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Digitalization across the lifecycle

From Integrated Engineering to Integrated Operations. Digitalization prepares the way for Integrated Engineering, Integrated Operations, and comprehensive plant management leading to Industry 4.0. Software tools and one common data base offer seamless planning, virtual commissioning and ensure efficiency during operation and maintenance.
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From Integrated Engineering to Integrated Operations

Achieving sustainable competitiveness

What if you could detect future outages at your plant today already? What if engineering and operational data could be used intelligently for your maintenance, and even plant performance could be centrally optimized at all sites? That would mean that you’d be enjoying the opportunities of progressive digitalization today already. Processes are becoming more transparent and productive thanks to the end-to-end integration of plant design and engineering for the commissioning, operation, and maintenance as well as the constant optimization of processes on the basis of one data platform. We can support you with Integrated Engineering and Integrated Operations solutions over the entire lifecycle of your plant.    

Plant design and engineering – reduced time to market

Shorter innovation cycles, reduced time to market and, above all, plant and project data terabytes all pose major challenges for plant designers and operators, even as early as the planning stage. Our COMOS software solution for plant lifecycle management consistently implements the complete integration of all processes – during both the engineering stage and the operation/maintenance stage. This close interconnection between the individual stages and the uniform data platform contribute significantly to increased plant availability and security. Thanks to the interplay between COMOS and our innovative SIMATIC PCS 7 process control system, you can benefit from a seamless integration of plant and automation engineering and a consistent bidirectional flow of data. At the touch of a button, the entire plant structure is generated in the control system from the engineering data and plant data is available in real-time.


COMOS

COMOS Modularized Engineering

SIMATIC PCS 7

Increased efficiency in commissioning and operation


Formerly, plant behavior was tested on prototypes. Today, software tools are increasingly used for simulations. A plant’s behavior can be simulated even before completion, and errors can be detected and resolved at an early stage. This opens up the possibility of virtual commissioning before the actual factory acceptance test. Putting plants or plant units into operation more quickly requires an optimized workflow on the engineering and automation side as well as the shortest possible setup, testing, and commissioning times. Our SIMIT simulation software enables real-time simulation and emulation, allowing for an extensive review of components and automation solutions. You can thus perform virtual commissioning simply and flexibly. In addition, SIMIT simulation software allows you to provide safe and efficient training in a virtual environment (Operator Training System). Staff can therefore be optimally familiarized with the plant before it’s even started up.

 

SIMIT simulation software

Download SIMIT brochure

Reliability in decision making with XHQ

The XHQ Operations Intelligence platform creates the foundation for continuous optimization. It visualizes operating processes at chemical plants in real-time. XHQ thus creates the basis for concrete and well-supported decisions and helps you to increase your performance and reduce operating costs by up to 8%, as well as to increase production by up to 10%.

 

XHQ software solution

Intelligent use of data

Over the entire lifecycle

The systematic monitoring of plant components directly prolongs their service life, prevents unscheduled downtimes, and thus significantly increases plant availability.
Efficient maintenance concepts with SIMATIC PCS 7 and COMOS MRO
Integrated system for diagnostic and optimized maintenance of a plant
High plant availability with Integrated Maintenance using common database

Asset Performance Management

Solutions such as SIMATIC PCS 7 and COMOS MRO (Maintenance, Repair & Overhaul) support you with efficient planning, implementation, and analysis of your maintenance activities – including the connection of portable devices for remote services, also in Ex zones. With COMOS MRO, all aspects of the management, planning, operation and maintenance, including plant documentation, are carried out in a single system. This means that any changes to the plant due to service and maintenance processes are also immediately available in the engineering system. And the Maintenance Station integrated into SIMATIC PCS 7 provides a complete status overview of all plant components, thus offering effective diagnostics, service, and maintenance of the plant. Then there’s the powerful COMOS Walkinside 3D visualization software, which realistically presents highly complex plant models based on 3D engineering data. Your benefits: maximum efficiency in planning and monitoring, operator training, and the forward-looking planning, simulation, and implementation of maintenance and servicing work.

Digital Services

Targeted use of data

Whether it’s the online monitoring of remote parts of a plant, predictive maintenance, energy data management, or resource planning – digital services are growing in importance. Fact-based decisions can be made based on data from the process, thereby increasing plant reliability and, thus, productivity.

Digital transformation in service

Making Digital Industry Services processes transparent and optimizing them while protecting your plants through security measures. Digital Industry Services supports you in improving your overall equipment effectiveness.

Plant Data Services

Discover how we can support you with Plant Data Services as part of our Industry Services Portfolio.

News and Events

What’s new in the digital world

Digital developments move at lightning speed. Follow current trends here.
References

More efficiency – thanks to perfectly tailored solutions

Whether our systems are implemented in new plants or introduced to current operations: Our solutions and services enable more efficient and more intelligent production throughout the world. Learn all about our comprehensive industry expertise and customized solutions in our references.
Kingdom Holdings Ltd.
China
Factory renovation and new digital factory

Kingdom's age of digital transformation

  • Building a new digital factory in Haiyan by creating a virtual factory for full-range simulation of the new facility, supported by manufacturing execution system (MES) and intensive training sessions.

  • The Siemens MES, fully compliant with ISA-95, is able to reduce costs of integration with the ERP and work with the product lifecycle management software teamcenter for more manufacturing flexibility.

  • Complete drive intelligence (SINAMICS S120), embedded in the control units, deployment of an energy management and monitoring system for annual savings of 20% in water and 10% in electricity. 

Stories Siemens China
Bentley and Siemens
Collaboration
Engineering Solution

New interface for the digital twin

  • Integration and linking of 2D and 3D information with COMOS and the Bentley tools

  • Integrated planning and maintenance of plant and engineering data throughout the entire lifecycle

  • The interface has laid the groundwork for creating a digital twin of process plants

Solvay/Butachimie
France
SIMIT

Factory of the future

  • The Solvay/Butachimie chemical factory in Chalampé, France, is one of the world’s largest facilities specializing in the manufacture of polyamide 6.6 and its intermediary products.

  • Investments in future-proofing their facilities resulted in the changeover of all production facilities to SIMATIC PCS 7.

  • To simplify the migration and further optimization, the real plants were tested before their actual commissioning – as a sort of “virtual twin” – using SIMIT simulation software.

INEOS Group AG
Germany

Engineering tool as efficiency lever

  • The Ineos Group AG, a group of global chemical companies, relies on a new planning system for computer-aided engineering (CAE) at its Cologne site.

  • With additional tools, it manages over 100,000 documented process control points.

  • Including safety equipment and over 3,500 piping and instrumentation diagrams.

Watch the video
Bayer MaterialScience (BMS)
Germany

Service model for any plant

  •  BMS manufactures polycarbonates, polyurethane and coatings, and adhesives and specialties.

  • Following a successful completion of a pilot project with clearly defined workflows for service processes, the service partnership between Siemens and Bayer is expected to be further expanded with other plants being reviewed step by step.

  • The results of the comprehensive service partnership and the requirements on the serviceability of control systems can be integrated into the development process.

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Whether you’re planning to optimize maintenance strategies or expand your plant, whether you want to improve performance or reduce operating costs – we’re here to support you.

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