Hand Reader
Other Lines*
Reject Station
Siemens AutoID ConnectorSieme
The pester pac coding
unit applies a unique
code to each package
info
contact
www.siemens.com/pharma
hans.bijl@siemens.com
SiemensAG
statutory requirements, and to be documented –
an important feature for Alcon, which exports its
products to many different countries. Together with
the Munich-based company Atos, Siemens imple-
mented a complete solution for serialization, rang-
ing from the packaging machines on the production
floor to the enterprise resource planning (ERP) sys-
tem. The machine solution was fully integrated into
Alcon’s six existing packaging lines. It is based on
standards and was implemented in close coopera-
tion with pester pac automation based in Wolf-
ertschwenden in Germany.
Integrated automation
The automation system in the serialization units
attaches the data matrix code to the folded boxes.
Two cameras determine whether the printout is cor-
rect and whether the single folded boxes were
packed completely in a 10-unit bundle. Siemens’ line
system (Siemens Line Controller) manages this infor-
mation and sends it as an aggregate via the Atos
AutoID Connector (AAC) to the back-end ERP system,
which processes and archives it. The AAC assumes
other tasks: It receives and processes the batch files
from the ERP level and the motion control informa-
tion system (MCIS) and prepares them for the line
system. In addition, it generates the unique serial
numbers for the folded boxes. This solution was
also integrated as a retrofit into two machines that
operate at a higher speed. Thus, the printers, cam-
eras, and machinery had to be calibrated accordingly
and coordinated with the line software.
A smart approach minimizes loss
of production
The serialization solution at Alcon meets all the re-
quirements for traceability of products in the phar-
maceutical industry and ensures high integrity and
transparency across the entire global supply chain.
Its open system architecture allows integration into
the existing machine environment, the inclusion
of third-party devices, and expansion as needed.
The project was started in June 2010, and the first
machines were already delivered at the beginning of
November 2010. The machines and the retrofit were
phased in over the course of the following year,
which allowed production interruptions to be mini-
mized. During the start-up phase, Alcon ordered an
additional machine. The entire project was processed
on the basis of the V-model typical for the pharma-
ceutical industry, according to GMP standards, and
was completed successfully and with the perfor-
mance qualification (PQ) in February 2012. Thanks
to the combined expertise of the project team and
good collaboration between Siemens, its partners,
and Alcon, even nontypical requirements and chal-
lenges were overcome. All technical issues were dis-
cussed with the team and together with Alcon. Even
the quality management systems of the companies
involved complemented each other seamlessly
throughout the project. p
20. 20 process news | 2-2012
Proccess feed
Cllosed-loo
control
To produce a range of modern drugs, pharma-
ceutical manufacturers must face the chal-
lenges of developing and controlling sophis-
ticated chemicals processing in a tightly regulated
environment. In the past, regulatory barriers tended
to inhibit manufacturers from moving beyond
established practices to adopt newer, state-of-the-
art manufacturing processes. Recognizing this
dilemma, the US Food and Drug Administration
(FDA) introduced new guidances in 2004 to encour-
age innovation in pharmaceutical manufacturing
p ICES, Singapore
Quality Medicine
A research institute in Singapore finds the formula for the
manufacture of advanced pharmaceuticals with the support
of the Sipat process analytical technology software.
and quality assurance (QA). This initiative involves
Pharmaceutical Manufacturing in the 21st Century,
and process analytical technology (PAT) was launched
as the cornerstone of the FDA’s Pharmaceutical Good
Manufacturing Practices.
Controlling manufacturing processes
PAT is a system for designing, analyzing, and control-
ling manufacturing processes. It is based on in-line
measurements of performance and quality parame-
ters of raw materials, in-process materials, and pro-
cess variables. The philosophy of PAT is that reliably
capturing and analyzing the flow of critical infor-
mation relating to process chemistry, unit opera-
tion, and scaling-up issues will facilitate faster pro-
cess understanding. With a complete understand-
ing of the processes, a manufacturer can take new
drugs more quickly from the research and develop-
ment (R&D) lab to pilot testing and hence full manu-
facture.
The key to PAT is the automated control of critical-
to-quality parameters based on mathematical mod-
els using real-time process data. With a predictable
process and product quality, the finished goods may
be dispatched direct from the line without holding
for QA batch release. Through PAT, the costs of man-
ufacturing, inventory, validation, and regulation can
all be dramatically reduced.
Pilot plant
In Singapore, the Institute of Chemical and Engi-
neering Sciences (ICES), a national research institute
under the Agency for Science, Technology, and
The integration of Sipat into the WinCC environment
provides a unique operator interface for each phase of the
process, resulting in a simple, yet complete and accurate,
picture of all operations
SiemensAG
I n d u s t r y P h a r m a c e u t i c a l I n d u s t r y
21. process news | 2-2012 21
T mp pH pO₂Temp., pH, pO₂
p
op
Processsssssssssssssssssssssssssssssssssss aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaalllllllllllllllllllllllllllllllllllyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyyzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeerrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrr
mp., pH, pO₂
ressureeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee ..................................
Sample
info
contact
www.siemens.com/pharma
chew_wee@ices.a-star.edu.sg
tions), reactor temperatures, flow rates, levels, stir-
ring speeds, and so on. The raw data were processed
by Sipat based on the knowledge obtained from
engineering analyses of the various stages of the
chemical processes. The resulting intelligent output
was then presented to the operators via script-based
programming of the WinCC interface. The result was
a unique operator-level graphical user display for
each phase of the process, providing a simple, yet
complete and accurate, picture of all operations.
All of the user data provided, such as process-specific
alarm management and MATLAB analysis of Raman
spectroscopy data, were automated through the
WinCC/Sipat integrated platform. All data were logged
in compliance with FDA 21 CFR Part 11 electronic
records requirements.
The ICES integrated platform, powered by Sipat and
WinCC, demonstrates the ability to link process ana-
lyzers, process control tools, data mining tools, data
analysis, and knowledge management tools into a
single system architecture. Through online quality
control, Sipat helps ICES provide better process
insight, manufacturing performance improvement,
regulatory compliance, and scalable PAT rollout and
deployment. p
Research (A*STAR), provides support for the growth
and development of Singapore’s chemical and phar-
maceutical sectors. A pilot plant run by ICES is used
to develop novel chemical processes and manufac-
turing techniques. To shorten the development
time of these processes, ICES has implemented an
integrated platform to support PAT, with the aim of
obtaining key operational data and of increasing
confidence in process implementation at full-scale
manufacturing sites. The integrated platform
employs Sipat, the software solution from Siemens
for the application of PAT, together with WinCC
supervisory control.
To test the capabilities of the integrated platform at
the pilot plant, ICES implemented a pilot-scale syn-
thesis of 4-D-erythronolactone (4-DEL). The synthe-
sis involved a four-phase hybrid process with both
batch and continuous unit operations. During opera-
tion, the critical process parameters were monitored
in real time via the WinCC SCADA system. This sys-
tem was dynamically linked to the Sipat software,
which managed all critical process data through
Object Linking and Embedding (OLE) for Process
Control (OPC) protocols.
Sipat also delivered data to a MATLAB software
server for more sophisticated analysis. The MATLAB
results were then fed back into Sipat and WinCC and
were stored by Sipat in an SQL database.
Applying intelligence to data
The process data monitored included Raman spec-
troscopy (to measure reaction mixture composi-
Fotolia–IngorNormann
22. 22 process news | 2-2012
Te c h n o l o g y P r o c e s s C o n t r o l Te c h n o l o g y
p BASF, Germany
Innovative Operating Concept
Ludwigshafen, Germany, is home to the largest
BASF production site worldwide. The more than
100 million cubic meters of wastewater gener-
ated on-site every year are treated in the facility’s
own wastewater treatment plant. Another 20 million
cubic meters come from the surrounding towns and
Quick identification of critical process states, process trends, and priorities,
as well as reacting purposefully – achieving these goals is no problem for
BASF, because the company is now benefiting from a user-friendly and
efficient operating concept for plant control systems.
municipalities. The total volume corresponds to the
amount of wastewater that approximately three mil-
lion persons in private households would generate. In
the context of the OPAL 21 project, this treatment
plant was to be designed according to the standards
of Operational Excellence. To achieve this, says proj-
The BASF wastewater treatment plant in Ludwigshafen handles the wastewater from the
company’s industrial plants as well as sewage from the surrounding towns and municipalities
23. process news | 2-2012 23
info
contact
www.siemens.com/hmiplus
lutz.glathe@siemens.com
ect manager Dr. Jens Bausa, “modern automation
infrastructure and tools” were required, “to support
continuous improvement of the process.” Specifi-
cally, this meant reducing complexity through stan-
dardized and simplified operator interfaces, effec-
tive alarm management, and uniform data inter-
faces.
New requirements
Today’s operating concepts have to match the cur-
rent situation in modern process plants, in particular
the high automation level, the adjusted number
of employees, the challenges that go with demo-
graphic changes in staff, and the high demands in
terms of safety and availability. Operator systems
of state-of-the-art control systems such as Simatic
PCS 7 support operator performance through a
graphical user interface and high-resolution 22-inch
screens. In addition, there are enhanced libraries
with new process icons for the visualization of oper-
ating states.
With the innovative Human Machine Interface PLUS
(HMI+) operation and visualization concept, which
was implemented in an industrial wastewater treat-
ment plant for the first time here, Siemens met the
high expectations of the BASF Excellency Project
OPAL 21 with regard to the optimization of process
visualization and operation. A dedicated HMI+ ser-
vice team develops a visualization solution tailored
to the plant together with the plant operators. An
efficient operation and visualization concept must
be based on the latest findings on ergonomics and
usability, but it must also be specifically adapted to
the workflows of the users. It is therefore imperative
to include the plant operators in the development
process to make sure that the experience accumu-
lated over years of system use and the valuable asso-
ciated know-how is incorporated and safeguarded
in the design of the control system.
For this reason, a workshop was organized for the
BASF employees to introduce them to the functional-
ity and methodology of HMI+. Among other things,
it addressed the color concept used, the new hybrid
displays, and the task- and topology-oriented pre-
sentation of the process-group level.
Transition in three phases
First, the available process charts were discussed
with all the participants to identify to what extent
they represent the actual processes and support the
required operating steps. Higher-level process-group
descriptions were created from the insights gained,
and the corresponding ideal representation – digital,
analog, and/or curve diagram – was determined.
This resulted in the level 2 process diagrams that will
cover 85 percent of all operating procedures. In the
subsequent optimization phase, the plant operators
had the opportunity to assess these process dia-
grams from the user’s point of view and to make
additional suggestions for improvement. Afterward,
the process visualization was finalized in PCS 7.
During the stepwise DCS migration, the first stage of
expansion of the HMI+ project was also completed in
the BASF treatment plant in Ludwigshafen. The per-
sons responsible at BASF are highly satisfied with the
result: “The active integration of all participants and
aspects into the design of the operating graphics led
to broad acceptance of the new operating concept.”
This opinion is also shared by the plant operators:
“We value the clearly displayed process visualization,
which, with a few clicks, makes recognizing critical
process states, process trends, and priorities easier.”
Meanwhile, the HMI+ project has been enhanced
and extended to three additional areas of the sew-
age treatment plant. p
H M I + p r o j e c t : k e y f a c t s
3 Human Machine Interface PLUS (HMI+) project
as an add-on to the PCS migration project of the
production facility’s sewage treatment plant in
Ludwigshafen
3 Upgrade of the operator interface to the HMI+
user interface integrated into PCS 7 in four
expansion stages (flue gas washing water
treatment, drainage, incineration plant, and
biology)
3 Complete operation of the effluent plant from
a central measuring station by four plant
operators (one per plant section) with the help
of only 50 information-oriented process-group
representations (level 2 overviews); the 500
conventional process charts support the process
operation, for example, for diagnostics.
BASFSE/Hans-JuergenDoelger
24. 24 process news | 2-2012
example, Siemens and its Solution Partners BST
Buck Systemtechnik, Rösberg Engineering, and
the on/off group will be represented this year
at ACHEMA, where they will exhibit innovative
solutions.
Process safety specialists:
BST Buck Systemtechnik
BST Buck Systemtechnik in Brunsbüttel, near Ham-
burg, is a typical Siemens Solution Partner. The sys-
tem integrator, founded in 1989, has acquired an
exceptional breadth and depth of knowledge about
batch processes and is a specialist for Simatic
Batch. BST implements factory acceptance tests
(FATs) much more efficiently with the Simit simula-
tion solution and can thus decisively accelerate the
start-up of operation. In addition, BST is one of
only 14 Siemens Solution Partners that are certified
as Simatic PCS 7 Safety Specialist Partners.
p Siemens Solution Partners
Partners for Global
Solution Expertise
The industry thinks and acts on a global
scale – and consequently, the solution part-
ner program provides a global network of
approximately 1,200 Solution Partners in more
than 60 countries. They are not only certified by
Siemens and work according to uniformly defined
quality criteria but they also keep their expert
knowledge up-to-date and verify their qualifica-
tions in repeated certification workshops and
audits. Solution Partners engage in continuous
exchange of know-how with Siemens and have
extensive knowledge about the various Siemens
products and systems. With the help of the
Solution Partner Finder on the Siemens web
portal, customers can find the solution partners
that match their requirement profiles.
Joint appearances at trade fairs and events are
also part of the Solution Partner program. For
Process control technology is a field for specialists with technology know-how as
well as comprehensive industry expertise. Siemens Solution Partners offer exactly
that. They are selected system integrators for automation and drive technology
that implement qualified solutions based on Siemens products and systems.
» Siemens Solution Partners are a global network of certified system
integrators that covers a broad field in the process industry with a
wide range of competencies. Siemens supports its partners regularly
through ongoing know-how transfer and expert support and makes
superior solutions possible with global quality standards. «
Joachim Kessler, director, Siemens Solution Partner Program
Te c h n o l o g y P r o c e s s C o n t r o l Te c h n o l o g y
25. process news | 2-2012 25
info
contact
www.siemens.com/solutionpartner
andrea.hammerl@siemens.com
At ACHEMA, BST will present the PCS 7 extension
BST ExPlate, which makes it possible to identify and
display PCS 7 faceplates for certain process control
loops on an Ex-protected handheld computer via
RFID. With appropriate authorization, operation and
the display of maintenance information from SAP is
also possible.
Continuity that counts:
Rösberg Engineering GmbH
A process control system is only one component
influencing the success of an automation project.
The specification of the instrumentation, the design
of the protective functions according to SIL, and
ensuring explosion protection as well as its docu-
mentation are at least as important. Besides, excel-
lent project management is also absolutely essential.
This is exactly the point at which the system integra-
tor Rösberg Engineering GmbH, founded in 1962,
comes in. The specialists from Karlsruhe in Baden-
Württemberg master the entire range of services
and offer their customers a complete solution from a
single source as a responsible engineering, procure-
ment, and construction (EPC) contractor. Further-
more, Rösberg provides a smooth flow of informa-
tion between the computer-aided engineering (CAE)
system, the manufacturing execution system (MES),
and the enterprise resource planning (ERP) world.
In this context, Rösberg supplements the solution
with applications for master data and document
management as well as for resource planning. Solu-
tions from Rösberg, such as the database-supported
PCS-CAE system PRODOK and LiveDOK for efficient
plant documentation, have proved themselves in the
international market for many years.
New dimensions made to measure:
on/off group
Customized process control solutions are key to cre-
ating or maintaining a competitive edge. With this
knowledge, the on/off group implements compre-
hensive solutions from the fieldbus level up to the
process control system. The Siemens Solution Part-
ner from Wunstorf, near Hannover, relies on its com-
prehensive industrial expertise and adapts its solu-
tions specifically to the processes of its customers.
The company is established throughout Europe and
is a specialist for industries such as pharmaceuticals,
food and beverages, water and sewage, and energy
and the environment.
A typical case story is the planning and installation
of a new production center for single- and multi-
chamber bags for B. Braun AG in Melsungen. To
meet all the requirements and at the same time
ensure the necessary flexibility of the system,
extremely modularized object-oriented structuring
of the software was carried out and strict standard-
ization of the interfaces to the adjacent systems
defined. The Simatic PCS 7 process control system
with the Simatic Batch option and the standardized
MES interface were used as a basis. With the devel-
oped system, the complete vertical integration of all
production and documentation processes (electronic
batch record) was implemented. p
allphotos:SiemensAG
26. 26 process news | 2-2012
p Industrial Security
Eliminating Vulnerabilities
with Updates and Patches
The first measure in a defense-in-depth secu-
rity strategy consists of recognizing and
eliminating known risks. This includes, in
particular, protection against malware. Systems
can be secured against viruses, Trojans, and other
attacks with patch management. To prevent the
penetration and spread of harmful software, sys-
tem operators and persons responsible for IT can
employ three tactics: scheduled installation of
software updates such as Microsoft’s security hot-
fixes and firmware updates, use of antivirus soft-
ware, and use of whitelisting software for preven-
tive system protection.
Updates: protection against known threats
Windows Server Update Services (WSUS) is a signifi-
cant component for updating operating systems, as
it handles the supply and distribution of provided
patches.
On every second Tuesday of the month, Microsoft
publishes security hotfixes for its systems. Siemens
checks these hotfixes to ensure that they are com-
patible with its systems and applications. Two weeks
A majority of attacks on industrial IT systems aim at vulnerabilities for which
patches are already available. However, few systems have all available
patches installed. Consequently, the first step to an effective security
strategy consists of efficient update management for virus protection and
security patches.
later, a list of the tested hotfixes is provided for
download. The Siemens support websites publish
detailed information on how to install the patches
and what to pay attention to in this process.
Antivirus software: security up-to-date
Using antivirus software is a good complement to
the installation of patches, since manufacturers of
antivirus software usually react most quickly in
terms of recognizing and removing newly appear-
ing harmful software. Their databases are gener-
ally updated daily and therefore contain the new-
est virus definitions. A virus scanner, which is regu-
larly provided with updates, is not only able to
defend against attacks against the system from the
outside. It can also free already infected systems of
harmful software. Here as well, the prerequisite is
that a specific solution be already implemented in
the system design. For example, by creating a
management console specifically for downloading
and distributing the newest virus definitions to the
individual clients. Siemens regularly tests all virus
scanners that are available on the market for com-
patibility with its systems and applications and
Te c h n o l o g y P r o c e s s C o n t r o l Te c h n o l o g y
27. IT Security Hinweis
Es sind geeignete Schutzmaßnahmen (u.a. IT Security, zum
Beispiel Netzwerksegmentierung) zu ergreifen, um einen sicheren
Betrieb der Anlage zu gewährleisten. Weitere Informationen
zum Thema Industrial Security finden Sie im Internet unter
www.siemens.de/industrialsecurity.
process news | 2-2012 27
info
contact
www.siemens.com/pcs7
stefan.woronka@siemens.com
publishes all compatible versions on a special sup-
port website.
Whitelisting: what isn’t listed isn’t permitted
Both software updates and antivirus software have one
fundamental disadvantage: they only enable a reaction
to threats to the IT system that have already become
known. Therefore, the use of whitelisting software is
recommended as the third step in an effective defense
strategy. Such solutions are based on a whitelist that
contains all executable programs required to operate
the system. If a user wants to install or execute a pro-
gram not included on this list, this is prevented in the
same way that the execution of harmful software
entering the system by another route is blocked. The
whitelisting software can be set to an update mode for
installing updates and new programs. After installa-
tion, the new programs are added to the whitelist.
Thinking in context
Together, the measures discussed here provide
low-level IT system protection that can prevent a
large share of attacks – but not all of them. There-
fore, installing further measures and intensively
raising the awareness of employees is essential.
The next part of our industrial security series will
focus on user administration, system hardening,
and protection using firewalls and secured
connections. p
D e f e n s e - i n - d e p t h
The defense of automation systems consists of
a series of obstacles that require various attack
strategies to overcome. Eight basic protective
measures are used in this concept:
Physical protection
Guidelines and directives
Security cells and DMZ
Firewalls and VPN
System hardening
User account management
Patch management
Malware detection and prevention
(antivirus, intrusion detection)
DCS
Potential
threat
IT security note
Suitable protective measures (including IT security, e.g., network
segmentation) must be taken to ensure secure operation of the
plant. Further information on industrial security can be found at
www.siemens.com/industrialsecurity.
D.Obertreis
28. 28 process news | 2-2012
R u b r i k r o t R u b r i k g r a u
p Spenner Zement, Germany
Energy Efficiency
as a Business Process
Founded in 1926, Spenner Zement, a medium-
sized family-run business in Erwitte, Germany,
produces cement, lime, and dry mortar in 10
locations and generates annual sales of more than
€100 million with approximately 220 employees. The
decision to introduce an energy management system
(EMS) in accordance with DIN EN 16001:2009 was
made for two reasons: energy is the decisive cost fac-
A comprehensive energy management solution with products and
systems from Siemens helps Spenner Zement identify savings potential
and establish a sustainable process for energy efficiency.ppp gygygyy yyy
tor in the production of cement, and Spenner Zement
has declared its commitment to a sustainable and
environmentally sound development in its guiding
principles.
One system for three different plants
On the technical part, Spenner Zement opted for the
Simatic B.Data software solution from Siemens as its
Te c h n o l o g y E n e r g y M a n a g e m e n t
29. process news | 2-2012 29
info
contact
www.siemens.com/cement
engelbert.lang@siemens.com
energy monitoring and management system (EMS).
B.Data can be completely parametrized, allowing
Spenner Zement to easily add further measuring
points, define new key performance indicators
(KPIs), generate reports, and adapt the system to
changed requirements in the future. The task con-
sisted of integrating the Felsenfest, Diamant, and
Nordstern plants into a uniform EMS and creating a
central control room with the initial intention of
monitoring electrical power. Thanks to the expertise
and excellent collaboration of the joint project team
of Spenner Zement and Siemens, the ambitious proj-
ect was implemented during running operation
within only six months.
The new EMS records measured values with 7KM
PAC3200 multifunction measuring devices at pres-
ently some 90 measuring points, which are con-
nected via Profibus to a central controller and a
higher-level control system, where parameters are
collected, processed, and archived. Simatic B.Data
retrieves the data from the control system database.
Siemens was responsible for installation of the hard-
ware and software, engineering for the integration
of the measuring devices, and parameterization and
engineering of the control system as well as the
commissioning of Simatic B.Data. Two key aspects
were the ability to create and display energy KPIs
and various reports.
Energy flow, consumption, and balance
With the new system, Spenner Zement can not only
display and examine all energy flows in the works
but also exactly balance the energy that was
required and actually consumed. Consumption per
product can also be recorded and evaluated, for
example, kilowatt-hours per ton of cement.
An important advantage is the automatic creation
of cost center reports. Managers of the individual
plants can easily obtain all the necessary informa-
tion to further optimize consumption in their own
areas. In the future, they should be able to generate
reports themselves to analyze the energy efficiency
of individual plant units, for example. The energy
consumption can be evaluated and compared across
any period. The load profiles for all core processes
– breaker, raw mill, rotary kiln, cement mill, and so
on – create the basis for active load management.
This helps prevent expensive load peaks. In addition,
qualitative conclusions can be drawn to coordinate
production process and energy consumption more
effectively and lower the basic load profile overall.
Spenner Zement is already thinking ahead and
wants to further optimize its energy purchases with
sophisticated reporting and increased transparency.
Based on the positive experience with Siemens as a
supplier, the persons responsible are also willing to
show the solution to external interested parties as a
reference project for the cement industry. p
E n e r g y m a n a g e m e n t a t S p e n n e r Z e m e n t
O b j e c t i v e s
3 Increasing energy efficiency
3 Reducing energy consumption
3 Active load management
3 Optimization of energy purchases
Te c h n o l o g y
3 Simatic B.Data energy management system
3 Simatic PCS 7 control system
3 Simatic S7-400 controller
3 Simatic ET 200 I/O system
3 7KM PAC3200 multifunctional measuring devices
R e s u l t
Robust and open, comprehensive solution that enables
3 adding measuring points quickly and easily,
3 defining new KPIs,
3 defining reports, and
3 making adaptations.
Franz-Josef Haselhorst, deputy manager of the electrical
engineering department, is very satisfied with the new
solution: “The reliability and robustness of the lower-level
system for recording and processing measurement values
with the 7KM PAC3200 multifunctional measuring devices
enables us to comprehensively record consumption.” Photos:SpennerZement
30. 30 process news | 2-2012
essnews www.siemens.com/processnews www
www.siemens.com/processnews www.siemens
emens.com/processnews www.siemens.com/p
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emens.com/processnews www.siemens.com/p
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emens.com/processnews www.siemens.com/p
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W e b E x c l u s i v e
New in Process Automation
Finding the Pattern
The ability to obtain process knowledge and understanding
supported by dedicated tools and methods facilitates the
development of process innovations and technologies. With
PCS 7 LAB Collection and Sipat, Siemens supports research
and development as well as process optimization and
development. The tools facilitate information acquisition and
help to detect and understand variations in the product
quality during the development and manufacturing process.
As an output of this advanced information management
online changes like adaptations of parameter settings can be
implemented in real time, for example, by using the by
default available Advanced Process Control (APC)
methods. p
Read the full story online:
www.siemens.com/processnews
New in Chemicals
Pure Automation
The world‘s largest lactic acid factory, operated by Purac,
was equipped with a Simatic PCS 7 control system by
Siemens system integrator ZI Argus and Siemens
Thailand. In the meantime, another plant for lactide was
also automated with Simatic PCS 7 and more projects are
being discussed. p
Read the full story online:
www.siemens.com/processnews
New in Engineering&Services
More than just SIL
“Functional safety” has been equated with the use of
IEC-conforming hardware and software. However, what
is really key to safer plants is introducing a safety culture
into the operation, which is described by the corre-
sponding standards. A challenging task that can be
made easier with dedicated services from Siemens. p
Read the full story online:
www.siemens.com/processnews
32. Answers for industry.
ACHEMA 2012
Guiding you through change
Join us for a journey through your plant lifecycle
At ACHEMA 2012, Siemens will present
its comprehensive portfolio of products,
systems, solutions, and services covering
the entire lifecycle: from research and
development, process development,
plant design, production, and mainte-
nance to optimization and
modernization.
Experience how we will leverage our
expertise and capabilities to be a reliable
partner in the changing process industry
landscape and contribute to increasing
productivity and efficiency.
Explore how Siemens can help guide you
through challenges occurring today and
in the future in the chemical and pharma-
ceutical industry.
ACHEMA 2012, Frankfurt am Main,
Germany
from June 18 to 22, 2012
Visit us in Hall 11.0, booth C3
More information:
siemens.com/achema
Siemens at
ACHEMA on
your
Smartphone:
scan the code!
