Automation Summit - A Users Conference

Monday, June 17 - Thursday, June 20, 2019, Gaylord Rockies Resort & Convention Center Aurora, CO, USA

Ramesh Kommu and Ariel Vargas, Dow Chemical

 

In an effort to speed up the training process for newly qualified operators, a dynamic Operator Training System (OTS) has been developed. The OTS has been designed to simulate the entire running plant, allowing operators to “experience” the plant under a variety of conditions and run through simulated scenarios to teach the appropriate responses in safely correcting or containing an event. Thanks to SIMIT V9.1 with its new Virtual Controller (VC) and the Siemens SIMATIC Virtualization as a Service (SIVaaS) product line, we were able to achieve these objectives. Additionally, we incorporated the DuPont in-house TMODS modelling software to facilitate accurate process modelling. As a follow-up to last year’s hit presentation “Are We Virtually There Yet?,” we’ll explore our latest integration of the sophisticated reaction control modelling that will demonstrate the power of this system. The presentation will include a live demonstration. 

 

Ramesh Kommu works at the DuPont Sabine River Works site in Orange, Texas as an Automation & Process Control Consultant. He has about 28 years of experience in implementing process control systems, 18 of which are with Siemens PCS 7 systems. He was responsible for upgrading the PCS 7 installations in three DuPont Ethylene Copolymer Units to V8.0. Ramesh earned his BS in Electrical Engineering from Indian Institute of Technology in Madras, India.    

                                                                                                                      

Ariel Vargas-Colon works at the DuPont Sabine River Works site in Orange, Texas as an Automation & Process Control Engineer. He has 8 years of experience in Process Automation and Dynamic Simulation. He is responsible for the development of the TMODs plant model. Ariel earned his MS in Chemical Engineering from the University of Puerto Rico, Mayaguez Campus.

Ankur Rastogi, Kongsberg and Landon Melcher, SBM Offshore

 

A topsides facility’s high-fidelity process simulator developed using Kongsberg’s K-Spice software was integrated with Siemens PCS 7 controllers using SIMIT for a large offshore deep water oil and gas field development. The simulator presented operational information in a similar form to that in the actual facility, using the same WinCC OS application that will be used in the offshore control room. This system provided operational personnel with extensive operational experience and training in scenarios that they may face in the actual facility, prior to and after plant startup. This also proved to be an effective tool to perform control system checkout during the pre-commissioning stage, well before actual startup. Input and output points were connected one at a time to the dynamically running process using a custom OPC link between the process model and SIMIT. 

 

The process was shut down, inventories were zeroed and the process was then started up from cold shut-in conditions. This startup was, in essence, the first-time integrated commissioning of the entire process, control system and logic. Thus, a “virtual” debugging of the process was performed. The OTS gave operators a feel for the process dynamics, process control and safety system as well as familiarity with DCS graphics well before startup. Since actual operating procedures were used for training, personnel could test and update the operating procedures to match actual sequences, process response, etc., in advance of actual facility startup.

 

Learn how Kongsberg’s Process Simulation Software K-Spice and Siemens PCS 7 control systems were integrated using SIMIT. We will also review lessons learned throughout the course of the project.

 

Ankur Rastogi is Operations Manager Americas and Senior Technical Advisor at Kongsberg in Houston. He joined the company in 2007 as a senior process consultant and subsequently served as technical advisor before assuming his current position. Rastogi had previously served as a process consultant at Fantoft and a simulation engineer at Trident Computer Resources. He holds a BS in Chemical Engineering from the Indian Institute of Technology, Kanpur, and an MS in Chemical Engineering and an MBA from the University of Houston.

 

Landon Melcher is the ICSS and Functional Safety Technical Expert at SBM Offshore USA. He has worked in both operations and engineering to develop and improve the process controls and safety for SBM’s fleet and project execution. He is currently involved with the Digital FPSO initiative that aims to improve operations through making use of the large amounts of data already available by embracing the latest technologies available.

Anthony (Tony) Kennedy, DuPont

 

How do you know where in their lifecycle your valves are? Are you waiting on the valves in your plant to let you know they need maintenance? Can a valve failure cost your plant valuable production time? We have two plants that are approximately 10 years old; we have not had valve issues that we felt were a problem. But we all know a failure of any equipment can cause downtime that will hurt our production schedules.

 

Our solution was installing the Siemens Valve Monitoring App in our plants in October 2018. We use Siemens SIPART PS2 positioners on our control valves. The PS2 is a digital positioner that gathers data from the use of the valves. We had the ability to look at this information at the valve, but the Valve Monitoring App has brought this information into the control room as an application that allows for scheduling and prioritizes the work needed on the valves.

 

This presentation will focus on:

  • Key Performance Indicators (KPIs) that the app gathers from the positioners
  • The work process utilized for analyzing the data
  • Some sample findings from the initial use of the app

Anthony (Tony) Kennedy is a Process Controls Specialist with DuPont. He has over 20 years’ experience working in a chemical process as a Maintenance Electrical/Instrumentation Technician, DCS Technician and Process Controls Specialist. Tony has worked with installation, operation and maintenance of a Siemens PCS 7 project that controls two manufacturing plants. He is a North Carolina-licensed Electrical Contractor with an Associate’s Degree in Computer Information Technology.

Josh Dickson, Tessenderlo Kerley

 

This presentation will compare and contrast the PCS 7 Logic Matrix application with our previously developed in-house approach for complex interlock configuration and visualization. We will focus not only on the engineering and visualization aspects, but also on examples from the ongoing maintenance and operations perspective of the two approaches at an individual plant site and across our fleet of plants.  The discussion will also include why and how we are moving to the PCS 7 Advanced Process Library (APL), where and why we use the standard APL interlock block, and our current understanding of the Control Module Type approach.     

 

Josh Dickson is a lead Process Control Engineer at Tessenderlo Kerley Inc., based in Phoenix, AZ.  Tessenderlo Kerley and its diverse business units and services within TKI support the agriculture, mining, industrial and reclamation markets with a broad range of products and technologies around the world.  TKI owns and operates eight USA industrial sites that use Siemens DCS systems and Josh helps support their capital, maintenance and operations needs around the process control systems. Josh previously worked at Linde Engineering North America in Tulsa, OK as a process control engineer, where he first experienced Siemens SIMATIC PCS 7. Josh earned a BS in Electrical Engineering from Oklahoma State University.

Leon Grossman, DMC Inc.

 

Siemens WinCC OA provides an extremely flexible and scalable platform that is broadly applicable across industries, especially when scalability is a factor. We’ve used if for manufacturing, pharmaceutical, automotive, and, in this case, defense. RT&T operates the National RADAR Test Facility for the US Air Force. The high risk nature of this application requires both high availability and ease of diagnostics in case of system faults. These requirements utilized the system’s native redundancy and the strong customization capabilities of WinCC OA’s scripting language. This solution utilizes reusable objects built on the new CTRL++ (object oriented) development concepts released in the latest versions of WinCC OA along with tight integration to PLC data structures to create self-configuring objects to adapt as the system grows and changes. This allowed us to create a system that was easy to use but still contained rich information for the user. The new CTRL++ design allowed for modifying the visualization of objects while maintaining the same core scripting behind objects. The mission-critical nature of the system required the use of WinCC OA’s redundancy feature to ensure that all test articles are secured properly even in the case of network or server issues. This redundancy even includes both servers operating independently in case of a catastrophic break in the network backbone. Finally, we were able to leverage the open connectivity of WinCC OA’s driver stack to integrate a holistic system with several different data sources and targets.

 

Finally, we were able to leverage the open connectivity of WinCC OA’s driver stack to integrate a holistic system with several different data sources and targets.

 

Leon is a Project Manager for DMC with over 20 years of automation and process controls experience. He is Siemens PLC Certified, and a certified WinCC OA Engineer. Over the years he has been responsible for architecting, programming, and commissioning applications of all sizes and industries. Leon is also an active member in the Siemens user community and oversees the recently released WinCC OA Open Library which complements the Siemens Open Library. He graduated with a degree in Chemical Engineering from Oklahoma State University.  Leon is a Project Manager for DMC with over 20 years of automation and process controls experience. He is Siemens PLC Certified, and a certified WinCC OA Engineer. Over the years he has been responsible for architecting, programming, and commissioning applications of all sizes and industries. Leon is also an active member in the Siemens user community and oversees the recently released WinCC OA Open Library which complements the Siemens Open Library. He graduated with a degree in Chemical Engineering from Oklahoma State University.  

Bob Pusateri, Electronic Drives and Controls

 

EDC was requested by a waxed paper manufacturer to assist in their in-house effort to increase productivity and reduce labor costs.  EDC chose the Siemens platform to create a customized solution which would interface to 3rd party equipment while utilizing a wide array of Siemens technology, including the S120 and G120C drives, S7-1500-F Safety PLC, 6GK Managed Ethernet switch, ET200SP Remote and Safety I/O, Comfort Panel HMI, and Mobile Panel HMI.  

Siemens equipment offered the required versatility, high-speed communications, advanced technology, and flexibility for control for an evolving production line.  Additionally, the Siemens equipment met the tight size requirements, allowing us to fit 24 axes of servo and vector drives, the PLC and control hardware into the available 48"x60" space.  

Attendees will learn how many functions can be accomplished with one processor.  Other highlights of the presentation will include:

  • The breadth of Siemens products available to meet a demanding and constantly evolving automation application
  • Designing for applications with limited physical space
  • Integration of 3rd party PLCs & drives
  • Design for Safety
  • Integrating product inspection sensors when a vision system is not viable
  • Adding unique features such as
      o  Mobile HMI panels
      o  Live, on-screen video for Comfort Panels
      o  Feed-to-length optimization algorithms

Electronic Drives and Controls (EDC), a Siemens Solution Partner, is a system integrator and field service team specializing in AC and DC drives, PLCs, and factory automation.  Working in the automation industry for nearly three decades, Bob has spent the past 12 years with EDC in the Systems group in sales, applications, systems design, and project management.  Bob earned his B.S. in mechanical engineering at Rensselaer Polytechnic Institute and spent the early years of his career on the plant floor as a manufacturing engineer.  Bob went on to become a specialist in servo and drive applications and sales before coming to EDC in his current capacity as Director of Business Development and Project Manager.

Ryan Landwehr, DMC Inc.

 

The Siemens Brewing Template is a TIA Portal based auto code generation tool developed in conjunction with Siemens. This presentation will highlight the use of Openness, Simatic Visualization Architect (SiVArc), and S7 Graph to auto-generate and link control modules on a PLC and HMI. We will also elaborate how to use these tools outside of the brewing world for any application. Additionally, we will illustrate the full development cycle of a project, starting with a Microsoft Excel document and a global library, and finishing with a fully functional project. With over a year in operation, DMC will also discuss Brewing Template success stories such as the complete automation of a craft distillery in Dallas, TX.

 

Ryan is a Project Manager who has worked at DMC for 5 years and is the head of DMC Dallas. He is Siemens certified, TÜV Rheinland Functional Safety Engineer, and teaches Rockwell-to-Siemens Conversion workshops across the country. Ryan earned a BS in Electrical Engineering from Rose-Hulman Institute of Technology in Terre Haute, Indiana. While working for DMC he has programmed and commissioned many Siemens PLC, HMI, and SCADA solutions in a variety of industries in the US and abroad.

DMC is an engineering and software development firm based in Chicago.  DMC is a Siemens Solution Partner that specializes in developing high-level industrial control systems, advanced motion control solutions, test and measurement systems, embedded devices, and MS SharePoint business dashboard solutions.  DMC has completed over hundreds of successful Siemens PLC, Motion, HMI, and SCADA solutions.  Their success is based upon leveraging modular, scalable code, intelligent information networks, and databases to deliver flexible solutions to our clients.

John Michael Frullo, DMC, Inc.

 

Developing a single SCADA application can be a time-consuming process. Expanding this effort across multiple plants nationwide with the desire for centralized data and reporting service can make this task even more daunting. Luckily, with WinCC 7, we can take advantage of key features that facilitate the rapid development and standardization of projects across multiple locations. Additionally, the Process Historian and Information Server can be utilized for long-term data storage and automated reporting across all sites from a central location. Come learn about the tools DMC used to modernize a client’s legacy SCADA into a multi-site WinCC 7 installation that collects information from a variety of PLCs, ranging from legacy TI-505’s and S7-300’s to modern S7-1200’s and S7-1500’s. This data is seamlessly passed through redundant servers and on to the central data storage and reporting center. See how these tools could help you on your next SCADA project!

 

John Michael Frullo is a Systems Engineer at DMC, Inc and is certified in both Siemens PLCs and WinCC OA. He received his BS in Bioengineering from Rice University in Houston, Texas. While working for DMC, he has programmed and commissioned many Siemens PLC, HMI, and SCADA solutions in a variety of industries in the US and abroad. He has also taught several WinCC 7 training courses.

 

DMC is an engineering and software development firm based in Chicago.  DMC is a Siemens Solution Partner that specializes in developing high-level industrial control systems, advanced motion control solutions, test and measurement systems, embedded devices, and MS SharePoint business dashboard solutions.  DMC has completed over hundreds of successful Siemens PLC, Motion, HMI, and SCADA solutions.  Their success is based upon leveraging modular, scalable code, intelligent information networks, and databases to deliver flexible solutions to our clients.

Ron Knight, Prism Systems, Inc.

 

A new control system was required for a greenfield ore handling facility on the Gulf Coast of Mississippi.  Container ships and barges deliver up to 50,000 metric tons of raw titanium dioxide ore (used as a coloring agent) that is offloaded and conveyed into 15 onshore silos.    Raw ore is then blended from any combination of silos and accurately measured and discharged into railcars or trucks for delivery to end users.  

 

Siemens TIA Portal V13 with an S7-1516 processor, WinCC Professional, and ComfortPanels were chosen as the control system over other hardware providers.  

The 2018 Siemens Summit had several sessions covering how Siemens SiVArc (SIMATIC Visualization Architect) could greatly streamline HMI development.  Unfortunately, SiVArc was not available during the initial development and commissioning of the Port control system.  However, Prism wanted to determine if SiVArc could be added to an existing TIA Portal Project so that future HMI modifications could be implemented more quickly.

 

This session will show how existing PLC code was analyzed and SiVArc rules created to not only duplicate existing WinCC HMI applications but also how SiVArc could then be used moving forward to streamline future HMI modifications.

 

Ron Knight has been designing, implementing, and commissioning control systems with Prism Systems for 26 years.  Ron earned a BS in Computer Engineering from Mississippi State University and holds Siemens certifications in both PCS7 and TIA Portal.    Prism Systems develops software for the manufacturing industry, boasts a world-wide client list, and has offices in Mobile, AL, Birmingham, AL, Orlando, FL, and Los Angeles, CA.

Kyle Weise, IAS Inc.

 

A Wisconsin-based auto parts manufacturer needed to ensure their core manufacturing processes were producing quality product through the monitoring and subsequent replacement of an important wearable component after a preset cycle count. 

 

IAS was consulted to engineer mobile tracking units that could interact with the Siemens controllers on the machines in order to track tooling cycle counts and provide notifications once the tooling required resurfacing or reworking. The mobile units were networked to the plant Layer 2 Network and controlled via a Siemens SIMATIC ODK 1500S that would monitor the stands and log important data for analysis to a custom architected MS-SQL Database.  

 

The system enables the customer to track, assign, create, remove, and decommission tools to prevent unauthorized deployment.  The custom HMI was developed in Siemens WinCC and deployed on Comfort Panels on the mobile stations.  The networked architecture allows the customer to manage data at multiple sites at a central location.

 

We will examine how IAS used PC to PLC interaction to handle the communication between the tracking system database and the machine’s internal logic. We will also discuss the manufacturer’s future plans for digitization and how this system can be expanded in the future.

 

Paul Szeflinski is the President of IAS; an automation integration company that brings cutting edge technology to life. He believes in the power of industrial automation to elevate the people, performance, and purpose of companies worldwide.

 

Paul & IAS have recently been featured in Milwaukee’s Future 50 to honor high growth companies in the area, and will be joining the Siemens Solution Partner Program in 2018. He holds a Bachelor’s Degree and a Master of Science in Electrical Engineering from UW-Milwaukee and was named Engineering Alumnus of the Year in 2004.

 

Julia Jacky and Johnathan Thrift, Vertech

 

Weber Metals/Otto Fuchs constructed a new plant featuring a 60,000 ton press surrounded by six heat treat furnaces. Weber needed a centralized SCADA system to monitor control systems and coordinate part flow through the press and heat treat operations. Operators needed on-the-fly instructions delivered to forklifts and individual, high-value parts required quality tracking throughout the process. A Siemens S7-1500F PLC and the Siemens WinCC OA software platform were selected to implement these requirements. The central PLC communicated with each furnace PLC and the press. This gave Weber Metals the ability to centrally monitor and control each furnace/press without modifying vendor programs. WinCC OA was used to provide visualization of each piece of equipment. A single operator can now launch “missions” from a central location. Forklift drivers receive instructions via rugged mobile tablets to move parts between locations. Individual parts are tracked as they move through the process and associated process values are stored for analysis. This system reduces labor costs and provides part trace-ability and quality information.

 

Johnathan Thrift is the Automation Controls Engineer in charge of the 60K Press Work Cell at Weber Metals, Inc. in Paramount, CA. He has extensive experience in electrical engineering within the machinery industry. He holds a BS in Electrical Engineering Technology from Georgia Southern University.   

 

Julia Jacky is a senior control systems engineer and project manager in Vertech’s Irvine, California office. She has designed and implemented control systems for a variety of plants and processes in aerospace and other industries over the last ten years. She currently develops high level project architectures and manages technical project development teams. She holds a BS in Electrical Engineering from LeTourneau University in East Texas. Vertech is a Siemens Solution Partner based in Phoenix, Arizona delivering traditional automation, SCADA, MES, and OT solutions.

Saransh Choudhury, Fabio Perini North America, Inc.

 

Industry 4.0 is a dynamic space for tissue converters, and digitalization has quickly become essential for continued success since optimized operations, customer satisfaction and profitability hinge on it.  In 2018 Fabio Perini North America partnered with Siemens to build and commission a Pilot Line Initially focused on product testing and development, Pilot Line offers tissue converters services aimed at optimizing production processes, product innovation and analytics that keep pace with Smart Factory advancements.  

 

During this session we will share our complete experience for transforming an existing machine into a digital machine and how through digitalization and modernization we were able to maximize both our productivity and profits.  The development of the Pilot Machine used MCD to model the core winder as part of the production design phase for the creation of the digital twin.  We upgraded the controls on the machine from a mix of older Siemens HW, Pilz, Emerson, Robox, and several other vendors, to a uniform Siemens design which resulted in going from 4 control cabinet sections to 1; a 75% reduction in cabinet space.  The new machine was engineered using TIA Portal allowing for complete transparency of the plant status with integrated system diagnostics. Lastly, we employed customized MindSphere apps to feedback data on the machine to develop continuous improvement.  This Digital Pilot Line is now a permanently installed machine at FPNA used by customers to develop new tissue products that can maximize productivity and profits.

 

Saransh Choudhury is Operations Manager for Fabio Perini North America, where he is responsible for overseeing machine and complex rebuilds, operational excellence, and the Smart Factory Cluster for BA Tissue. He has over 6 years of experience with Fabio Perini, has a Black Belt in Lean Six Sigma, a master’s degree in Industrial management and a bachelor’s degree in metallurgical and materials science.

Jim Wilmot, Siemens

 

Join the PLC/IO/SW team for an overview of the latest and greatest product and technology innovations that directly impact your applications, including a sneak preview into the near-term roadmap for future product releases.  Come learn about the new features/functionality within the TIA Portal, innovations and additions to our various PLC and IO product lines, and much more.  Come out and see how these latest innovations can help improve your applications; reduce your engineering time and increase your productivity.  We will also be asking for your feedback as well - we encourage you to ask questions and provide feedback pertaining to PLC/IO/SW that can help us improve our product portfolios moving into the future.

 

Jim Wilmot is a manager in the Digital Factory, Factory Automation business unit of Siemens Industry – focused on the product management and marketing of Siemens SIMATIC Controllers, distributed IO, engineering software, and motion control in the United States.  Jim has an MSEE degree from Georgia Institute of Technology and has over 25 years of experience working with industrial automation systems.  He has been with Siemens for 21 years, holding various positions in engineering, business development, and product management/marketing.  Jim is an avid promoter/presenter of new technologies with Siemens SIMATIC product lines.

Mark Vandebrake, BNSF Railway

 

In order to operate classification yards, BNSF used a proprietary real-time control system which became difficult to maintain, had no life cycle path and required a very specialized skillset. Due to an increasing demand for freight logistics and pressure to lower dwell times, BNSF had to migrate to a control system for continuous integration and continuous development. Using a SIMATIC based approach that relies on hardware robust enough for harsh yard environments, BNSF is bringing together smaller factions within our highly distributed company to streamline updates and upgrades while decreasing downtime and cost; reducing field equipment by moving complex physical logic to software logic and combining real-time and diagnostic data into one high-speed data stream. With classification yards able to collect over 12 Million data records a day, BNSF was able to move from a traditional control system approach to a path for tomorrow’s digital world.

 

Mark Vande Brake, Assistant Director of Signal, has been with BNSF for 12 years. Before joining the railroad he worked as a controls engineer for 7 years. Michael Wickersheim, Signal Engineering III, has been in the railroad industry for 5 years with 11 years of military rocket and satellite system experience.

Gina Brooks-Zak, DMC, Inc.

 

Advanced manufacturing of the 21st century requires the ability to commission automated lines efficiently and to adapt to manufacturing changes with agility. The S7-1500 platform is ideally suited to meet these needs.  This presentation will dive into solutions that DMC developed that fully leverage S7’s hardware and development flexibility to create efficient and agile manufacturing deployments. Our customer required a solution that allowed end users to create standard wiring schemes that could be updated in the field without programmers. We will demonstrate how we achieved this using TIA Portal Extended Addressing instructions to dynamically update IO addresses used in program modules. Additionally, utilizing Option Handling we were able to create a standard program with a variety of hardware options that could be deployed quickly. Learn to leverage TIA Portal flexibility to create a better standardized solution for your application.

 

Gina holds a B.S. in Mechanical Engineering from the University of Illinois at Urbana-Champaign and an S.M. in Mechanical Engineering from the Massachusetts Institute of Technology. Before joining DMC in 2015, Gina worked with automation and process controls in the water and wastewater industry. Gina earned her Siemens PLC certification and is a TÜV Rheinland Functional Safety Engineer. As a Project Engineer at DMC, Gina has designed, programmed and commissioned many Siemens PLC, HMI, and SCADA solutions in a variety of industries including automotive, chemical manufacturing, and food & beverage.

 

DMC is an engineering and software development firm based in Chicago.  DMC is a Siemens Solution Partner that specializes in developing high-level industrial control systems, advanced motion control solutions, test and measurement systems, embedded devices, and MS SharePoint business dashboard solutions.  DMC has completed over hundreds of successful Siemens PLC, Motion, HMI, and SCADA solutions.  Their success is based upon leveraging modular, scalable code, intelligent information networks, and databases to deliver flexible solutions to our clients.

Amanda Beaton, Siemens

 

Transforming classroom learning into more relevant concepts for today’s advanced manufacturing environment takes ingenuity.  Using our proven curriculum and hands-on training, Siemens and our key industry and academic partners have been building programs focused on leading-edge technologies for over a decade. Attend the session to discover how advanced technologies such as digitalization and IoT are impacting the learning landscape and how Siemens Cooperates with Education, our PL Academic team, and our Mechatronics Systems Certification program are employing these innovative technologies in real-world classroom projects.

 

Amanda Beaton, US Program Manager, Siemens Cooperates with Education 

 

She has been with Siemens since 2003 in manufacturing and project management roles and is responsible for facilitating the use of Siemens Factory Automation products in schools.

Alan Cone, Siemens

 

We'll discuss Siemens latest product innovations, complete with their best-in-class features that meet customer's needs. Come hear about the latest innovations and get a peek at the roadmap for the upcoming year.

 

Alan is the Manger of the Product Marketing team for HMI/IPC and SCADA in the US.  He is responsible for WinCC SCADA in the US and leads the team for HMI and IPC marketing.  He has worked with Siemens HMI/IPC 18 years in various roles.  Alan has a Bachelor of Mechanical Engineering degree from Georgia Institute of Technology.

Cheryl Benson, Mary Kay Inc.

 

After 40+ years at our prior manufacturing site, Mary Kay Inc undertook a significant capital project to build a new cosmetics production facility rather than remodeling the older plant. Our aims were to reduce production risks, increase flexibility, support R&D and provide room for expansion to meet global product demand. This presentation will discuss the phases of the project including competitive PLC migrations to Siemens, expansion through OEM skids provided with TIA Portal-based SIMATIC PLCs such as S7-1500s, the addition and integration of SINAMICS drives, and the approach toward a distributed system architecture with local visualization using SCALANCE switches.  As the project developed further, we introduced S88 Batch to satisfy FDA validation requirements and deployed Siemens SIMATIC PCS 7 using SiVaaS virtualized solutions as a supervisory system. As part of the presentation we will share our strategies and best practices for managing such a diverse project.  

   

Cheryl Benson is Corporate Engineering Manager for Mary Kay Inc, based in the Dallas/Fort Worth area.  Cheryl has held roles of increasing responsibility and her current position as Corporate Engineering Manager has her focused on controls and automation as well as this most recent capital project.  Cheryl earned a BS in Chemical Engineering from Howard University and an MBA with a focus in Marketing from Southern Methodist University – Cox School of Business. Siemens Automation and Engineering project engineering solutions team members will also support the presentation.

Katelyn Kelsey, Dow Chemical

 

Today’s control system designs must address a variety of challenges, ranging from safety classifications to high speed and big data acquisition to the integration of third-party instrumentation and applications. Recent advances in control system technology have made it easier to overcome some of these challenges. 

 

This presentation will explore the advantages and disadvantages of integrating Siemens PCS 7 and TIA Portal into a single network via high-speed fiber and PROFINET protocols. Our case study will follow the design and implementation of a building chemical feed system comprised of three standalone process areas controlled by an AS410, S7-1500 and S7-1200. These automation technologies communicate with each other through shared databases to control flow and reaction chemistry. We will discuss the selection criteria for a particular Siemens automation technology or application. For example, local Comfort Panels were placed near the process area for manual control and equipment performance trending, while the control room utilized PCS 7 for supervisory control and integration with our internally developed Dow Recipe Control (DRC). We will also discuss the advantages and disadvantages of PROFINET technology in small-l to medium-scale control systems, including the network design using SCALANCE technology. The overall presentation will provide viewers with a holistic approach to integrating both state- and process-based control schemes with emerging technologies for a modular, modifiable and scalable control system.

 

Katelyn Kelsey works as an R&D Process Control System Engineer with Dow Chemical R&D in Lake Jackson, TX. She came to Dow with a BS in Biomedical Engineering from the University of Texas and a background in embedded sensor design, signal processing and software algorithm development for biological applications. In her current role she works with the Laboratory Automation team to provide turnkey solutions for process control systems within Dow Chemical R&D globally. Her most recent projects include designing and programming both Siemens TIA Portal and PCS 7 control systems.

Josh Hilewick, Rovisys

 

Adding a new customer and new product formulations required an edible oils packaging facility to add new tanks, railcar unloading spots and piping headers. Additionally, multiple existing tanks were repurposed as a part of the piping header changes. For most facilities and control system platforms, such an expansion would be an engineering headache requiring a large amount of reprogramming of valve interlocks, transfer sequences and filling operations. Engineering at this location required none of those things, because PCS 7 Route Control was already in use in the plant.

 

This presentation will show how Route Control enabled nearly 200 valves to be added to the system without a single PCS 7 Sequential Function Chart (SFC) change required. Methods and tips for designing and simplifying a Route Control-based system will also be discussed. In parallel with the expansion, a PCS 7 V8 to V9 upgrade was completed. Special considerations taken while upgrading and expanding the Route Control and the Advanced Process Functions (APF), which is used for material management to ensure seamless operations, will be covered. Testing the entire system including running all new and reconfigured routes before site deployment with SIMIT, providing a high level of confidence for the receiving engineers and operation staff.

 

Josh Hilewick is a senior systems engineer at RoviSys.  Josh holds a B.S. in Electrical Engineering from Penn State and has 15 years of experience in controls and automation, focusing on the chemicals and glass industries at RoviSys. Josh is a certified Siemens PCS 7 engineer and contributes to the Siemens PCS 7 UAB Product Roadmap User Group. RoviSys, a Siemens Solution Partner, is a process integrator and software development company serving the chemicals, food and beverage, glass, life sciences, metals, oil and gas, and power and energy industries worldwide.

Paul Snodgrass, Stepan Corp. and Jeffrey Clark, PhD, Cross Corp.

 

The Stepan Company is a specialty chemical manufacturer with sites located throughout the world and producing a wide variety of products. The site in Columbus, GA specializes in liquid and solid polyester resins and utilizes SIMATIC PCS 7 with SIMATIC Batch and Route Control. The variety of products have multiple different reactions and require both solid and liquid dosing. The batch management system systematically maintains production scheduling across multiple reactors. As the plant expanded with additional reactors, the underlying logic handling material transfer became more cumbersome to track, maintain and troubleshoot. The solution was to begin using a hierarchical recipe structure and implementing Route Control to provide a simpler, more compact view when developing, monitoring and troubleshooting recipes. 

 

The ability to integrate SIMATIC Route Control with SIMATIC Batch, results in invaluable enhancements and unforeseen production advantages. These include reducing the overall programming effort, incorporating an additional troubleshooting interface for operators, providing more versatility and flexibility in batch recipes, and allowing for efficient program additions for future expansions. The use of Route Control allows for simplified material transfer, reducing the need for complex logic to handle each individual transfer possibility. This presentation will focus on the benefits of the use of SIMATIC Batch and Route Control, the ease of incorporating and designing Route Control into an existing project, and phasing in Route Control in stages. 

 

Paul Snodgrass is a Process Control Engineer at Stepan, located in Columbus, GA. Paul holds a BA in Chemistry and a BS in Chemical Engineering from Mississippi State University and has 20+ years of experience in the process control industry. 

 

Jeffrey Clark, PhD, is a PCS 7-certified Lead Systems Integration Engineer at Siemens solution partner Cross Company. Jeffrey obtained his doctorate in Chemical Engineering at the University of Tennessee before joining Cross. He specializes in PCS 7, SIMATIC Batch and Route Control, and process design.

Wendy Cheng, Sartorius Stedium Biotech and Michel Claes, Siemens

 

While the standard SIMATIC Batch report includes the needed data for a batch record of a product, it doesn't always correspond to the customer's wishes on content and layout. Fortunately, our reporting is based on the powerful Microsoft SQL Server Reporting Services engine, which gives you a lot of flexibility.

 

In this presentation, we'll show you how to handle customized batch reporting, with and without the process historian and information server. We'll give you insight into the data flows, the standard available views and stored procedures, and practical tips to properly extract and format data, so it's easier to create the desired layout. We'll also demonstrate how to include data from other sources, such as unit operations that possibly come with the TIA Portal solution or SIPAT. The reporting for the Siemens-Sartorius integration concept will be detailed to highlight this. Special attention will be given to combined SIMATIC IT eBR and Batch reporting using the SSRS, bringing electronic batch recording to the next level.       

 

Wendy Cheng, Automation Sales Manager at Sartorius Stedium Biotech located in the San Francisco Bay Area, has a strong background designing control systems for process automation. She is well-versed in ANSI/ISA-88 batch control philosophy, Good Automation Manufacturing Practice (GAMP 5), system virtualization, risk-based system commissioning/qualification, automation optimization and support. She has experience with DeltaV, Siemens and Rockwell automation systems and has led automation projects at Genentech, Boehringer Ingelheim and Sanofi.      

              

Michel Claes, Senior Industry Consultant, Siemens, has served the pharmaceutical industry as a consultant for the past eight years. He's done numerous innovative projects including PAT and continuous plants. He's also worked extensively with the SIMATIC Batch and Process Historian team to come to a tightly integration reporting solution and has made numerous reporting templates for end-customers.

Warren Johnson, aeSolutions

 

Companies need to meet OSHA’s requirement of proper safety procedures for environments that are Immediately Dangerous to Life and Health (IDLH). They need to have the ability to rapidly identify, locate and respond to indoor and outdoor gas leaks across a large operating facility while minimizing spurious alarms. This presentation will talk about the lifecycle of safety automation projects in the life sciences and chemical industry to meet and exceed these requirements at your production facility. In the early phase of the project, we work to optimize the number and location of gas detectors using computational fluid dynamics (CFD) technology. The presentation will also discuss how the PCS 7 system has been used to monitor detectors as well as control local audio and visual alarms and the facility’s HVAC system. We will discuss design, implementation, testing and commissioning efforts to successfully reduce process hazards and meet regulatory compliance as an integrated solution.      

   

Warren Johnson is a Senior Project Manager for aeSolutions of Greenville, SC, which is a Siemens certified solution partner company and the first North American Process Safety Specialist partner. Warren has a BS in Electrical Engineering from Clemson University. He holds a PE license in the Electrical discipline for several states, and holds a PMP certification for project management. He has over 25 years of experience either implementing or managing industrial-based control systems. For the past 15 years Warren has specialized in developing products based on Siemens process automation and factory automation hardware and software platforms.

Golden Grain Energy, LLC and Trident Automation 

 

In order to maximize profits, today's market conditions demand that plants to increase throughput and/or reduce costs by improving yield and using optimizing production techniques. Multivariable Predictive Control (MPC) or Advanced Regulatory Control (ARC) techniques play a vital role in achieving this goal. This presentation talks about these techniques and how to determine which best fits your needs. We will show examples of how we used the PCS 7-embedded MPC Advanced Process Library, discussing how we identified the control loops, set up, tested and deployed the system in a chemical plant across multiple application areas.  We will also discuss how we used Advanced Regulatory Control to take the guesswork out of a process dryer application and how it helped operations during startup as well as to avoid tripping the system.

 

Chad E. Kuhlers has been the Chief Operating Officer at the ethanol producer Golden Grain Energy, LLC in Mason City, IA since July 19, 2010 and served as its Plant Manager since August 11, 2004. Mr. Kuhlers served as Chief Operating Officer at Homeland Energy Solutions LLC from December 2008 until 2011. He served as the Operations Manager for Koch Hydrocarbon's Medford, Oklahoma facility from 1994 to 2004. Mr. Kuhlers also served as the maintenance manager, process control engineer, reliability engineer and project engineer within the Koch Hydrocarbon organization. He has been a Director of Homeland Energy Solutions LLC since December 7, 2005. Mr. Kuhlers has an Electrical Engineering degree from Iowa State University and an MBA from Phillips University in Enid, Oklahoma. 

 

Craig Ebert is a Controls Engineer and certified PCS 7 engineer from solution partner Trident Automation, Inc., located in Kimberly, WI. In his role Craig has commissioning numerous PCS 7 systems and migrated APACS+ systems to PCS 7 utilizing PCS7 APL Library and Advanced Process Graphics for programming, commissioning and operating systems. He has a Degree in Instrumentation from Northeast Wisconsin Technical College and has 35 years of experience in the automation industry. His work experience includes design, installation and startup of projects at power generating stations, paper mills, chemical manufacturers, wastewater treatment facilities and ethanol production facilities.  

Keith Stafford Sr., Berry Global and Luis Marin, Cross Corp

 

Berry Global is an international, publicly traded, multi-billion-dollar corporation with a large manufacturing facility located in Hickory, Tennessee that produces specialty materials for filtration, healthcare and homebuilding industries. This facility was faced with significant risk from operating a high-production system using antiquated legacy DCS hardware and software. The only solution was to rip out the legacy equipment and provide minimal production interruptions or outages while doing so. The Siemens and Cross team devised and orchestrated a migration plan that leveraged the flexibility of SIMATIC PCS 7 and allowed Berry Global to maintain production goals. The ability to distribute the hardware, thoroughly test the software and fully integrate existing raw material handling systems made PCS 7 a perfect fit for the facility. The first outage proved to exceed the minimal downtime expectation of the system switchover through extensive planning and commissioning tools leveraged within the system. This presentation will focus on the migration options and flexibility benefits of SIMATIC PCS 7 when deploying into a distributed environment while maintaining minimal production outages.

 

Keith Stafford Sr. is a Lead Project Engineer for Berry Global at the Old Hickory, TN site. He has over 24 years’ experience and has held several positions in the industry including Electrician, Group Foreman, Maintenance Specialist and Reliability Engineer. Keith is currently supporting production in several areas of the facility as well as leading major capital projects.                                      

 

Luis Marin is a Lead Systems Engineer at solution partner Cross Integrated Systems Group based in Knoxville, TN. He has over 25 years’ experience in process control projects across the globe, specifically in the chemical and pharmaceutical industries. Luis is a certified Siemens PCS 7 automation engineer and holds an Electrical Engineering degree from National Polytechnic University, Venezuela.

Dennis (Damon) Walker, Airgas and Ken Pilotti, Applied Control Engineering

 

Airgas, an air separation company, has a facility in Coatesville, PA that produces liquid and gaseous medical and industrial oxygen, nitrogen and liquid argon. The process involves the control of compressors, cooling water systems, air purification and distillation. The legacy system is a Foxboro DCS originally commissioned in the late 1990s. The legacy DCS system is starting to fail and maintaining the system has become increasingly difficult due to lack of spare parts, unsupported operating systems and engineering knowledge. The replacement is a PCS 7 DCS that includes PROFINET and ET 200SP HA I/O components. The presentation will focus on the justification, approach and constraints for developing and commissioning the replacement, considering changes to the operator interface, I/O wiring changes and future integration with Siemens S7-300 PLCs.  

 

Dennis (Damon) Walker is a Control Systems Specialist at Airgas, an Air Liquide Company. Over his nine-year career with Air Liquide/Airgas, he has worked with a variety of control systems. Prior to Air Liquide, Damon spent nine years working for DuPont in various process and process control engineering roles. In these roles, he has been responsible for the maintenance and upgrading of various control systems include Honeywell, Allen Bradley, Siemens, Texas Instruments, Modicon and Emerson. Many of his projects were system migration projects, providing him with a vast library of lessons learned when performing system migrations. Damon earned his BS in Electrical Engineering from Morgan State University in Baltimore, MD and his MS in Electrical and Computer Engineering at Michigan State University in East Lansing, MI.                                                                                                                                                         

Ken Pilotti is a Senior Project Engineer for Applied Control Engineering, a Siemens solution partner. Over his 15 years at ACE, he has worked on developing, commissioning and maintaining control systems in various manufacturing industries including air separation, food manufacturing and pulp and paper manufacturing. Ken has held leadership positions at ACE including Team Leader and Operations Manager. Ken’s main focus is on the Siemens PCS 7 and TIA portal platforms for discrete and process manufacturing. Prior to joining ACE, Ken served as Director of Process Technology for Messer, US (MG Industries). While at Messer, Ken designed, developed and commissioned control systems for over 20 air separation and compressed air facilities. Ken earned a BS in Information Systems at King’s College in Wilkes Barre, PA.

Bill Mackin, Birla Carbon

 

Birla Carbon of Franklin, LA is a leader in carbon black production that was looking to modernize our APACS+ system and selected PCS 7 V9 using the AS410H CPU, PROFINET IO ET 200SP HA for HART and conventional signals in addition to the Compact Field Unit (CFU) using Profibus PA for new field instrumentation. We also moved our HMI architecture to PCS 7 using the SiVaaS virtualized platform.  

 

This presentation will review the various aspects of the project including the selection, design, installation, training and operational aspects of moving from a conventional automation system to a new digital platform. We will provide details, including cabinetry design and SCALANCE networks, of how the APACS+ control system was migrated to the ET 200SP HA I/O using the FAD cabling approach (reducing cutover time in a sold-out business environment) as well as details about the PROFIBUS PA field instrumentation connectivity to the CFU.  

           

Bill Mackin is a controls engineer with a focus on process improvement at Birla Carbon, the world’s largest producer and supplier of carbon black additives. Carbon black additives are used in the manufacturing of products such as tires, specialty black pigments and rubber goods (belts, hoses, gaskets and molded parts). Bill is based at the company’s Louisiana facility, where he has overseen process control improvements in several process areas. Bill has also supported other North American Birla Carbon facilities on their modernization efforts. Bill is an electrical engineer, earning a degree from Mississippi College. He has 20+ years of process automation experience.

Nathan Nutter, Trident Automation

 

This presentation will review design considerations and configuration approaches based on our experiences when migrating a DCS to PCS 7 using distributed SIMATIC ET 200SP HA PROFINET architecture. This new I/O system uses properties of the Industrial Ethernet standard PROFINET to meet the ever-increasing demands of flexibility, scalability, availability and security within the process industry. In this presentation we will detail how we went about designing the new system architecture, starting from I/O card selection, required termination and cabinet design. We will also highlight designing the PROFINET network, using SCALANCE switches, the role of the Service Bridge in accessing the I/O system, network security considerations and available cabling solutions to aid with field wiring. Finally, the presentation will discuss the ability to use the HART capabilities of the ET 200SP HA signals for commissioning and maintaining field instrumentation.

 

Nathan Nutter is a Controls Designer II and certified PCS 7 engineer from solution partner Trident Automation, Inc. He has over 7 years of experience in the automation industry. In his role Nathan has commissioned numerous PCS 7 systems, migrated over 10 APACS+ systems to PCS 7, and utilizes the Advanced Process Library and templates provided by Siemens for standardized programming. Trident Automation is an independent professional services company specializing in process control technology solutions that deliver increase productivity, reliability and measurable cost savings to clients. The firm designs, fabricates and installs process control systems. Trident Automation serves over 100 plants throughout North America working extensively in biofuels, pulp and paper, power, chemical, and general manufacturing industries. Based in Kimberly, WI, the firm serves clients throughout North America. For more information, please visit www.tridentautomation.com.

Devin Kownurko, Air Products

 

With each major release of PCS 7, new features are added and others are no longer supported. On top of this, consider that each legacy configuration is unique. So, when a system is upgraded from V7 to V9, problems can emerge or, even worse, remain covert. By methodically following best practices, irregularities can be flushed out and addressed to ensure a high-quality system. 

 

This presentation outlines the best practices to upgrade PCS 7.

 

Best practices include:

  • Selecting the correct intermediate versions for migration;
  • Identifying and preserving customizations;
  • Understanding in detail how WinCC migrator changes the project;
  • Developing an efficient test procedure for the upgraded system.

We will also discuss when, why and provide highlights of how to upgrade a project configuration to PCS 7 Advanced Process Library and ultimately to Control Module Types. We will also highlight some of the key features of PCS 7 V9, beyond just the Microsoft operating system, which helped us justify the migration.

 

Devin Kownurko is a process controls engineer for Air Products and Chemicals Inc., supporting a fleet of nitrogen and oxygen production plants that vary in terms of production capacity and control system vintages. Specific technological experience in controls includes cryogenic distillation, molecular adsorption systems and reaction control. He is responsible for managing DCS changes, control modernization and migration for the high-purity nitrogen systems running on PCS 7. Devin graduated from Drexel University with a BS in Chemical Engineering and a minor in Nuclear Engineering.  

 

Pete Graglia is a control system engineer for solution partner Applied Control Engineering. Pete has worked as Automation System Engineer for 30 years. Over the last 15 years he has led numerous PCS 7 projects, including HMI migrations and AS migrations to PCS 7. Prior to that he worked as a software engineer for Moore Products/Siemens and Honeywell, where he developed device drivers and integration solutions to DCS systems.

Karen Pigler, Pigler Automation

 

Siemens’ guideline to prepare for the upcoming innovations emphasizes the use of the Advanced Process Library (APL) and Control Module Types (CMT). As an early adopter that has used the Process Automation Accelerator (PAA) for several years now, Pigler Automation has developed a project template for a typical small project application utilizing not only APL and CMTs, but also standard setups for PAA and an available SIMIT model for the virtual commissioning/FAT support. Armed with these preparations, Pigler Automation attempts to replicate our standard application in the new innovation. This paper will share our findings regarding the necessary training, best practices in the workflow and required efforts for the conversion, lessons learned, our wish list for improvements and general feedback about the innovation.

 

Karen Pigler, CEO and co-founder of Pigler Automation, LLC has worked in process automation all of her professional career. The first 17 years she worked for Siemens in various positions both in Germany and in the US. In 2005 Karen founded Pigler Automation LLC together with her husband Harry. Today Pigler Automation LLC is a Siemens solution partner with 95% of sales related to PCS 7 projects and services. Karen has been active in the Siemens PCS 7 Product Council for many years, and as an early adopter Pigler Automation has been a pilot tester for SIMIT and other products, as well as one of the first US companies to use the Process Automation Accelerator (PAA). Outside of work Karen enjoys hiking, biking, kayaking and skiing.

Please join the Process Automation Product Roadmap Workgroup to find out how your feedback from the previous years' sessions has influenced product development and provide you an opportunity to shape the priorities for the future. The session will start with discussion and live demonstrations of how Siemens is working to address key user community requirements. We will highlight innovations in both plant operations and system engineering through multiple system use cases. This session will be interactive and include time for your questions and feedback      

 

This will be hosted by the Siemens Process Automation Council user community representatives and supported by Siemens process automation product managers and the application engineering team.

Come meet the head of Siemens’ global Simulation Center and learn about the product roadmap and overall offering for the SIMIT Simulation Portfolio as well as the joint model-based solutions offering with Siemens’ strategic partner PSE (gPROMS). SIMIT is tightly integrated with many Siemens control systems including TIA Portal, SIMATIC PCS 7 and Process Safety Systems. It provides the foundation for creating a digital twin of your plant that can be used for project commissioning, testing and optimization as well as operator training systems. In combination with PSE’s technology it elevates the digital twin to a new level of detail in regard to the process and enables intensive use for operational optimization. This presentation will also provide a preview of the new features that will be available with the upcoming release of SIMIT Version 10.1 in July 2019 and will offer insight into future SIMIT developments as well as the joint developments with PSE. Finally, we’ll take this opportunity to discuss your experiences with SIMIT and ask for your feedback and suggestions for the strategic direction of the portfolio. We’re looking forward to collaborating with you on SIMIT’s continued growth and development.

 

Mathias Oppelt graduated from the Hamburg University of Technology in 2010 with a Diploma (Dipl.-Ing.) degree and from Northern Institute of Technology Management in 2010 with a Master in Technology Management (MTM). In December 2015 he finished his dissertation about the use of simulation within the lifecycle of a process plant at the Technische Universität Dresden with a Doctor’s degree (Dr.-Ing.). He has been working for Siemens since 2010 in various positions, among these in strategy for process automation, project business and product management. Currently he is the head of the simulation center for process automation including the responsibility for the SIMIT simulation portfolio. He is deputy chairman of the VDI GMA working group 6.11 for virtual commissioning and has published various papers over the past several years.

Forrest “Woody” Hulbert, Air Products

 

Industrial IoT is a disruptive technology that can enable new revenue streams for industrial companies. Over the past 10 years Air Products has developed predictive models on more than 750 oxygen, nitrogen and hydrogen plants, using our proprietary “ProcessMD” algorithms and key performance indicators that optimize a plant’s operations and prevent unplanned downtime. In some cases, third-party customers own and operate Air Products-designed plants themselves but want the added value of Air Products’ software technology and operating experience captured in ProcessMD. In 2018, Air Products and Siemens MindSphere partnered to enable Air Products’ third-party customers to leverage ProcessMD. In this presentation we will discuss how Air Products is using Siemens’ MindSphere hardware, software and services to securely collect and send continuous real-time data from third-party customers’ control systems – including Siemens SIMATIC PCS 7 and SCALANCE switches – to Process MD. We will also share experiences from our first third-party customer deployment and share the next steps for this exciting new platform.

 

Woody is the Plant Services Manager for Air Products, a global supplier of technology and services for the industrial gasses business. He has been with Air Products for 32 years, working at their Allentown headquarters in various roles including Start-up, Systems and Process Engineering, then moving into Operations as a Plant Process Engineer, upgrading and optimizing Air Separation plants in the Americas. In his current role he supports customers that own and operate Air Products equipment, consulting on their operations, planning upgrades, extending the life of old plants, etc. His current focus is digitizing these plants so that his customers can tap into Air Products expertise and experience to add real value. He earned his BS in Chemical Engineering from Georgia Tech University.

David Watson, Solid State Automation and Controls

 

Traditional large control systems use junction boxes to consolidate IO from different regions of the system and then these cabinets are connected to large remote IO cabinets with big, bulky multiconductor cables. There is a lot of labor involved in installing these junction boxes as well as material costs to run all the cable. In addition, there is a lot of room for human error in the landing of all the cables and troubleshooting these issues can be time-consuming. We have been able to remove the need for these bulky multiconductor cables with the SIMATIC ET 200SP line of IO from Siemens. This line of IO is an economical solution with wide temperature range support and field power distribution built into the product. Because of the modular form factor of the product, it is even economical to populate small junction boxes with just a handful of IO in them. Additionally, the ET 200SP IO has built-in short circuit protection and open wire diagnostics, thereby eliminating the need for fuses. With the ET 200SP modules populating what were the junction boxes, these enclosures no longer need multiconductor cables. Instead, Ethernet cables connect these boxes back to the central control system. The ET 200SP IO even supports direct fiber connection to the modules, thereby streamlining connectivity to fiber networks as well. We will go over the many network topologies this IO technology allows us as well as review case studies where we have used it, both in traditional PLC applications with the ET 200SP line and in DCS applications with PCS7 and the ET200SP HA line. In one case study, we will share how a Petrochem design-build firm arranges whole facilities in modular skids that are mass-produced at their factory and how these very modular control systems help them to build, test, install and commission their systems faster with the ET 200SP IO. To get the most out of this new IO technology, old assumptions and designs must be relegated to the past and a more modern approach applied, thereby providing better diagnostic functionality along with quicker installation and commissioning. This will culminate in a system that is more expandable than traditional systems of the past.

 

David Watson is a control systems design specialist with more than five years’ experience spent in programming and support of automation products for the oil and gas industry. He currently serves as an Automation Specialist at SSAC specializing in programming and design of packaged equipment based on Siemens Controls.

Jason Lopez, Western States Controls

 

This project consisted of migrating the client’s Siemens TI 505 PLC to a Siemens SIMATIC PCS 7 410 H system with an R1 PROFINET architecture for reliability. An R1 ring was designed to ensure maximum reliability for the plant communication with the IO. The challenge was to incorporate the existing Rockwell MCC communication and controls into an R1 PROFINET architecture. We used a gateway protocol conversion device, made by HMS Anybus, to communicate to Rockwell 755 VFDs and E1 Plus devices. Conversion took place at the byte level by changing bits for control. We took care to also note the endianness of each device. In some applications the bytes had to be rearranged by word to account for the change of bit order. Control Module Types (CMTs) were created for each control type to help with the project development, allowing quick changes and modifications to be made to the charts. To help the client’s onsite maintenance team with troubleshooting, we created a chart instance within the CMTs to handle the bit conversion to bytes, with the bits labeled. Another issue that arose was the inability to find a PROFINET S2 capable gateway. As such we had to duplicate the hardware as well as the input logic. Due to the hardware’s inability to communicate to the two Siemens CPUs, we had to coordinate the active gateway device that was connected to the Master CPU. We opted to cycle the power on the former master gateway device to release its connections to Rockwell devices. This allowed us to keep the active gateway connected to its native CPU.

 

Jason Lopez is a Control System Engineer with nearly 20 years’ experience in control system design, electrical and mechanical maintenance, and plant operations.  He is currently employed by California based solution partner Western States Controls focused on process automation.  He previously worked for Sweetener Products Company where he had roles of increasing responsibility including automation, maintenance and networks.  The site included a PCS 7 system for process control.  

Jeff Meneau, Trident Automation

 

Industry Library is a powerful tool – one that at times is underutilized or, even worse, undiscovered. This presentation describes how the SIMATIC PCS 7 Industry Library (IL) can be leveraged as an add-on product and can help extend the functionality of the Advanced Process Library (APL), which in turn will reduce the need for customization and improve time-to-market for your project. The Industry Library module icons and faceplate look and feel like standard APL blocks and this can aid in creating an environment, suited for better user/operation interaction (example: 4x3 and 8x4 interlock blocks, setpoint curve).  We will discuss a specific example of how the 8x4 interlock block, with the and/or option, has empowered operators to better understand, visualize and control their process while also greatly simplifying the engineering and maintenance of the configuration.  As operations requests more visualization in the field, we will discuss how we are using the Industry Library to operate and monitor touch panels (like Siemens Comfort Panels) into the SIMATIC PCS 7 applications.  We will also discuss our efforts to introduce high performance graphics, using the PCS 7 Advanced Process Graphic Library, as an additional option for the operators including how we select the KPI, engineer the solution and introduce/train operations to begin adopting it.

 

Jeff Meneau is a Controls Engineer and certified PCS 7 engineer from solution partner Trident Automation, Inc., located in Kimberly, WI.  In his role Jeff has commissioning numerous PCS 7 systems, migrated 12+ APACS+ systems to PCS 7 and utilized SIMIT, Industry Library and Advanced Process Graphics for programming, commissioning and operating systems.  Jeff is also a certified PROFIBUS DP\PA and PROFINET engineer by PI International.  He attended Northeast Wisconsin Technical College focusing on both electro-mechanical technology and Automation Engineering Technology.

DTE Energy is a Detroit-based diversified energy company involved in the development and management of energy-related businesses, including operation of a 26 MW Heat Recovery Steam Generator (HRSG) utilizing natural gas-fueled cogeneration located in Calvert City, KY. The facility provides contractual utilities such as power, steam, compressed air and boiler feed water to seven industrial manufacturers in adjacent sites. They faced significant production risks from operating aging node-to-node redundant legacy APACS+ and QUADLOG equipment. Due to customer demands the site was only allowed three days of complete downtime to replace the entire control system, which included redundant S7-410H controllers utilizing redundant IO as well as S7-410HF redundant safety systems for Burner Management Systems (BMS). The only solution was to retrofit the existing enclosures while maintaining the existing field terminations and simultaneously performing a demo on alternative units around the clock. The robustness of SIMATIC PCS 7 allowed for the legacy node-to-node redundancy architecture to be mimicked and easily swapped over without having to relocate any field wiring. Leveraging the APACS+ library and extensive pre-testing functions allowed this critical project to be delivered on time and on budget. This presentation will focus on the robustness of utilizing PCS 7 redundancy options while capitalizing on the operational and productivity enhancements included in the PCS 7 technology improvements.

 

Josh Dalzell is a Senior Integration Engineer at Cross Process Control Systems Group located in Knoxville, TN, which is part of the Cross Company based out of Greensboro/Charlotte, NC. Cross PCI are certified solution partners. He has over 22 years’ experience in process control integration projects across the globe. Josh holds a Bachelor of Science degree from Missouri University of Science and Technology and is an expert in the Siemens PCS 7 product line. He has extensive experience with Siemens products and supported the product development of both SIMATIC Batch and Route Control add-on products.

Virtualization plays an important role for next-generation industrial automation by providing companies a more efficient way to operate industrial control systems infrastructure, which serves a range of functions such as increasing productivity in manufacturing, reducing downtimes in case of hardware failure, and ensuring safe work environments for employees.  While there are great benefits from virtualization, there can also be serious challenges. One of the challenges is the isolated storage for multiple vSphere clusters.  

 

In this session, SIMATIC Virtualization as a Service will be presented as a solution for PCS7 users who are ready to transition to virtualized automation.  We will discuss how a pre-configured, hyper-converge storage approach can be easily implemented to your control system platform as well as the different configurations of vSAN systems for standard and stretched cluster which is a particular interest in process automation applications.  End users who want to virtualize new or existing SIMATIC control systems will be presented case examples demonstrating the benefits of this pre-packaged, pretested and supported solution.

 

Alexander Huber joined Siemens AG in 2012 as a Product Manager for the Industry Services business.  For the past 7 years, he has been integral in supporting customers on the road to digitalization with Siemens SIMATIC Virtualization as a Services (SIVaaS) and SIMATIC DCS SCADA Infrastructure (SIDSI).  More recently, his role has expanded to Regional Marketing Manager, with business development responsibility for Siemens US, CA, RU, UK and SG.   Alexander holds a Bachelors degree in Business Engineering from Karlsruhe University of Applied Sciences in Germany.  He completed post graduate work at the Karlsruhe Institute of Technology (KIT) where he was awarded a Masters in Service Management and Engineering in 2018.

Defense in depth is a security concept that has been around for quite a while, however, recently it has received renewed interest with the addition of the newest layer and defensive mechanism, Industrial Anomaly Detection. For manufacturers, it is easy to implement and provides full transparency over connected assets and their performance. Plant personnel can quickly check flagged deviations and act accordingly. This is all done by non-intrusively listening to the network traffic of an industrial automation and control system.

 

A common theme of anomaly detecting solutions, however, is that they document facts after they occurred. This brings us to the question, is it possible to progress from detection to prevention? What is the best way to start the cyber security journey? For those who have started, how to efficiently and effectively continue? 

In this fireside chat, cyber security experts from Siemens and invited guests will explain why anomaly detection plays a vital role in asset-intensive industries.  They will share their perspective on improvements being made to current security solutions that will help move businesses squarely into the future and respond to audience questions.

 

Stefan Woronka joined Siemens in 1997 and held various positions in consulting, business development and sales for Siemens in Germany. In 2010 he joined the Process Automation unit of Siemens in Karlsruhe to start the Industrial Security business. He was responsible for creation and alignment of the portfolio, regional rollout and development, and alignment with other Siemens units. In 2014 he took over the project lead for an internal project to develop a holistic security concept for Siemens for two Siemens divisions (Digital Factory and Process Industries & Drives). The holistic security concept is now rollout to all R&D centers and production sites of these divisions. After the project he took over the Product Management for the Plant Security Services and further coordinated the development of the portfolio. Stefan holds a BS in Commercial Economics from Vlissingen University (Netherlands) and a MBA from Purdue University

Cyber Threats are becoming increasingly more common within the OT environment.  There are some simple steps that can be taken to reduce the risk of a cyber incident on your industrial network.  This can be done without any additional software or hardware.  This session will help guide you through the steps needed to make your network devices more resilient by securing and disabling features, implementing Access Control Lists, and more.

This session will teach you the details about PROFINET technology, a review of system architectures for the process automation industry, the application of these networks to Siemens process automation IO (ET200SP HA and Compact Field Unit) and examples of cabinetry designs.  You will learn the fundamentals of the technology and best practices on how to design, implement and maintain these systems.  We will also provide an overview of the network tools so that you can design, engineer and maintain your system efficiently.  We will include examples of best practices for integrating Siemens instrumentation as well as electrical devices such as SINAMICS Drives and SIMOCODE via PROFINET to the process automation system.  We will discuss the roles of the Siemens SCALANCE network devices (BANY, Service Bridge, Y-Switch…) to design and support your network.  This session will include a combination of presentations, live demonstrations and hands-on experiences. 

This session will review the reasons and steps to adopt the innovations in PCS 7 V9 including the hardware, software and cyber security benefits.  We will also discuss the Advanced Process Library (APL) and Control Module Types (CMT) and provide presentations, demonstration and hands-on exercises to help define what they are and why you may want to pursue them as your configuration approach today.  We will also discuss how the APL and CMT approach will simplify the adoption of future upgrades and innovations.  The session will also provide time for you to ask specific questions regarding your upgrade to and adoption of these innovations. 

Come meet the head of Siemens’ global Simulation Center and learn about the product roadmap and overall offering for SIMIT Simulation Portfolio and the joint model-based solutions offering with Siemens’ strategic partner PSE (gPROMS). SIMIT is tightly integrated with many of Siemens control systems including TIA Portal, SIMATIC PCS 7, and Process Safety Systems. It provides the foundation for creating a digital twin of your plant that can be used for project commissioning, testing, and optimization as well as operator training systems. In combination with PSE’s technology it is able to put the digital twin to a new level of detail in regard to the process and also to use it intensively for operations optimizations. This presentation will also provide you a preview of the new features that will be available with the upcoming release of SIMIT Version 10.1 in July 2019 and offer insight into future SIMIT developments as well as the joint developments with PSE. We’ll also take this opportunity to discuss your experiences with SIMIT and ask for your feedback and suggestions for the strategic direction of the portfolio. We’re looking forward to collaborating with you on SIMIT’s continued growth and development.

The SINAMICS G120X is a simple, seamless, easy-to-use infrastructure drive - right out of the box for simple applications in the manufacturing industry such as pump, fan, compressor, conveyer etc. Learn about what's new & exciting in this product along with its key hardware & software features & dedicated functions which will help you provide simple, cost effective, and time & energy efficient solution for your needs related to the above-mentioned applications in the manufacturing industry.

Participants will gain a better understanding of how to integrate Sinamics General Purpose Drives into Rockwell Automation control platforms through Studio 5000 and FT View ME software using new efficient integration techniques such as Faceplates, AOI's, UDT's, and EDS files.

Explore a new way of motion control within TIA Portal V15.1 to help you reduce machine development time while increasing performance and diagnostics.  We’ll highlight the SIMATIC S7-1500T controller and SINAMICS S210 drives that offers an unprecedented level of integration to solve your motion applications.

Motors are often at the center of the equation for improving your productivity and providing a path to Digitalization. This hands-on workshop for PROFINET/OPC enabled full voltage and reduced voltage starters will help you to provide better Control, Monitoring and Protection of your machine or process. At the same time, this solution will provide key diagnostic, operational and statistical information to your Cloud Database for analysis. Motor Control data that has been stored on a cloud database and analyzed will then be displayed on a dashboard.

Over the last two years, the three major standards for the design and construction of industrial control panels - NFPA70 (NEC), NFPA79 and UL508A - have had new editions released. What are these changes and how will they affect you? In this seminar, we will answer this question with an overview of the latest changes to the standards. In addition, we will cover other important topics for panel building such branch circuit requirements, short-circuit current ratings and Siemens tools and resources for control panel design and engineering. Come learn how Siemens can support you in your control panel design and engineering.

At this interactive, hands-on workshop with a brand-new modular demo set, you will get an opportunity to explore capabilities of the SIMATIC S7-1200F basic safety controller We will discuss safety standards, trends, wiring and safety functions, in order to provide you with the required guidance to feel comfortable and confident with your upcoming safety projects.

Apply the LAxisCtrl libraries for your standard application axis control to quickly and efficiently get your machine axis up and running.  In addition, generating a path data from a CAD or graphic vector file for interpolation in the S7-1500 Technology CPU. 

What does your customer care about? Understanding this helps you get to “Yes!” Whether you are promoting a project internally, selling a product or service to customers, or gaining willing cooperation from your team, there are process steps to make you more successful. This is an updated version of a popularly requested Automation Summit training back for the fifth year in a row – it works! This year even more examples and hand-on exercises. If you want better results selling your ideas and projects using your own style and a proven process, join us. In this fun and interactive session we will explore how to sell without seeming like a “typical salesperson.” If you like helping others and want to make it easier to get to a “Yes” without tricks or deceit, this session is for you. You will apply these skills to your own real-world situations and learn specific questions to coach others in the process as well. Come join!

This is a hands-on opportunity to experience, how the Totally Integrated Automation Portal (TIA Portal) Has been extended to support transparent redundant programming with the new S7-1500R/H redundant controllers.  This will greatly reduce engineering development time for applications that require redundancy to eliminate unexpected machine downtime and the product damage it can cause.   In this session you will work with the TIA Portal engineering software to configure an automation station consisting of a S7-1517H and ET 200SP remote I/O, connected via a redundant standard Ethernet ring.  In this lab environment, you are free to explore the software and hardware at your leisure or a step by-step guided instruction lab is available for use. In addition, Siemens experts will be on hand to help demonstrate relevant features or answer specific questions.

At this interactive, hands-on workshop,  you will get an opportunity to explore capabilities of the SIMATIC Basic and Comfort panels. We will discuss interfacing with Rockwell PLCs, faceplates and library objects, trending and alarms, along with other WinCC features available within TIA Portal.

Digitalization…You’ve heard all about it, your company is investing in a digitalization strategy, and you know that you need to implement it to be competitive in the future…Now what?

 

To get started, consider one of the available digitalization apps as a low cost method to take advantage of data that is likely already available in your plant. User-friendly and easily accessible tools are now available to address problematic areas such as control valve maintenance and failures, inefficient PID control loops, and overwhelming alarm conditions.

 

At our booth you can also learn about the holistic Siemens Manufacturing Operations Management (MOM) solution that enables implementation of a strategy for the digitalization of operations. Our portfolio provides end-to-end visibility into production allowing you to identify areas for improvement within the product design and associated manufacturing processes, and make the necessary operational adjustments for smoother and more efficient production.

The Motion Control and Low-Voltage Drives & Motors business of Siemens Industry, Inc. serves OEMs and end-users with a wide range of solutions. We have an extensive offering of best-in-class technology such as variable speed drives, servomotors and gear motors.  Come learn about our new products including our award winning new Smart Access web server for wireless commissioning and maintenance, Sinamics S210 and Simotics 1FK2 motor package which uses one cable technology combining power and feedback, and our UL1 Kits that exceed NEMA1 kit requirements. Combined with years of experience and technical expertise, Siemens is capable of providing complete solutions for even the most challenging applications. Come visit us at our booth to learn more about how we can reduce downtime, engineering time and training.  

Providing continuous operation, maintaining consistent product quality, and reducing plant costs are only a few of the many challenges that the process industry is facing today. Distributed control systems play an important role in helping you meet these challenges head-on. Siemens' flexible DCS offerings enables you to respond quickly to constantly changing market requirements, whether you have a small laboratory application or a large plant network. Visit us in the Tech Café to learn more about SIMATIC PCS 7 and SIMATIC PCS neo. 

Control products and components that communicate at the smallest device, a push button, for complete system digitalization over a new or existing network for total transparency. We like to call it, “out of the box,” ready to communicate with AS-Interface, IO-Link, PROFINET, and other networks providing the monitoring and diagnostics that are needed throughout the entire supply chain. Our SIRIUS portfolio showcases IP69K-rated pilot devices and push buttons, IEC motor control & management with AS–interface, I/O-Link and EtherNet/IP to help prevent faults in automated processes and reduce plant downtime, and a vast array of starters & relays that are flexible and modular to help you save wiring and costs in your control cabinet. 

Begin your digital transformation confidently - with the support of Services for the Digital Enterprise.    From consulting to implementation.to optimization, we work together with you to tailor a strategy for success on your journey to become a digital enterprise.

Come and experience the latest innovations in automation software and hardware, giving you full access to all digitalized automation functions, from digital planning and integrated engineering to transparent operation. This exhibit will highlight the integration of engineering, visualization, safety, motion control, SCADA, and PC-based automation, which can enhance your engineering efficiencies and increase your productivity using Smart Manufacturing Solutions.

As we journey toward the digital factory with our machine builders and end-customers in the industry, Siemens offers today's manufacturers the most advanced CNC technology on the market. From controls that run the most basic milling and turning machines to multi-axis, hybrid machines with full automation and robotics, CNCs from Siemens handle the full range of motion control requirements.  Beyond the hardware suite of CNC, drives, motors and PLC, Siemens further provides a full array of communications technology to capture and transmit data from the shop-floor to the top floor, as highlighted by Mindsphere. With customizable apps, end-customers can monitor and analyze machine data, whether on a local network in a job shop, or globally in the cloud. 

In today’s economy, business model innovation and digital transformation have become key topics of discussion among executives – and understandably so. No management activity is more critical than having clarity about how a company creates, delivers, and converts value for its customers. Identifying scalable business models and delivering value quickly is the core of Digital Enterprise Labs activity. Clearly defined and scalable applications in the Cloud deliver a full stack of vertical slices of your business data, from functionality and reliability through analysis and interpretation. By integrating these applications into your daily operations – with minimal financial commitment and in conjunction with your existing systems, like PCS7 – apps enable your future and unlock your potential.

Tour the control products and components walls!  Our products communicate at the smallest device, a push button, for complete system digitalization over a new or existing network for total transparency. We like to call it, “out of the box,” ready to communicate with AS-Interface, IO-Link, PROFINET, and other networks providing the monitoring and diagnostics that you need. Our SIRIUS portfolio showcases IP69K-rated pilot devices and push buttons, IEC motor control & management with AS–i, IO-Link and Ethernet/IP to help prevent faults in automated processes and reduce plant downtime. You can also see the vast array of flexible and modular starters & relays that help save you wiring and costs in your control cabinet. 

Siemens offers a comprehensive range of process instrumentation for pressure, temperature, flow, and level measurement. Pneumatic valve positioners, process recorders, and process protection devices complete the package. Whether you need a single transmitter or a complete package, Siemens has the technical expertise for your process requirements.

Take the opportunity to explore what a Totally Integrated Power (TIP) solution looks like. From the components that make up a power distribution solution to the actual power distribution equipment itself to the digitalization that integrates them, Siemens has an offering that is sure to make your facility a safe, intelligent and more reliable system. Learn about our new 3VA circuit protection offering, the benefits of power monitoring and metering, the efficiencies found with our Smart Switchboard and Switchgear offerings and about the state-of-the-art technologies in low voltage motor control.

The Gaylord Rockies is located approximately 6.3 miles southwest of Denver International Airport.

 

Estimated/One Way from the airport:

Taxi – $20

Uber/Lyft – $15

 

Super Shuttle – $25 (one way)

 

Denver Regional Transportation District (RTD) – $10.50

 

“A Line” from Denver International Airport (DIA) to the 61st & Peña Station (first stop). 

 

Hotel shuttle departs 61st & Peña Station on the Hour & Half-Hour.

Gaylord Rockies Resort & Convention Center | Aurora, CO |, Jun 17 - Jun 20

Siemens Automation Summit - June 17 - 20, 2019

Gaylord Rockies Resort & Convention Center
6700 North Gaylord Rockies Boulevard
Auora, CO, USA 80019

Phone: +1 720-452-6900
Gaylord Rockies Resort & Convention Center website

Pricing

Description 
Price
Full conference (3 days/3 nights – including meals, events and lodging)
$1,795
Conference registration but no lodging
$1,395
Daily conference fee
$500
Early career (with a full paying company colleague)
$995
Early career with no lodging
$595
Guest (3 breakfasts in the conference center, plus Mon & Wed social evening events)
$295
Guest for Monday and Wednesday evening social events
$100
Guest for Monday night only
$50
Guest for Wednesday night only
$50
Downloads

Automation Summit downloads and links