You are invited to join your peers, Siemens experts, and industry technical leaders for our next Automation Summit, June 17-20, 2019. Join us at the brand new "rustic chic" Gaylord Rockies Resort and Conference Center in Denver's eastern suburb of Aurora, Colorado.Don't miss this opportunity to interact with Siemens experts and see demonstrations of the latest technologies - hardware and software. All areas of industrial automation will be covered including factory, process, motion, and drives.
Abstracts are approved in three rounds of voting by the User Advisory Board. Below are the approved abstracts for 2019.
Go to the Automation homepage to learn more about the summit and to submit an abstract.
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, Dow Chemical
Ramesh Kommu works at the Dow Chemical Sabinet 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, Dow Chemical
Ariel Vargas-Colon works at the Dow Chemical Sabinet 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.
Kongsberg and 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, Kongsberg
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, SBM Offshore
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.
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, DuPont
Anthony 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.
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, Tessenderlo Kerley Inc.
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.
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, Trident Automation
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
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.
Forrest “Woody” Hulbert, Air Products
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.
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, Mary Kay Inc.
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.
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, Dow Chemical
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.
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, RoviSys
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.
Stepan Corp and 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, Stepan Corp
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, Cross Corp
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.
Sartorius Stedium Biotech and 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, Sartorius Stedium Biotech
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, Siemens
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.
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, aeSolutions
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, Golden Grain Energy, LLC
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, Trident Automation
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.
Berry Global and 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, Berry Global
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, Cross Corp
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.
Airgas and 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, Airgas
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 Pilotte, Applied Control Engineering
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.
Birla Carbon of Franklin, LA is a leader in carbon black production. We were 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, Birla Carbon
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.
MilliporeSigma and 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.
Andrew Sheppard, MilliporeSigma
Andrew Sheppard is a Senior Process Engineering at MilliporeSigma in Sheboygan Falls, Wisconsin. This chemical site has several capital projects that are using PCS 7 control systems for their automation. Andrew has more than 20 years’ experience as a process engineer in roles of increasing responsibility. He earned a B.S. Chemical Engineering from Massachusetts Institute of Technology.
Nathan Nutter, Trident Automation
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.
Air Products and Chemicals and Applied Control Engineering
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, Air Products and Chemicals
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.
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, Pigler Automation
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.
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, Solid State Automation and Controls
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.
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.
Mark Smith, Western States Controls
Mark Smith is a Senior Control Systems Engineer for solution partner Western States Controls based in California. Mark is a PCS 7 certified engineer experienced on PCS 7 and migration projects. He has been with Western States Controls for more than 20 years, and in the process control industry for over 35 years.
Cross Process Control Systems Group and DTE Energy
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, Cross Process Control Systems Group
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.
Road Map & Feedback Sessions
Roadmap and feedback sessions give the user community a chance to hear about Siemens latest innovations and provide feedback on these topics.
The PCS 7 Product Management team will provide an overview of the new products and features introduced with the latest PCS 7 release. This session focuses on PCS 7 V9 and V9.1, and also includes how Siemens is adopting the Global Digitalization Initiative into our product portfolio with the introduction of new I/O hardware solutions based on PROFINET, improved engineering tools to support digitalization, improved maintenance tools and improved operational awareness. We will highlight where the user community feedback has helped shape these innovations and where we can share best practices to help improve your experience with the system. We will also discuss where you can learn more about these topics from breakout sessions and hands-on training.
Stacey Jarlsberg has spent the last 35 years providing process and control engineering assistance to a wide segment of the controls market, including nuclear and fossil power generation, automotive assembly, pulp and paper, chemical, pharmaceutical, food and beverage and petroleum. During the past 17 years, Stacey has been working to provide DCS solutions based on both APACS+ and PCS 7. Specifically, Stacey is responsible for the product management for PCS 7, APACS+, QUADLOG including Logic Matrix, and the migration of products including APACS+ OS, OPEN OS and Bailey systems to PCS 7. Stacey spent nine years in the US Navy aboard ships and nuclear-powered submarines. He was responsible for reactor operations and maintenance, and it was here that he developed a passion for automation.
Global collaboration, empowered operations, intuitive user guidance, digitalization and modular automation. In this session, the Process Automation Product Management team will share how these key requirements of the process industries provided the motivation behind recent innovations in process control. We will discuss the process we went through to “reThink” process automation and imagine what a DCS could be like and the advantages it should be able to provide to all users. We will share some of the key innovations and highlight how they improve both engineering and operation efficiencies today, and then take a look into future of the DCS.
Doug Ortiz has worked passionately for 13 years exclusively on Siemens process control systems. Much of his time was spent in control rooms while his responsibilities have ranged from PCS 7 Project Execution for medium and large-scale plants to PCS 7 Technical Support. His skillset is centralized around control theory, bulk engineering, system architecture, hardware, device and fieldbus integration, fail-safe systems, medium-fidelity process simulators, virtualization, and sequential processes. Doug's current assignment takes him to Karlsruhe, Germany, where he works collaboratively on several aspects of the innovations with regards to the hardware and software for DCS. He holds a BS in electrical engineering from Temple University and an MS in Systems Engineering from Pennsylvania State University.
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.
Choose from our available free, hands-on training sessions led by Siemens Sr. Technical Consultants. Students will be led through exercises and labs using the latest technologies while sharing a workstation and equipment with another student. All classes include a certificate that can be submitted for professional development hours
Making you a Pro at PROFINET and Process Automation
Thursday, June 20, 8:30 – 12:30
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.
Please join product management and technical consulting team of Siemens Process Automation, Automation & Engineering for this training event.
PCS 7 Innovations Adoption and Preparing for the Future
Tuesday, June 18, 1:00 - 2:45 PM and Wednesday, June 19, 1:00 - 2:45 PM
This session will review the reasons and steps to adopt the innovations in PCS 7 V9 including the hardware, software and cybersecurity benefits. We will also discuss the Advanced Process Library (APL) and Control Module Types (CMT) and provide presentations, demonstrations 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 include time for you to ask specific questions regarding your upgrade to and adoption of these innovations.
Please join the technical consulting team of Siemens Process Automation, Automation & Engineering for this training event.
SIMIT Roadmap, Feedback, and Training Workshop
Wednesday, June 19, 8 – 9:45 AM
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 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 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.
Tech Cafe Solutions
The industry is right on the threshold of the fourth industrial revolution. Automation is being followed by the digitalization of production. The goal: an increase of productivity, efficiency, speed, and quality, resulting in higher competitiveness for companies on their way to the future of industry. Here you will find Siemens’ comprehensive offering for automation technology and the digitalization of production.
Only the consistent integration of data allows benefiting from all advantages of digitalization. Integrating industrial software and automation, extending communication networks, security in automation, and using business-specific industrial services achieve this..
Designed for reducing risk in your process applications, the SIMATIC SIS Compact is a standalone safety control system based on proven SIMATIC system components. It features the world’s first controller certified for both safety and security and was specifically designed for critical industry applications where third-party DCS systems are already installed.
Digitalization is about information from the field. Whether it’s a pressure value measured at a pump, a temperature hot spot measured in a vessel or a maintenance alarm coming from a valve positioner, Siemens process instrumentation provides all the most vital data to ensure efficient and safe operations.
SIMATIC PCS 7
Expanded functions and intelligent features such as the Advanced Process Library, Control Module Types, Logic Matrix, and Advanced Process Graphics provide even more efficiency, security, and flexibility in PCS 7 engineering and operations. Software innovations include the SIMIT Simulation Platform for virtual commissioning and training as well as the Process Automation Accelerator (PAA) for automated engineering.
SIMATIC Hardware for Distributed Control Systems
Be Ready for the Future with a system based on PROFINET and the SIMATIC S7-410 controller, ET 200SP HA I/O, and Compact Field Unit.
SIMATIC PCS neo
Reach a new level of usability, collaboration, and digitalization in process automation with Siemens’ innovative web-based distributed control system. SIMATIC PCS neo’s open and flexible architecture supports multi-user engineering and is scalable from small process applications up to large scale plants.