totally integrated - Siemens Industry, Inc.

Flexible, comprehensive and customized.
Automation solutions
for the Chemical Industry.
totally integrated

Your competent partner in
automation
Siemens – a name recognized all over the world. A name
that stands for innovation, customer orientation and a
global competitiveness. Not only for 400,000 employees
and millions of customers, but also for hundreds of thousands
of suppliers and partners in more than 190 countries.
Chemicals are part of the fabric of life – from the ingredients
in our shower gels and the shoes on our feet, to the colors
that surround us and the electronic devices that make life
so convenient. Chemicals help to make our world a safer,
more comfortable, more pleasant place to live.
It also stands for a unique range of products, systems and
solutions.
Siemens also embodies the timeless vision of its founder,
Werner von Siemens: “Progress serving mankind”.
With more than 50,000 employees in 70 countries, Siemens
Automation and Drives (A&D) is one of the largest groups
within Siemens AG. As a technology and market leader in
automation and drives technology, we are continually
making rapid advances in this field – and setting new
standards again and again.
Siemens A&D offers a unique, complete range of innovative
products, systems and solutions. Totally Integrated Automation
(TIA) and Totally Integrated Power (TIP) form the
backbone of our portfolio – and the basis for customerspecific
solutions in the field of automation and energy
distribution.
2

Industry Suite Chemicals –
the customized solution for you
In the Industry Suite Chemicals, the worlds of automation
and power engineering merge into one comprehensive and
modular offer for your needs – including the required services
across the entire life-cycle of your plant.
Industry Suit
Totally Integrated Automation
Optimization of the complete workflow
With Totally Integrated Automation, Siemens
is the only supplier of an integrated range
of products and systems for automation of
chemical plants – from the field level and
production control level to the enterprise
level. Your benefit: considerably lower lifecycle
costs for the plant, shorter time-tomarket
and consequent improvement of your
competitiveness.
Process know-how
On the basis of our comprehensive industry know-how, we
implement solutions that guarantee optimum fit and maximum
process transparency for your plant – while requiring
a minimum of manpower.
Tailor-made energy concepts
With our solutions in the field of energy supply, we make a
decisive contribution to the smooth, economical and environmentally
friendly operation of your plant.
Process optimization by means of MES solutions
Our MES solutions are essential to enable you to optimize
your processes throughout the plant. They ensure integrated
data transfer – vertically from the field to the enterprise level
and horizontally from your suppliers to your customers.
3

industry
Basis of the Industry Suite Chemicals: Totally Integrated
Automation and Totally Integrated Power – plus our
comprehensive know-how in your industry.
e Chemicals
Totally Integrated Power
Power management and distribution
from a single source
On the basis of Totally Integrated Power (TIP),
we implement integrated solutions for power
distribution across all chemical production
units and industrial buildings, from the medium-voltage
supply to the outlet. Equipped
with the same communication standards as
Totally Integrated Automation, all resources
– for automation, power distribution, energy
management and building automation – can
be seamlessly integrated and comprehensive
solutions can be implemented in your plant.
Drive solutions
Innovative technology, precisely coordinated components
and comprehensive engineering know-how are your
guaranty that our drive solutions will meet even your highest
requirements – in terms of performance, torque, dynamics,
availability, diagnostics capability and cost effectiveness.
Life-cycle services
Our comprehensive range of services is an efficient lever
ensuring continuous optimum performance of your plants.
With our solutions we cover the entire life-cycle of your
plants – from planning and implementation to modernization
and maintenance.
System integration
In addition to our own established competence and expertise
in the field of system integration we work closely together
with Siemens Solution Partners. The result: a global network
of automation professionals that you can use to your advantage.
Throughout the world, the quality seal of Siemens
Solution Partners has long been a guarantee for world-class
services.

Content
Your Partner in Automation .............................. 2
Industry Suite Chemicals .................................. 3
Totally Integrated Automation .......................... 4
Process Competence ......................................... 6
Process Control System..................................... 8
Manufacturing Execution System ..................... 13
Field Devices .................................................... 14
Industrial Communication ................................ 16
Drive Systems .................................................. 18
Process Instruments and Analytics ................... 20
Industrial Controls ............................................ 22
References ....................................................... 24

Improve your competitiveness
in your industry.
With Totally Integrated Automation
With Totally Integrated Automation (TIA), Siemens offers a unique,
integrated portfolio of products and systems for the implementation of
automation solutions. TIA fulfills your objectives with Siemens technology
and products providing an impressive and unique level of integration.
This not only reduces the cost of interfaces, but also ensures maximum
transparency across all levels – from field, through the production level
to the corporate management level. For all processes in the Chemical
Industry from bulk chemicals, specialty chemicals to consumer products.
It goes without saying that you benefit with TIA throughout the life-cycle
of your plant – from the product design phase, through the operation to
the modernization. With a high level of consistency and integration of
our products and systems, we provide you a high security of investment
– avoiding unnecessary interfaces in the system.
On the basis of Totally Integrated Automation,
we implement solutions that are perfectly
tailored to your special requirements in the
Chemical Industry and which are characterized
by their excellent integration. In this way,
TIA makes an essential contribution to the
optimization of your production processes.
ERP
Enterprise
Resource
Planning
Ethernet
Totally Integrated
Automation
MES
Manufacturing
Execution
Systems
Ethernet
Production
Order
Management
Production
Operations
Recording
Material
Management
Equipment
Management
SIMATIC IT Framework
Production Modeler
Plant
Information
Management
Detailed
Production
Scheduling
Control
SIMATIC NET
Industrial
Communication
SINAUT Telecontrol
System
SIMATIC
Software
SIMATIC Controllers/
Automation System
PROFINET
SIMATIC
Sensors
SENTRON
Circuit Breakers
SIMATIC PCS 7
Process Control System
Industrial
Ethernet
Safety Integrated
PROFIBUS
PC-based Automation
Field Instrumentation/
Analytics
AS-Interface
KNX/EIB
Building
Technology
HART
GAMMA instabus
Micro Automation and
Actuator-Sensor Interface Level
ECOFAST IP65
Distributed
Automation System
SIMOCODE pro
Motor Management
System
SIRIUS
Soft
Starter
SIMATIC
Distributed I / O
PROFIBUS PA
4

The answer to growing demands
Productivity, flexibility, safety and resource efficiency are the key to
economic success in the production processes of chemical plants. Only
companies that can successfully master these challenges can meet the
market demands for short delivery times, ensured quality and prices that
are always in line with the market.
You know the factors required to achieve higher productivity in chemical
plants: a maximum degree of automation, consistent quality – and, last
but not least, the highest possible availability.
Thanks to the system-oriented engineering
environment as well as the integrated communication
and diagnostics options of TIA,
your plant will benefit in every phase of the
life-cycle. What is more, the consistency in
ongoing product innovation offers you
maximum security of investment in case of
modernization.
Product Specification
Management System
Advantages for plant operation
The Siemens range of products and solutions is specifically tailored to
your requirements. Top priority is placed on integration and openness –
in all key areas from automation to drives right up to process instrumentation.
These solutions are based on proven industrial standards and are
optimized to achieve the highest possible degree of economic efficiency
throughout the entire life-cycle of a plant.
Advantages for system integration
Growing pressure on the production side, ever shorter product life-cycles,
rising production demands and an ever greater complexity. On the one
hand, the end customer demands for you as a system integrator are
immense. On the other hand you require solutions, which let you execute
and engineer your customer projects more quickly, precisely and economically
– from the design to commissioning.
Totally Integrated Automation is the foundation for:
shorter time-to-market from the planning to the delivery
higher system availability and flexibility
improved quality of engineering
shorter and easier engineering and commissioning
cost savings in projects
Laboratory Information
Management System
Advantages for the EPC
As an EPC, you must respond to a continuously rising competitive pressure.
At the same time, more is being expected of your solutions all the time
and the demands that you must meet are becoming increasingly complex.
SIMATIC HMI
Human Machine
Interface
SIMOTION
Motion Control
System
SINUMERIK
Computer
Numeric Control
Totally Integrated Automation is the foundation for:
standardized interfaces between E&I engineering packages
highest availability of plant equipment
lower design and engineering costs
faster project execution
higher productivity and flexibility
Drive Systems/
SINAMICS
SINAMICS
SIMODRIVE
SINAMICS
5

Competence for the processes in the Chemical Industry
To ensure economic success in the chemicals business, you
need top productivity, highest flexibility, maximum safety
and the efficient use of resources in all your production
processes. This is the only way to meet the demands for fast
delivery, high and constant quality, and competitive prices.
Typical process units in chemical plants
Reaction
The reaction process is at the heart of chemicals production,
and the greater the efficiency and performance of the catalyst,
the better the product yield and quality. To ensure the best
possible results, key process parameters such as temperature,
pressure and flow must be controlled with great precision.
Heat Exchange
When process media are being warmed or cooled, it’s crucial
for heat exchangers to quickly and precisely reach the right
temperature. At the same time, of course, it’s important to
prevent any contamination or unnecessary energy loss.
Extraction
Using the best possible extraction agents, together with
seamless integration of heat with downstream columns,
brings long-term cost savings in extraction while maximizing
product quality and minimizing environmental impact.
Distillation
Two key parameters determine the economic efficiency of
the distillation process: how much energy is used for vaporization
and condensation, and – as with heat-sensitive
substances, for example – whether environmental conditions
can be completely controlled.
Absorption
Successful, efficient absorption of gaseous product mixtures
depends on selecting the right absorbing agent and controlling
all process parameters. High process and product
quality can only be achieved when all factors are optimally
combined and coordinated.
6

Tailored to the demands of the Chemical Industry:
Siemens automation solution with SIMATIC PCS 7
SIMATIC® PCS 7 is the Siemens distributed control system
(DCS), based on TIA, using standard hardware and software
components and can easily be connected to the Manufacturing
Execution System level (MES).
SIMATIC PCS 7 benefits for the Chemical Industry:
One common engineering tool PCS 7-ES for the complete
process – saves engineering time
One common visualization of all data in all PCS 7 operator
stations with a standard alarm visualization – reduces
production downtimes
Field instrumentation, motors and drives are fully integrated
in TIA and PCS 7, relative to engineering, operation, maintenance
and diagnostics
Pre-configured function blocks and libraries, adapted to
different industry requirements, simplify configuration
High performance automation systems with SIMATIC
S7-400 controller on Ethernet up to 1 Gbps. At the field
bus level, PROFIBUS DP and PA is provided
Redundant controller and PROFIBUS communication for
high-availability processes keep the process running and
reduce production downtimes
Safety Integrated with the PROFIsafe profile on a single
PROFIBUS cable, using one controller and one engineering
tool. This saves time and the expense of additional
components
Standard and fail-safe remote I/O modules on PROFIBUS DP
ensure reliable data transmission and diagnostics.
SIMATIC ET 200M remote I/O modules provide a large
variety of digital and analog input and output channels.
8

Flexibility and scalability – from a small laboratory
system up to distributed client/server architectures
As a result of its modular and open architecture that is based
on selected hardware and software components from the
standard SIMATIC range, SIMATIC PCS 7 can be applied
effectively in small and large plants. It allows easy expansion
or system modification (online) to enable customers to meet
the changing production requirements of their facility.
SIMATIC PCS 7 is scalable from a small single system consisting
of approx. 160 measuring points (motors, valves, PID controllers),
such as might be used for a laboratory system or
a pilot plant, up to a distributed multi-user system with
client/server architecture and approx. 60,000 measuring
points, such as might be used for automation of a very large
production plant or for groups of connected facilities.
Depending on the plant’s requirements, the operator and
the planning engineer can
Select from various automation systems with graded
performance characteristics
Use distributed (remote) or central I/Os step-by-step
Layout an optimum architecture for the operator system:
from single-user standalone stations up to distributed
multi-user system
Select the engineering and runtime system software
according to the size of the system (scaled by process
objects)
Configure communication networks and determine network
components to support required levels of redundancy
and availability
Extend the functionality of the operator stations by
adding various hardware and software modules, e.g. using
SIMATIC BATCH or with a standalone, redundant archive
server
Integrate applications connecting SIMATIC PCS 7 to legacy
systems and the IT system.
Stand-alone systems
Production facilities
Various plants of a production site
Scalable from small applications
(~160 process objects) …
… to the distributed system in client/server
(~ 60,000 process objects)
9

SIMATIC PCS 7:
the distributed control system in Totally Integrated Automation
Open DCS for the future
SIMATIC PCS 7 is based on modular SIMATIC hardware and
software components. The innovative process control system
is fully harmonized with TIA. It is flexible, expandable and
open for future enhancements through the use of standard
interfaces with long-term stability.
SIMATIC PCS 7 consistently applies state-of-the-art, powerful
technologies together with internationally established
industrial standards such as IEC, XML, PROFIBUS, Ethernet,
TCP/IP, OPC, ISA S88 and ISA S95, to mention just a few.
The openness of SIMATIC PCS 7 covers all levels and applies
equally to automation systems, process I/Os and field devices
as to operator and engineering systems, industrial communication
networks or the SIMATIC IT framework. Furthermore,
the system offers completely integrated function blocks for
motors, valves and control devices.
Common and integrated system
SIMATIC PCS 7 can be used on its own or in combination
with Motion Control and further SIMATIC components.
High performance, flexibility and ease-of-use, together with
common data management, communication and configuration,
guarantee that the typical demands placed on a process
control system can be met and exceeded by SIMATIC PCS 7:
Simple and safe process control
Intuitive operation and visualization
Powerful system engineering tools with a common interface
simplify the engineering and save money throughout
the entire plant life-cycle
Online modifications possible throughout the system
System openness at all levels makes plant enhancements
easy
Redundancy at all levels makes high availability scalable
to your needs
Flexibility and scalability simplifies plant improvements
Automation solutions avoid any injury to humans and
damage to equipment and provide high process availability
at the same time
Comprehensive fieldbus integration makes the connection
of field devices easy and optimizes the handling
Direct interfacing to the IT system opens the DCS.
10

Maximum plant availability, with overall
redundancy through all levels
Availability is one of the most important criteria in a chemical
production, and consequently the availability of the automation
solution itself plays a key role in the economical effectiveness
of the plant. On the one hand the capital investment
for a chemical plant is extremely high, and on the other
hand, any production loss due to shut-down and start-up
operations can imply huge economical loss. Plant shut downs
must then be avoided as far as possible – with periods usually
reaching from once a year to less than one shut-down every
5 years for example for a steam cracker.
To guarantee the highest availability of the automation
system, all system facettes have to be taken into consideration:
starting from the controllers up to the operator level
and including the whole plant communication networks,
from the field to the production control level.
optionally with
redundant
power supply
Redundant OS clients and
SIMATIC BATCH clients
OS-LAN (Ethernet) segment 1 OS-LAN (Ethernet) segment 2
OS server
BATCH server
Double redundant Industrial Ethernet plant bus
S7-400H
high-availability automation system
ET 200M
ET 200M
BATCH server
Actuator/Sensor
Depending on each of your specific requirements, environmental
and vulnerability aspects of your plant, TIA and
SIMATIC PCS 7 can provide you the best adequate redundancy
configuration. Based on a flexible, comprehensive concept
we can offer up to the highest availability levels, seamlessly
integrating all plant levels, from the sensor/actuator to the
control room – while responding to the harshest Chemical
Industry environment conditions.
Operator stations (OS) and batch clients
Operator station bus level (terminal bus):
• Use of standard off-the-shelf components (switches,
cards etc.)
• Increased availability, with single ring architecture or
terminal bus split into several LAN segments
Multi-monitor operator stations, up to 4 monitors per
client
Batch client/server architecture, permitting up to
32 OS/SIMATIC BATCH clients to access the data of a
single OS/Batch server.
OS- and batch servers
Redundant OS server, with automatic and transparent
switch-over of the OS client stations, between primary
and backup server
Redundant batch server
Process data can be archived on each OS server or can be
stored on a standalone, and optionally redundant, plantwide
historian
Critical OS/SIMATIC BATCH running as a background task
on the server are continuously monitored for faults that
would result in a client switchover
Process data and alarm messaging archives can be automatically
synchronized when a partner server is returned
to service, thus eliminating data gaps.
Redundant PROFIBUS DP
Redundant
DP/PA Link
ET 200M
fail-safe
PROFIBUS PA
Y-Link
Connection of
non-redundant
PROFIBUS DP devices
on redundant
PROFIBUS DP
11

Automation system and plant bus
Dedicated Ethernet LANs for client-server and server-server
communication
Communication between automation systems, engineering
stations, operator systems over Industrial Ethernet plant
bus, at up to 1 Gpbs; both line or ring topology possible
Increased availability with redundant ring architecture
Redundant, high-availability S7-400H automation systems,
connected to plant bus over dedicated Ethernet communications
processor (CP)
Optionally, for even higher level of redundancy, each of
the 2 automation station CPUs can be connected via two
separated CPs, thus each CPU to be connected simultaneously
to both networks of redundant plant bus architecture.
Redundancy at the distributed I/O level
Multiple PROFIBUS DP segments can either be connected
to distributed I/Os via the onboard PROFIBUS DP interfaces,
or using additional PROFIBUS communications processor
modules
Using the ET 200M distributed I/O system, redundancy can
be extended down to the I/O module level, whereby a
single sensor/actuator can be connected to redundant I/O
modules
Using redundant controllers, each ET 200M unit is connected
to the redundant PROFIBUS DP segments.
Redundancy of field devices
Intelligent field devices on PROFIBUS PA fieldbus segment
can be connected via a redundant DP/PA link
Non-redundant PROFIBUS DP devices can also be connected
to a redundant PROFIBUS DP network segment, using our
Y-link.
Asset Management for systematic automation and
maintenance of plants
Siemens offers an efficient solution for plant maintenance:
SIMATIC PCS 7 Asset Management. The particular highlight
here is that the new feature is simply integrated into the
SIMATIC PCS 7 process control system. No additional hardware
or software tools are required. Plant operators and maintenance
engineers use the same SIMATIC PCS 7 tools and
operator interfaces with information that has been filtered
and prepared for the relevant application area.
Complete integration of field devices
SIMATIC PCS 7 is optimized for integration of distributed field
equipment into the process control systems, and is based
on PROFIBUS technology. It supports redundancy and failsafe
architectures, in addition to online expansions, and can
be used in standard environments or in hazardous areas.
The plant can be equipped with conventional SIMATIC ET 200
distributed I/Os, or with state-of-the-art, intelligent field
devices.
12

SIMATIC IT: the basis for increased productivity
Maintaining a highly flexible and efficient production process
allows chemical manufacturers to maintain market position
and deal with competition. SIMATIC IT is the Manufacturing
Execution System from Siemens. It enables chemical manufacturers
to optimize production. This is possible by bridging
the gap between business systems and the control level and
by synchronizing operations all along the production and
product life-cycle. SIMATIC IT offers integrated quality assurance,
product specification management, tracking and tracing
and comes with functionality specifically tailored to the
needs of the Chemical Industry, complying ISA-95 standard.
MES – Manufacturing Execution System SIMATIC IT
SIMATIC IT links the plant floor with the business systems
and increases plant visibility. Due to its modular, object
oriented, open and scaleable architecture, SIMATIC IT enables
customers to standardize repeatable processes at the production
level while increasing flexibility at the operational
level.
SIMATIC IT Production Suite is composed of the SIMATIC
IT Framework and SIMATIC IT Components. These components
include MES functionality for order management,
material management, personnel management, report management
and messaging. SIMATIC IT Framework provides
the graphical environment to model the production process,
allowing for a clear understanding of the plant’s behavior
and visualization of the production.
SIMATIC IT Unilab is the Laboratory Information Management
System that models and manages the complete workflow
of all quality data in the laboratory and on the production
line, optimizing the collection, analysis, retrieval and reporting
of laboratory data. SIMATIC IT Unilab is able to manage all
types of analysis in a lot of languages and helps organizations
to deal with critical issues in communication between the
laboratory and customer service, by making it easier to share
information with internal as well as external customers.
SIMATIC IT Unilab complies with regulatory rules such as FDA
(cGMP, GLP, 21 CFR 11), GALP, GAMP4, ISO 9000:2000, and
ISO17025.
SIMATIC IT Historian is a collection of software modules
to collect, store and quickly retrieve process and production
information for Quality Assurance, Reporting, Certifications,
Statistical Analysis, Performance Monitoring, Down Time
Management, Overall Equipment Effectiveness (OEE) etc.
SIMATIC IT Historian delivers business information for decisionmaking
and plant optimization and complies with the FDA’s
21 CFR 11. SIMATIC IT Historian is part of SIMATIC IT or can
be implemented separately.
SIMATIC IT Interspec is the specification management
system that handles product specifications for raw materials,
semi-finished and finished products, as well as packaging
materials. This incorporates company-wide specifications as
well as individual specifications for a single plant, supplier
or customer. SIMATIC IT Interspec can be implemented
separately or as integrated part of SIMATIC IT.
SIMATIC IT Report Manager is an optional component of
SIMATIC IT and offers advanced, fully integrated and userfriendly
reporting functionality. The Report Manager meets
regulatory requirements for standard and ad hoc reporting
(for example, the upcoming REACH and Global Hazard Classification
System) and offers valuable operational insights.
13

SIMATIC S7: the comprehensive range of controllers –
highly reliable and powerful
SIMATIC S7 controllers provide network communication,
IT service functionality etc. with the help of highly efficient
operation processing, flexible communication extension and
reliable, powerful control capabilities. That is why SIMATIC
S7 controllers have the highest global market share.
SIMATIC S7 controllers can be installed and operated in
different environmental conditions, such as dry tropical, low
temperature, humid tropical etc.
Our controllers meet the following standards: DIN, EN, IEC,
UL certification, CSA certification, Class FM1 Sec.2; group A,
B, C, D, temperature group T4 (°

SIMATIC ET 200:
decentralized field devices for all requirements
SIMATIC ET 200 distributed I/O modules can all be connected
to PROFIBUS DP, some of them like ET 200S can even be
connected to PROFINET. They are used to connect various
field devices to the industrial control system, e.g. switches,
sensors, transducers, pushbuttons, panel lights, valve positioners
etc.
SIMATIC ET 200 offers a complete product range for any
application needs – ET 200M with multi channel design,
ET 200S for bit granular I/Os and function modules, ET 200iSP
for intrinsically safe applications, ET 200pro for high protection
in IP65 and ET 200eco in a cost-effective design with IP65
protection.
Advantages
Powerful functional modules – internally integrated standard
and safety motor starter module, frequency converter module,
pneumatic system modules, standard and safety I/O modules,
local intelligent and technological modules and safety technology
modules. Hot swapping means fast replacement of
I/O modules or motor starters during operation in order to
keep production downtimes and maintenance work at a
minimum.
Powerful system diagnoses, offering three levels of diagnoses
for the interface module and bus communication. This means
that faults are immediately detected and can be solved easily,
resulting in lower service and maintenance costs.
Distribution with SIMATIC ET 200iSP in hazardous areas
In most companies, time and cost pressures belong to everyday
life. Increasingly shorter production times and reduced
costs are requested in all operational areas. In order to
manage these demands, many users in the process and
production industries apply distributed solutions, with remote
I/O devices allowing sensors and actuators to be connected
to a bus system in a cost efficient way.
Cabling costs and the number of standard terminal blocks,
junction boxes, IS barriers, which are normally used, are
clearly reduced. PROFIBUS has become the standard fieldbus,
also extending into hazardous areas.
The SIMATIC ET 200iSP (iSP stands for intrinsically safe for
process industry) from Siemens is a modular, intrinsically
safe I/O system with IP30 degree of protection for hazardous
areas. It can be used both in gaseous and dusty atmospheres,
and offers many convincing advantages.
SIMATIC ET 200S motor starters: for simple parameterization,
diagnostics, and monitoring
The communication-capable motor starters of the distributed
I/O system ET 200S offer integrated safety and diagnostic
functions in one device. The motor-starter is a pre-wired and
remote-parameterized unit consisting of a circuit breaker,
an electronic overload relay and a contactor or soft starter
which switch the motors up to 7.5 kW. By means of PROFIBUS,
the motor starter reports diagnoses, for example short-circuit,
phase asymmetry, operating current or overload, to the
control system. This helps to reduce downtime costs by a
quick and detailed diagnosis.
15

SIMATIC NET:
industrial communication for plantwide automation
The business drivers in industrial communication are improved
efficiency and safe data transfer in the plant. These
criteria are crucial to ensuring that process in your plant
works perfectly. This can be achieved by using open, transparent
communication not just on the process level, but
also through ERP systems.
The SIMATIC NET industrial communication products provide
the technology you need to:
Realize true distributed automation
Enable data transparency from the field level through to
the management level
Integrate IT technologies.
Industrial Ethernet: today’s leading local area
and cell network
Across all applications, Ethernet is number one worldwide
in today’s LAN landscape. Ethernet provides important
features and performance characteristics which can provide
many important benefits for your application:
Virtually unlimited communication capabilities and
scalable performance
Company-wide communication thanks to Wide Area
Network (WAN) technologies.
SIMATIC NET provides important additions to traditional
Ethernet technology for use in industrial environments:
Network components designed for use in rugged industrial
environments
High-availability networks using redundancy
Constant monitoring and diagnostics of network
components
Fast on-site industrial cable assembly.
SIMATIC NET communications processors:
connecting controllers, computers and notebooks to
Industrial Ethernet
Utilize Industrial Ethernet for programming, monitoring,
peer-to-peer communication, connection to IT
Ability to function as Web and FTP server and client for
communication of production information
OPC server included with the communications
processor.
SCALANCE W: industrial mobile communication
Install a plant-wide Ethernet network without running any
wires
Wireless flexibility with the reliability of a wired network
Eliminate wireless “dead zones” with active antenna
diversity – the strongest signal is constantly used
Deterministic data transmission allows time-critical
connections to be realized
Industrial WLAN adheres to the specifications defined in
IEEE 802.11 and Wi-Fi 802.11 in order to enable a high
degree of interoperability
Security wizard enables Wi-Fi Protected Access (WPA)
with encryption for maximum security
Designed for industrial applications with enhanced
resistance to vibration, shock, and environment (IP65,
temperatures from –20 to +60 degrees Celsius) with
options for redundant power supply.
SCALANCE X: switches for Industrial Ethernet
This product family provides a graduated portfolio of industrial
switches, some of which feature comprehensive diagnostic
functions via PROFINET, SNMP and the Web, for a
variety of requirements (e.g. network structure, data rate,
degree of protection, number of ports). These network
components are optimally tuned to one another. They have
been designed for a rough industrial environment and
facilitate consistent, flexible and safe structuring of highperformance
networks.
16

PROFIBUS: the world’s leading field bus
PROFIBUS network technology provides rich benefits for
almost any application in industrial automation. Devices
such as remote I/Os, drives, controllers, identification systems,
motor starters, weighing & dosing systems, human
machine interfaces etc. are connected via a single cable.
PROFIBUS is primarily used at the field level with interfacing
capabilities downward to the sensor/actuator level as well
as upwards to the production and enterprise levels.
SIMATIC communications processors:
connecting controllers to PROFIBUS
Utilize PROFIBUS for connecting distributed devices,
peer-to-peer communication, and programming
Independent communications coprocessor ensures
consistent scanning of distributed devices regardless
of controller scan
Multiple communication processors can be used to
segment distributed devices
Support for redundant I/Os in conjunction with
redundant controller
OPC server included with the communications
processor.
AS-Interface:
communication for sensors and actuators
Sensors and actuators play an important role in automated
processes. Whether it concerns the detection of valve states
or the correct level in a reactor or tank: sensors are the eyes
and ears of process control.
For a long time the cabling of transmitters and recorders
followed the old pattern: each sensor or actuator was
connected individually and with parallel wiring to the higherlevel
controller. Because the AS-Interface now provides you
with a bus system that implements the connection of all
automation nodes in the field to the higher-level controller
– simply, securely and cost-effectively. The AS-Interface
transmits process-level digital and analog signals and
connects proximity switches, valves, indicator lights and
other actuators and sensors to the higher-level controller.
17

Drive systems: reliable, precise and efficient
In many applications in the Chemical Industry, the use of
frequency drives to regulate motor speed makes drive
technology more efficient. Variable speed allows much
more precise control of processes, such as the transport
and dosing of products, and at shorter response times than
do mechanical control concepts. In addition, soft starting
and deceleration in the variable-speed mode goes easy on
the entire drive train’s mechanical components. This prevents,
for example, pressure waves in pipeline systems.
Unfavorable operating conditions, such as cavitation, parallel
transport of gas or solids, ultrasonic compression shocks
and vibration can be avoided by using a frequency converter.
Savings potential
Variable-speed mode also saves a very significant amount
of energy, particularly in applications involving quadratic
load torque, like fans, pumps and compressors, as compared
to fixed-speed motors. Depending on the plant characteristic,
energy savings may reach 50%. Because of this, a frequency
drive soon pays for itself, often within only a few months.
For the most part, variable-speed drive tasks in the Chemical
Industry are covered by MICROMASTER 440 frequency drives
and SINAMICS G150 frequency drives.
SINAMICS: the new drive family
All members of the new SINAMICS drive generation profit
from the same core technology and have the same ”look
& feel“. An example are the standard engineering tools –
SIZER to engineer drives and STARTER to commission them.
In addition, all high power cabinet units of SINAMICS are
equipped with an AOP 30 operator panel with its selfexplanatory
menu prompts, which are output in plain text
via the user-friendly graphic display. This permits extremely
simple operator control and diagnostics. For the Chemical
Industry with its pumps, fans, mixers and extruders, the
SINAMICS G150 cabinet units and the SINAMICS G130
chassis units are the primary choices for consideration.
MICROMASTER 440 frequency drives: packed with
functionality for a wide range of applications
Whether it involves mixing drives in conjunction with offset
shaft geared motors, agitators in hazardous areas, extruders
requiring a high starting torque or, for example, foil processing
machines where several drives run in synchronized
operation – our MICROMASTER 440 frequency drive is the
best selection where maximum functionality and higher
dynamic performance is demanded. Typical applications:
Transportation of fluids or gases and solid substances,
metering and mixing, filtering, extruding, lifting.
18

Specially for pumps, fans, compressors, mixers
and extruders
The units are specially geared toward drive tasks without
regenerative feedback in applications with quadratic torque
characteristics, such as pumps, fans and compressors, but
also constant-torque drives such as extruders, mixers, mills
and conveyor belts.
SINAMICS G150 cabinet units cover voltage classes from
380 V to 690 V. Power ranges are from 75 kW to 1500 kW.
The clear, well-structured design of the SINAMICS G150s
makes the units rugged and reliable. In case of service, the
modules can be replaced in just a few steps.
Simple and user-friendly
Above all, however, the units are appealing thanks to their
user-friendly operation. Preconfigured and thanks to the
clear operating concept, customers take profit from
functionalities that they really need. The easy-to-use
operator and commissioning functions are shown on the
graphic display in plain text. In addition, SINAMICS G150
cabinet units have a footprint that is up to 70 percent
smaller than the footprint of conventional converters. Noise
levels of only 69 db(A) during full operation, even in the
case of cabinet units with a power output of several 100 kW,
make additional soundproofing measures unnecessary.
Demands of the Chemical Industry are fully satisfied
SINAMICS G150s fulfill all demands made by the Chemical
Industry. For example, the units are equipped with NAMUR
terminal blocks as well as NAMUR functionalities specifically
for the Chemical Industry. As alternative to NAMUR terminal
blocks, it is possible to use the PROFIBUS Profile PROFIdrive
3.1, ”Process Engineering“ mode. Safe electrical isolation
according to PELV is also ensured.
In order to restrict the steep voltage edges customary for
IGBT voltage source converters as well as phase-to-phase
voltage on the motor, dV/dt filters are available which limit
the voltage gradients. In addition, the phase-to-phase
voltage is also limited in the case of long motor wires. An
EMC filter for secondary environment category C3 to EN61
800-3 is integrated as standard. Sinusoidal filters are also
available for particularly high demands.
SINAMICS G150 covers the majority of drive tasks with high
power requirements. If required, the SINAMICS G130, a
chassis unit with the same functionality and performance,
is also available. SINAMICS S150 cabinet units and
SINAMICS S120 chassis units represent a viable alternative
when the energy supplier places particularly high demands
on the network quality or in the case of weak networks.
With these units, the active infeed technology reduces
phase effects on the system to a minimum and protects
the drive system against power dips. For drive tasks requiring
several megawatts – such as very big mixers or extruders –
SINAMICS GM150 medium-voltage frequency drives are
the most cost-effective solution.
19

Process instruments and analytics:
the full range for all measuring tasks
Siemens offers a broad product portfolio of process instruments
and analytics. All devices fulfill the needed certifications
in the Chemical Industry.
Process Instruments
Throughout the Chemical Industry, measurement requirements
can be extreme. Every substance is different and
needs an individual solution. As the measurements are
often done in extremely harsh ambient conditions, specialized
process instruments (e.g. pressurized enclosures) are
often required for the relevant approvals (ATEX, FM, SIL,
WHG etc.)
Siemens process instruments offer advantages on the
automation level as well as for the asset management of
your plant.
Level
Continuous measuring or point level detection is based on
radar, ultrasonic or capacitive methods. From a storage
tank to stirring machines with high pressure, foam and
steam – with the product family SITRANS L and POINTEK,
we can fulfill the most common challenges in the level
measuring technology.
Flow
Especially in the Chemical Industry, the tasks in measuring
the flow are versatile, just as our products are.
Magnetic-inductive and ultrasonic flowmeters or Coriolis
flowmeters are used for this. “Classical” mechanical methods
are also available: Rotary piston meters, variable-area
flowmeters, or measuring orifices remain an integral part
of our product family SITRANS F.
Temperature
Whether high temperatures, high pressures, or aggressive
media, temperature measurement applications are not
always easy and are often done in harsh ambient conditions.
Our SITRANS T transmitters are available in different types,
from simple to intrinsically-safe with diagnostics and simulation
options.
Pressure
Whether relative, differential or absolute pressure, the
SITRANS P pressure transmitters provide precise pressure
measurements. The SITRANS P DS III instrument is ideal
where highly aggressive media and harsh ambient conditions
require experienced solutions and can be used for
safety-related measuring points in accordance with SIL 2.
Weighing
The SIWAREX weighing systems can easily be integrated
into the automation structure of the process, and the
SIMATIC PCS 7 process control system. In addition to electronic
weighing systems and cells, you can select from an
extensive range of Siemens-Milltronics belt scales, weigh
feeders and solids flowmeters.
Diagnostics
Reducing production downtimes is an increasing challenge
for a plant operator. Easy and versatile diagnostic functions
help to achieve these requirements.
To parameterize these functions, you can use our Process
Device Manager (PDM) software tool, usable for all field
devices. It facilitates the manufacturer-independent operation,
adjustment, maintenance and diagnostics of intelligent
process devices. Regardless of the automation system, it
can be applied via PC, or programming devices, or integrated
into the SIMATIC PCS 7 automation system.
With our SIPART PS2 valve positioner e.g., which is the most
frequently used intelligent positioner for linear and rotary
actuators, leakages at valve drives can be detected immediately.
A created warning message helps the maintenance
team to keep the process in optimized run.
20

Analytics
The capabilities of modern process analytics can be the key
to a significant increase in efficiency, productivity, or safety
of chemical processes.
Continuous process analytics
The continuous gas analyzer of the Siemens series 6,
ULTRAMAT, OXYMAT, FIDAMAT, and CALOMAT, were originally
designed to fully meet the requirements for process analytics
in the Chemical Industry. Except for the FIDAMAT, based on
flame ionization detection, all analyzers are available in field
housings for operation in hazardous environments.
The intrinsic design of the analytical part of ULTARMAT and
OXYMAT and the materials in contact with the process gas
stream are chosen to withstand even highly corrosive gases.
Because the measuring system has no moving parts and
can be ordered in corrosion resistant materials like titanium
or tantalum the OXYMAT became the standard oxygen
analyzer in chlorine chemistry. Beside this, the excellent
analytical performance of the series 6 analysers make them
first choice in critical process applications in terms of
sensitivity and stability.
Optimized production of ethylene oxide
The efficiency of the ethylene oxide process increases with
the concentration of oxygen, while it is crucial to stay below
the lower explosion level (LEL). Due to its outstanding
stability, only the OXYMAT allows the process to be operated
at a set point of 5% O 2 , where competitive analyzers only
allow 4% O 2 . Thus, the process efficiency is increased by 1%.
21

Industrial controls and power distribution
More often the data of the motor feeders are also integrated
into the process control system. Intelligent motor management
systems, communication-capable motor starters and
circuit-breakers support this trend and make all relevant
data available via PROFIBUS. This increases the transparency
of your process and ensures a significantly greater density
of information in the control system – at no extra cost.
Standardized motor function blocks, for example, simplify
the integration and the engineering.
SIMOCODE pro: the flexible and modular motor
management system
SIRIUS motor management and control devices (SIMOCODE
pro) are the first choice for constant speed motors in the
low voltage range. SIMOCODE pro optimizes the connection
between control system and motor feeder, increases the
plant availability and achieves considerable savings in the
construction, commissioning, operation and maintenance
of your plant.
It also involves an extremely compact design, a straightforward
and efficient service and maintenance as well as a
range of graduated functions. In addition, SIMOCODE pro
meets all requirements for future-proof energy management
and offers advantages in all areas: in process management,
operations management or in switchboards.
Some extensive features:
Multifunctional, electronic full motor protection,
independent of the automation system
Flexible software instead of hardware for the motor
control
Detailed operating, service and diagnostics data
Open communication via PROFIBUS DP
Integration and monitoring of additional process values
Detection and monitoring of power-related measurements
ATEX-certified (overload protection of explosion-protected
motors).
SIVACON systems: for customized communication
solutions
SIVACON systems are low-voltage communication-capable
switchboards and busbar trunking systems with a high
degree of flexibility and availability. All of these features
provide a seamless integration into the automation environment.
Using switchgear and switching devices we offer a common
integrated communication concept for customized solutions:
e.g. with SENTRON circuit-breakers, SIMOCODE motor
management system and SIMATIC.
So SIMOCODE pro is likely to be used in SIVACON lowvoltage
Master Control Centers (MCC) and allows load
feeders to be configured. Load feeders that have a higher
performance and at the same time are extremely compact
and able to communicate.
The high degree of modularity allows all communication
components to be simply retrofitted. Innovative software
products offer user-friendly parameterization, diagnostics,
operator control and visualization locally via PROFIBUS DP
or Ethernet/Internet.
22

SENTRON: power distribution
With only a few modular components, you have the possibility
of thousands of different combinations for all of your
energy distribution applications. The products in the
SENTRON circuit protection system tie into your automation
architecture giving you the power to increase production
system availability. In addition, you can further optimize
the energy distribution process with a networked power
management solution. Never before have circuit-breakers
been so versatile and so simple.
SENTRON: optimized energy solutions
SENTRON circuit-breakers address your critical needs for
less installation space, reduced operating costs and optimized
energy usage for molded-case circuit-breaker 3 VL
from 16 A up to 1600 A and for air circuit-breaker 3 WL
from 630 A up to 6300 A. Web Server – Breaker Data Adapter
(BDA) is the first circuit-breaker communication device with
integrated web server to parameterize, operate and monitor
SENTRON circuit-breakers. Circuit-breaker data can be
accessed from any device supporting an Internet browser
with Java Virtual Machine. The BDA Plus incorporates an
Ethernet interface for direct connection to Ethernet / Intranet /
Internet. Switch ES Power, a configuration software, offers
complete integration into the automation engineering
environment.
The parameterization, operation and monitoring of the
SENTRON circuit-breakers can be done via the PROFIBUS DP
network. SENTRON circuit-breakers are completely integrated
into the SIMATIC world and the STEP7 engineering software.
Data management, configuration and programming is
integrated into the automation project SIMARIS manager
– Power Management Software to manage energy distribution
systems.
This modular and integrated power management software
is based on SENTRON switching devices and Totally Integrated
Automation. This not only facilitates efficient diagnosis,
alarm, and maintenance of SENTRON circuit protection
devices as part of a Totally Integrated Power solution but
also optimizes laboratory, investment and energy supply
costs through continuous analysis of energy data.
23

Best practice example:
INEOS Phenol production site in Gladbeck, Germany
INEOS Phenol is the world’s largest manufacturer of phenol
and acetone, with production sites in Gladbeck, Germany;
Antwerp, Belgium; and Mobile, Alabama, USA. In the course
of the company’s history, the Gladbeck site has experienced
significant development. The capacity of the plant at the
beginning of production in 1954 was a relatively modest
8,000 tons of phenol and 5,000 tons of acetone. Today,
Gladbeck is the largest phenol plant in the world, with an
annual capacity of 630,000 tons of phenol and 390,000
tons of acetone.
Customer requirements
When INEOS was looking for a partner to modernize the
existing process automation system for the entire factory,
the company first performed an extensive comparison of
various control system suppliers. SIMATIC PCS 7, though
facing strong competition, was able to establish itself as
the winner.
The INEOS order included replacement of all the installed
control technology on the entire site, with about 8,000
I/Os, and the merging of two control rooms. One decisive
factor for awarding the contract to Siemens, aside from the
previous positive experience INEOS had made with Siemens
in low-voltage projects, was the fact that PCS 7 offered a
modern, innovative, and efficient control solution that is
based on future oriented standards and Totally Integrated
Automation. The integrated safety technology and the high
system availability due to redundant solutions were also
decisive. In addition, PCS 7 offered the possibility of replacing
installed control technology during ongoing operation –
allowing the Gladbeck plant to continue to operate without
interruption.
Siemens solution
The new solution is based on a total of eight SIMATIC
S7-400FH automation systems. One redundant OS Server
and ten Clients plus one MultiClient as well as one
Engineering System were installed in the new control room
that resulted from merging the legacy system. The entire
plant was upgraded with no shutdown of production –
a very important aspect in high throughput continuous
processes such as phenol synthesis. The legacy systems
were changed over “loop by loop“, and the application
software of the legacy controllers was also converted.
Customer benefits
The conversion from the previous control solution to SIMATIC
PCS 7 went smoothly, without interrupting plant operation.
With SIMATIC PCS 7, INEOS now benefits from increased
safety and system availability through redundancy on all
levels, and integrated fail-safe technology.
24

Best practice example:
Jilin Fuel Ethanol Co. Ltd., China
Jilin Fuel Ethanol Co. Ltd., a subsidiary of China National
Petroleum Corporation (CNPC), is a joint venture formed
by CNPC, Jilin Grains Group (JGG) and China Resources
Group. This project was the first plant dedicated to the
production of fuel ethanol from corn in China with a capacity
of about 600,000 tons of ethanol per year. The plant consists
of two production lines and the capacity of a single line is
300,000 tons per year. The first production line was started
on September 22, 2001 and was launched on August 31,
2003. This ethanol fuel pilot plant in China has become a
prestige project for the Chinese government.
Customer requirements
This significance and the fact that the application is quite
large regarding the extension and the number of I/Os were
asking for a state-of-the-art automation solution. When
choosing the appropriate automation solution, high availability,
safety, and a future-oriented solution were central
criteria for Jilin Fuel, as was local expertise and know-how
for project engineering and maintenance.
Seamless integration of the safety technology, the great
openness of the system, an excellent price/performance
ratio of the concept, and last but not least the benefits of
the uniform automation solutions based on Totally Integrated
Automation tipped the balance in favor of automating the
plant using SIMATIC PCS 7.
Siemens solution
The entire system, which comprises a total of 9,000 I/O
points, is controlled from two PCS 7 control rooms. Eight
safe and fault-tolerant S7-400FH automation systems and
two fully redundant optical Industrial Ethernet rings form
the reliable backbone of the control system. The system
also collects and transfers all production and units data,
including the corn storage facilities and other utilities, to
a real-time production monitoring system. The devices at
the process level are connected to the PCS 7 systems via
PROFIBUS DP fieldbus, using the fiber-optic technology to
bridge distances of up to 1100 meters on the plant field.
Customer benefits
The production and process management has been optimized
and plant efficiency has been improved. Production
cost, such as materials cost and management cost, have
also been reduced.
The data management has become more transparent, with
the implementation of Manufacturing Information System
(MIS) and the web functionality at the operator-station
level. At the same time, the maintenance workload has
been reduced, due to the high stability and reliability of
the SIMATIC automation systems and components. At the
bottom line, product quality has been improved and now
meets one hundred percent of the market requirements.
25

Best practice example:
Bayer polycarbonate production facility in Map Ta Phut, Thailand
Global companies are increasingly relying on standardized
processes and systems – in order to exploit rationalization
potential for spare parts, training, and service across all
their locations. Bayer is no exception. The company-wide
specifications were recently implemented with the SIMATIC
PCS 7 process control system in the modernization of a
small batch line in Thailand.
Customer requirements
Bayer operates a polycarbonate production facility in Map
Ta Phut in Thailand that supplies base materials for a number
of applications. The company wished to equip a small-lot
compounding line that produces colored thermoplastics
resin with an automation system that was state of the art
and also complying with Bayer’s worldwide technology
standards. The aim was an integrated solution for the automation
of the entire production process – a task that was
completed through close cooperation between Bayer and
Siemens directly on-site in Thailand. The SIMATIC PCS 7
process control system provided the basis.
Siemens solution
SIMATIC PCS 7 and the Bayer toolkit control all processes
in the plant. The compounding line is one of the first in the
world to use the latest version 6.0 of PCS 7. SIMOCODE and
SIMOREG (DC Drives), linked to the control system by
PROFIBUS, were used as well. The feeders are also integrated
with the control system via a gateway.
The front end is a graphical user interface that is now being
used in all Bayer plants throughout the world. It is characterized
by a flowchart that displays the entire production
process so that the operating personnel have a complete
overview of the current production steps at all times. New
recipes can be created using a PC in the lab sector and then
simply up- or downloaded to the control system in the form
of Excel tables. After completion of a batch, all the production-related
data are returned for documentation, and can
also be displayed as an Excel table.
Customer benefits
The automation concept was implemented jointly with
local partners and uses standard routines developed by
Bayer and Siemens Thailand. The application is a typical
example of a company-wide strategy encountered today
in more and more globally active companies: exploiting
rationalization potential in production through the standardization
of processes and systems. With the company’s
unique combination of a local presence and global knowhow,
Siemens is able to optimally support this strategy.
26

Best practice example:
RohMax Additives production facility, Germany
RohMax Additives GmbH, a Degussa AG´s Company of the
Specialty Acrylics Group, develops and produces innovative
and customized additives for lubricants. With a wide product
portfolio of roughly 120 products RohMax belongs to the
high-yield companies on the specialty chemicals market.
Customer requirements
The production of additive is a complex multi-phase batchoriented
polymerization process – with numerous ingredients,
that have to be selected and batch recipes, that lead
to the highest requirements in the matter of batch planning,
batch control, recipe management and route control. Among
several goals of the production improvement, the plant
operational safety was also important. A further optimization
potential in this plant has been exploited in creating a direct
coupling between the production and business level. The
existing ERP-legacy system SAP, via the Production Planning
Module for process industries (PP-PI interface), is seamlessly
integrated into the management execution level with
SIMATIC IT, thus enabling the tightest synchronization
between production orders and the plant operation, and
avoid any wrong production orders.
Furthermore, the SIMATIC IT MES functions work perfectly
with SIMATIC PCS 7 batch flexible at the batch and control
levels. It provides the required extensive and flexible production
order and material and resource management as
well as the necessary archiving and reporting functions in
an efficient and user-friendly graphic environment.
Customer benefits
A higher plant availability was also a decisive factor – with
the high standardization level of using TIA components
throughout the whole plant, the stock of spare parts was
reduced. Maintenance times could also be reduced thanks
to the efficient diagnostic and error identification of the
system.
During and after this project, improvements could also be
reported at several levels of the plant life-cycle. For operators,
processes have been made easier to control and at the
same time, the production has become more flexible. At
the bottom line RohMax can now deliver products with
higher and more stable quality.
Siemens solution
Heart of the modernized plant are the SIMATIC PCS 7 process
control system and the innovative Manufacturing Execution
System (MES) based on SIMATIC IT. The openness, use of
standards and the scalability of this solution are securing
ability for quickly and economically adapting the additives
production with high flexibility to changing demand.
27

Further information:
www.siemens.com/chemical
www.siemens.com/totally-integrated-automation
Subject to change without prior notice 10/06 | Order No. E20001-A310-P200-X-7600 | Dispo 06303 | 41C9847 MK.GC.LT.YTIA.52.7.06 WS 10062. | Printed in Germany | © Siemens AG 2006
Siemens AG
Automation and Drives
www.siemens.com/automation
All product designations may be trademarks or product names of
Siemens AG or supplier companies whose use by third parties for
their own purposes could violate the rights of the owners.
The information provided in this brochure contains merely general
descriptions or characteristics of performance which in case of actual
use do not always apply as described or which may change as a result
of further development of the products. An obligation to provide the
respective characteristics shall only exist if expressly agreed in the
terms of contract.