Efficiency Days HMI Hannover

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1 Efficiency Days HMI Hannover Condition Based Monitoring as part of Asset Management, Condition Management and Energy Efficiency in order to improve Plant and Production Optimization. Siemens AG Alle Rechte vorbehalten.

2 New Trends in Prozess Automation Asset Management Condition Management Energy Efficiency

3 Production Efficiency Process Optimization with intelligent Analytics and Instrumentation Solutions with advanced Diagnostic functionalities in order to improve Plant / Energy Efficiency

4 Reduction of unscheduled downtime,protection of equipment, improvements on safty and reduction on preventive maintenance

5 Unique Portfolio or Hybrid Industries Level Flow Example: Brewery Mashing Pressure Positioner Lautering Temperature Fermentation Brew Kettles Heat Exchangers Yeast Propagation Aging & Storage Filtration IWLAN / PB Link Industrial Wireless LAN Machine Vision Proximity switch Fail safe sensors Filling Line RFID

6 Sensors & Communication Industry Competence and Tools Chem / Petrochem and Oil&Gas Industry

7 Topics Keyboard Chem/Petrochem and Oil&Gas Industry SIEMENS Customized Presenation Market Analysis Segmentation Up/Downstream Segmentation Chem/Petroch Segmentation Oil&Gas Total Cost of Ownership Energy Efficiency Asset Managem. Condition Mgmt. Diagnostics Training Documents Company References Competitor Analysis Technology Keyboard Product Portfolio Product Selector Product Fit Analysis Key Customers Vendor Listing Prequalificat. Country Activities Wireless Sensors/Com. Quality/Cert. Safety SIL,EEx,Profis. MarketingComm. Solutions 3.1 / 3.2 Operational Conditions Innovation Application Keyboard Fiscal Metering Custody Transf.

8 Toluene Loading Station Condition based Monitoring and Process Optimization using Process Automation and Analytic Technologies with intelligent Diagnostics and Monitoring Functionalities

9 From Condition based Monitoring to Condition Management Condition based Monitoring / Management is a major process in order to optimize production processes concerning facility operation, efficiency, production quality, quantity and to achieve production repeatability particular during the running production process. A major step is to identify the actual requirements, demands and future trends in various industries in all international regions, part of this process is the development and establishment of the competemce concerning detailed segmentation of industries by total solutions, partial solutions as well as single components,applications and support. In order to improve the achievement of business results, a reactive and preventive maintenance process of production facilities has to be turned into a predictive concept.

10 Selection Criterias / Requirement Specs Physical Measurements Technology-Selection Industry-Segments Solutions Application Database Product-Selection Solutions

11 Chemical/Petrochem and Oil&Gas Industry Segmentation Offshore Drilling LNG Pipeline Oil&Gas Onshore Oil&Gas Fields Chemical Industry Basic Chemicals (e.g. Fertilizers) Fibers/Foils (e.g. Nylon) Specialty Chemicals (e.g. Oil additives) Compression Gas Treatment Injection Gas Storage Refinery Petrochemicals HPI Fine Chemicals (e.g. pharmaceutical pre-products) Tankfarm Air Separation Bio Chemicals (e.g. Bio-Ethanol)

12 Upstream - Offshore Exploration and Drill Rigs

13 Process Optimization on FPSOs Flare Gas Compression Water Injection Power Generation LQ & TSR* Turret Offloading E-House Cargo & Ballast Tanks Gas/Oil Separation & Stabilisation

14 Total Breadth of Solutions for Oil & Gas Transportation - Pipelines and LNG/CNG Carriers IT Solutions Engineering, Project Management, Site Services Automation Systems, Process Instrumentation, Motors & Drives HVAC, Fire Protection, Security, Building Automation Maintenance & Service Power Transm. & Distribution, Energy Mgt. Power Gen., Compressors, Gas/Steam Turbines Upstream Transport & Storage Midstream Downstream Control Center Pipeline Metering Station Valve Station M Compressor Station

15 Leak Detection and Location

16 Storage - Tank Terminals

17 Safety shut down Systems Ethanol tank farm on fire in Australia Chemical tank farm accident Barton Solvents tank farm fire in Kansas, 2007 Tank farm explosion near Dumas, Texas

18 Refineries ES OS OS Graphics Alarms Trends Diagnostics Control PCS 7 BOX PROFIBUS ET 200M ET 200iSP Ethernet ET 200S DP/PA PROFIBUS PA

19 Process Instrumentation on Blending Utilization Processes Level / Mass-Flow Measurement with LR 300 and LC 6000

20 Polyol and Additives Production Processes

21 Subsegment Process Reactors Polymer Production

22 Condition Based Monitoring - ENERGY EFFICIENCY Asset and Condition Management Condition Monitoring and Process Optimization using Process Automation and Analytic Technologies with intelligent Diagnostics and Condition Based Monitoring Functionalities in order to improve Plant Efficiency / Energy Efficiency

23 Energy Efficiency The topic of energy efficiency has come to dominate the field of industry. This is set to continue into the future as a result of political requirements and concern about the environment and climate. The opportunity to gain cost and competitive advantages through the more efficient use of energy will also ensure that the topic does not lose its importance. Although efforts have been made in the area of energy efficiency in the past, there is still significant room for improvement in the various industrial sectors.

24 Increase of Energy Effeciency with Process Automation Solutions Source ZVEI

25 Energy Efficiency Studies show that, from the energy source to the consumer, up to 80 % of the energy currently used in the various production, transmission and conversion stages can be lost. Source ZVEI

26 Energy Efficiency Source ZVEI

27 Major Market Trends in Process Automation Goal: Reduction of unscheduled down-time, protection of equipment, improvements on safety and reduction of maintenance. Asset Management Process Analytical PAT Security Wireless Communication M2M Communication Industrial Ethernet Wireless Sensors Intelligent Field Devices RFID Machine Vision

28 Definition of Plant Asset Management Plant Asset Management Therapy / Maintenance Proposals and support Operation Communication Prediction / Prognosis Communication of the below Forecast Information Provision and Archiving Evaluation Maintenance Diagnosis Evaluation Cause Diagnosis finding Analysis Processing Distribution Engineering Condition Monitoring Signal Characteristic Analysis Business admin.

29 Totally Integrated Automation: Seamless Integration from Field to MES Automation Hierarchy Management level MES PAMS Host computer Products and Systems Control level OS MS Monitoring & control systems Programmable logic controllers Field level CM CM CM CM CM CM CM CM CM CM Sensors, actuators, drives, field instruments Detectors, switches

30 Integrated Plant Asset Management Monitoring & Operating OS MS AS1 AS2 ASn S1 Sn... Maintenance Station integrated into the Operator Station OS OS MS C1 Cn AS1 AS2 ASn... Maintenance pictures OS Clients with access to maintenance area (pictures, messages, faceplates) Maintenance Station has additionally direct online access to PDM and hardware engineering AS Automation System C Client MS Maintenance Station OS Operator Station S Server All diagnostic capable SIMATIC PCS 7 components + non-intelligent assets + Common and unified symbols for representing the status of all assets Good Announcement of request for maintenance (low) Request for maintenance unknown/not activated Simulation Function control/ local Request for maintenance (medium) Maintenance alert (high) Request for maintenance activated Request for maintenance in process

31 Remote Monitoring Service Tool for CBM Supported Products & Data Security Supported Products Compressors (STC) Steam Turbines (SST) Small Gas Turbines (SGT) Medium Gas Turbines (MGT) Generators and Motors STA RMS supports all products from Energy Oil & Gas / Chem / Petrochem Common Remote Service Platform (crsp) Secure connection (VPN) Data Secure Zone (DSZ) Redundant Fall Back concept Authentication and authorization concept CERT (Computer Emergency Response Team) und ISO certificated Guarantees the security of your data

32 Life Cyvle Management - Single Source for Services Automation, Instrumentation, Electrical and Power Introduction/ Situation Requirements Service Concept Concept in detail Benefits Summary Become a substantial part of the customer's operations team for entire scope of delivery OTN PLC Automation & Telemetry Product Related Services Keeping specialists readiness for 24/7 hotline support and On-site fault elimination Software & Hardware updates Maintenance & uptime Services Includes third party equipment Value Added Services Remote assistance & diagnostics Condition based monitoring Modernisation & Migrations Shut Dows Services Consultation for Energy Saving, Project Management and Maintenance Process Multi Vendor Services Operation of the maintenance concept Planning Scheduling Performance Improving services focussed on Key Performance Indicators Reliability guarantees on demand

33 Life Cycle Management Concept Partner for the whole life-cycle of your plant Capabilities for project development, Implementation and operation Erection System Test Assembly/ engineering Putting into operation Delivery/ Shipment Projectmanagement HW, SW Engineering Studies / Planning Documentation Lifecycle Management Product Related and Value Added Services Operation Related Services (Frame Agreement) Modernization / Migration Services Total Cost of Ownership / Plant Availability

34 Condition Based Monitoring - Insulation Analysis Examination of the insulation enables damage to be detected at an early stage. For example: grounding and interturn faults, core burning, and damage to the end winding or laminated core. Remaining life analysis the winding seasons due to electric and thermic stress. For an extensive assessment of a machine's winding, we perform the following measurements: Insulation measurement Calculation of the polarization index Measurement of the loss factor tan δ Measurement of partial discharge (for critical machines during operation as well) Measurement of the charge and discharge curves (acording to the IEEE standard)

35 Condition Based Monitoring-Analysis of Electrical Networks Voltage curve anomalies, high energy consumption and wrong measured values may be caused by line faults. To identify weak spots like this and their causes the following analyses are carried out: Analysis of system perturbations Line fault analysis with measurement of all relevant network parameters Analysis of performance in supply systems and frequency converters Analysis of harmonics Evaluation of the network quality as defined in EN 50160

36 Prozessoptimization with advanced Diagnostic Functionalities Evaluation of Frequencies / Frequency Shift / Phase Shift / differiential Frequencies/ Frequency Attenuation

37 Flow Technologies Flow, Volume,Density, Concentration and Massflowmeters Closed pipes applicable restricted Open Channel, non-filled pipes Solids Flow/ Impact Flow non applicable Comparison Applications Rotary piston meter Oval wheel meter Twist flowmeter Belt Scales Mass Dynamics Turbometer, Positivdisplacement meter, Woltmanmeter Massflowmeters Coriolis omega / bent tube Coriolis parallel tubes Coriolis single straight tube Thermal Variable Areaflowmeters Volumemeters Volumeflowmeters Ultrasonic Flowmeters Vortex flowmeter Effective Pressure Technology Magn. Ind. flowmeters Flowmeter Single Beam Intrusive Transit Time Multi Beam Transit Time Magn. ind. Flowmeters Venturi US Flow rectangle-, triangle weir Non Intrusive (Clamp on) Single Beam Doppler Doppler TransitTime Pipe Spool Piece Multi Beam Transit Time CLOSE Pulsed DC Pulsed AC AC Narrow Beam (Shear Mode) Wide Beam Narrow Beam (Shear Mode)

38 Technology Comparison e.g. Flow,Volume,Density,ConcentrationMass - Detection

39 Pulsed AC / DC, Rectified Field MAG Flowmeters Flow and Condition Monitoring

40 Magnetic Flowmeters Condition Monitoring Metal Particles in Media Metal particles in media

41 Effective Pressure Flow Technologies Flow and Condition Monitoring

42 Differential Pressure Condition Monitoring Fouling of Impulse Line Impulse Line

43 Ultrasonic Clamp on Flow Meters

44 Optimization and Reduction on Waste of Natural Sources and Environmental Cleaning Energy and Costs of more than 1 mio Condition Monitoring an Durchflussleitungen zur Optimierung von Pumpen- und Kompressorleistungen zur Erhöhung der Energie - Effizienz, Leckage Detektion und Monitoring von Rohrverschmutzungen zur Reduzierung von Reinigungsenergien, Pumpenund Kompressorenergien, Umweltverschmutzungen, Verschwendung von Rohstoffen sowie Betriebsenergien. Optimization and Reduction on waste of natural source s and Environmental Cleaning Energy and Costs Einsparungpotential: Erfassung und Optimierung von Betriebskonditionen an Flüssigkeits- und Gasdurchflussleitungen zur Optimierung der Energie Effizienz, Produkttransportkosten sowie Anlagenverfügbarkeit und Umweltbelastungen. Detektion von Verstopfungen, Verschmutzungen, Verschleiss und Leckagen die zur Erhöhung des Energiebedarfes beim betreiben von Durchflussleitungen führen. In mehrern Leckagesituationen bei Ölpipelines konnten durch Früherkennungen die Verschwendung von Rohmaterialien um mehrer Millionen und die Kosten für Reinigung der Umwelt und Reinigungsenergien sowie Folgeschäden zusätzlich um mehrere Millionen verhindert werden.

45 Level Technologies Continous Point Level Mechanical Electronic contact Electronic Non contact Interface Overfill Protection Servo Di splacer Capacitance Ultra sonic Servo Di splacer Oscillating Vibrating Servo Sense Disc TDR Optical Laser Capacitance Capacitance Float Conductive Nucleonic TDR Conductive Magnetostrictive Static Weighing Hydrostatic Static weighing Radar Ultra sonic Radar Nucleonic Hydrostatic Delta P Submersible Chirp Puls Hydrostatic Optical Laser Ultra sonic Absolute Bubble System Reflectometer FMCW Radar Pressure Keyboard Low / High Frequency CW TDR

46 Level Measurement Technologies Sitrans LG Sitrans LU Sitrans LR Sitrans LR Sitrans LR Sitrans LC Guided Wave Radar / TDR Ultra sonic 2 wire Pulse Radar 4 wire Pulse Radar 4 wire FMCW Radar Capacitance Interface LEVEL TECHNOLOGIES Technology Description Application Simulation

47 High Temperature Application with Level-Radar on Polymer and Paraffin Ractors (Cond.Monitoring)

48 Level-Radar High Temp Unit with 200 mm heat extension

49 Production Process Paraffin Thermographie after new configuration (Management)

50 Process Optimization with Instrumentation Technologies Styrene / Styrol Process Reactor Level Radar Dust Vapour Steam 10dB Construction Obstacles Tubings Interference Foam Turbulent Product surface Votex Heating Coils Agitator 30dB

51 Energy Savings due to reduced Down Time and Cleaning costs of /month on each Reactor Produktionsoptimierung in Prozessreaktoren als Teil von Asset Management. Optimierung der Energiebilanz, Produktionskosten beim Anfahren von Produktionsprozessen, Sicherstellung der Produktionseffizienz sowie Reduzierbarkeit Schaum der Produktionsqualität und Quantität sowie Erhöhung der Energie Effizienz in der Prozess Industrie Einsparungspotential Reduzierung von Energiekosten beim Anfahren von Produktionsprozessen Erhöhung der Energie-Effizienz hinsichtlich Einsparung bei Heizprozessen und Reinigungsprozessen Erhöhung der Anlagenverfügbarkeit Vakuum Entleerung Harzprodukte Bypass / Filter Optimierung der Produktionsqualität durch Erhöhung der Messsicherheit von Sensoren sowie Monitoring von Prozessparamern wie Schaumbildung, Verschmutzung und Überfüllung Das Energieeinsparungspotential wurde vom Anlagenbetreiber mit im Monat pro Reaktor ermittelt 40 db Rohmaterial Verkrustungen Entleerung Titandioxide 30 db 20 db

52 Pressure Technologies Ceramic Cell Piezo Resistive Remote Seal Diaphragme Capacitance Dry / Ceramic Cells Inductive Resonance Vibration Differential Pressure Absolute Pressure Gauge Pressure Submersible Bubble system Air/Nitrogen Injection LEVEL Differential Pressure Absolute Submersible Bubble- System Differential With PLC Air/ Nitrogen Injection Hydrostatic Incl. density FLOW Orifice Screen condition detection Calibration Goldplated Diaphragme CLOSE Venturi Steam Shock P300

53 Pressure Measurement Condition Monitoring - Fouling of Membrane

54 Acoustic Condition Monitoring Pump Worn and Efficiency Monitoring Hose Membran Pump

55 Oscillating Displacement Pump

56 Positioner Technologies Actuaters Electric Pneumatic Hydraulic Valves Linear Rotary PS3 Enclosures Flame proof Stainless Steel Plastic Perforated Plug Valves Linear Plug Valves Eccentric Plug Valves Sliding Gate Valves Gate Valves Bray Butterfly Valve Ball Valves Turn Plug Valves Damper Drive Positioners Pneumatic Electro Pneumatic Electro Pneumatic Digital Intelligent Single Acting Double Acting CLOSE Diagnostics 3D PDF Exploded view Configuration Simulation

57 Valve Condition Monitoring Preventative Maintenance

58 Asset Management / TCO / Condition Management Valve and Positioner Configuration Optimization

59 Condition Monitoring and Management on Valves and Flow Lines

60 Energie Savings on intelligent electr.pneumatic Valve Positioners /a Energy Savings on Motors driving pumps of /a Condition Monitoring an Ventilen, Pumpen, Filtern, Kompressoren Optimierung von Energie - Effizienz, Produktionseffektivität und Operationskosten mit intelligenten Prezess- Instrumentierungstechnologien und Sensoren Einsparungspotential Erfassung und Optimierung von Betriebskondition an Aggregaten und Aktoren zur Erhöhung der Energie Effizienz von Antrieben und Versorgungsenergien, Erhöhung der Produktionseffizenz sowie Reduzierung der Maintenance Kosten Detektion von Verstopfungen, Verschmutzungen, Verschleiss und Leckagen die zur Erhöhung des Energiebedarfes beim betreiben von Anlagen/ Aggregaten führen. Einleitung von Lösungen zur Verhinderung bzw. Reduzierung von ungeplanten Prozesszuständen die zur Erhöhung der Produktions- und Energieeffizenz führen. Am Beispiel von elektro-pneumatischen intelligenten Ventil-Stellungsreglern im Vergleich zu konventionellen Stellungsreglern liegt die durchschnittliche Druckluftersparnis bei ca m³ pro Jahr was einer Ersparnis von ca. 500 entspricht. Bei einem mittleren Betrieb mit 1000 Ventil-Stellungsreglern entspricht das einer Energieersparnis von ca pro Jahr. Durch Wirkungsgradverlust und Falschauslegungen von Pumpen bei 5% erhöhter Leistungsaufnahme ergibt sich folgender erhöhter Energieverbrauch:Motor 100KW bei Betrieb von 300Tagen KWh = /Jahr Kosten (Invest ition und Instandsetzung) Wirtschaftlichkeitsvergleich einer Schlauch-Membran-Kolbenpumpe mit und ohne Online-Ventildiagnosesyst em 0 Einsparpotenzial Einsparpotential ohne Onl ine- Ventild iagnose mit Online- Ventild iagn ose Jahre

61 Process Analytics Applications Continuous Gas Analyzers Gas Chromotagraphy Spectrometry Exhaust Gas Analysers UV Oxygen FID Hydrogen Infrared Standard Miniature Laser Spectrometry Mass Spectrometry AOTF FTIR/FTNIR Sibench E-box Single or few components Stack Emissions Monitoring Combustion Control Incinerator Measurement H2O/Trace H2O Multi Component Complex Gas Streams Single or few components Stack Emissions Monitoring Combustion Control Incinerator Measurement H2O/Trace H2O

62 Liquid Analytics Conductivity ph/orp/redox Dissolved oxygen Nutrients Turbidity/Solids Sum Parameters Disinfection Cationic/Anionic Turbidity Suspended solids Sludge level Chlorine Chlorine Dioxide Ozone Total Organic Carbon Dissolved Organic Content Total Phosphate Ortho Phosphorus Ammonia Acidity/Alkalinity Chloride/Cyanide/Fluoride Hardness/Hydrazine Hydrogen peroxide Silica/Silicic Acid Sodium/Sulphide/Sulphite

63 Recovery of Hydrocarbons with an Energy Equivalence of 7mio Liter of Cruide Oil per year

64 Industry Segmentation Bioethanol Production Processes

65 Product Fit for Ethanol Applications Delivery Storag e Millin Saccharification g Liquefaction Fermentation Di stillatio n Dehydration Storage Petrolium spirit Enzym es Yeas t Methylation Water Co 2 Distillation Fracti onatio n Bioethanol Superheated steam Cooling tower/cooling plant Separation Concentration Destiller s wash Syrup DDG S Drying DGS Bioethanol Storage / Loading

66 Industry Segment Biodiesel Production Process

67 Biodiesel Production Process Flow Chart

68 Biogas Production Process

69 Flow Chart Biogas

70 Industry Segment Solar Opportunities in Solar Industry Siemens AG Alle Rechte vorbehalten.

71 Value Chain Solar Industry Feed Stock Products for Energy Conversion Field Installation PV Cell based MG silicon Poly Silicon TCS synthesis CVD reactor Ingot Brick Wafer mono, poly Cell mono, poly Glass assembly Module assembly On grid power farm On grid roof top PV Thin film Amorphous Silicon, compound Semi materials, float/cast glass Metallization of float glass Thin Film coating Tempering of glass Module assembly Off grid installation Glass substrate float Bending Mirror coating Glass tube receiver On grid power farm CSP PV = Photo Voltaic, CSP = Concentrated Solar Power

72 Connectivity with emphasis on Wireless Solutions Alcohol,Solvents,Lubricants

73 Wireless Technologies,Concepts and Applications

74 Wireless Communication today and tomorrow Customer requirements can be solved optimally and reliably Example: Brewery Mashing Level Flow Pressure Positioner WAN GSM Wireless HART Fermentation Lautering Brew Kettles Temperature GPRS Yeast Propagation Aging & Storage Heat Exchangers EDGE Filtration Industrial Wireless LAN.. IWLAN Machine Vision Proximity switch Fail safe sensors RFID Filling Line Wide Area Networks (wireless)

75 Wireless Sensors for Process Automation Wireless makes stranded diagnostics data airborne MS Asset Management Station This application allows predictive maintenance and condition monitoring without impact to any installed automation system which doesn t support integrated HART communication (~90% in market)

76 Condition Based Monitoring / Management The goal and target is competent support starting with the planning process of production facilities until the commisioning and start up as well as support and consultance over the whole facility life cycle in order to reduce follow up costs as part of Total Costs of Ownership and Down Time and avoid additional unexpected modifications to optimize production volume and quality. The key tasks for the increase of efficiency during the implementation of condition based monitoring management are: Reduction of unexpected down time Production quality Production quantity Production effectivity and repeatability Protection equipment and components Increase of safty Reduction of non useful preventive maintenance Energy Efficiency Up to 50% of preventive maintenance investments are not neccessary, these expenses can increase up to 20% of the total maintenance costs. This conclusion is a clear statement and fact to change from preventive to predictive maintenance strategies.

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