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Content Modular solutions for maximum productivity Integrated solutions Scalable automation systems Comprehensive instrumentation Flexible power management One partner worldwide Experienced Industry Partner 03 04 05 06 07 08 09 10 11 12 13 14 15 2
Modular solutions for maximum productivity Biogas plants are often installed under extreme time and cost pressure. This can only be achieved with the support of an experienced, globally coordinated and locally focused partner. Furthermore, a high level of efficiency must always be maintained during operation of the plant. In the field of automation and energy management, Siemens offers a perfectly balanced portfolio. Renewable energy with the greatest potential Biogas is a flammable gas which is produced by fermenting organic material in biogas plants and is then used to generate renewable energy. This type of energy has a much more favorable environmental impact than many other types of alternative energy and also offers a high level of fuel output per hectare. Biogas can be used universally as a rule, it is used as the fuel for combined heat and power plants (CHP) for power and heat generation. However, it can also be processed and transferred to the natural gas grid, making biogas available more widely and enabling more flexible and efficient use, e.g. in gas turbines with combined heat and power. A wide range of natural materials can be used to generate biogas: e.g. liquid manure, corn silage, sewage sludge, organic waste, straw etc. Increased transparency for economic production Regardless of the raw material used, the size of the plant or the process used, we can offer products and solutions which cover all aspects of the biogas production process. A certain degree of automation will provide the necessary transparency for repeatable and efficient uses of raw material for conversion to biogas. Based on Totally Integrated Automation (TIA) and Totally Integrated Power (TIP), we offer solutions for the optimum integration between automation and electrical infrastructure which will help simply your operations, avoid unnecessary downtime and make for more efficient maintenance. One partner for the entire production process During system installation, which is usually subject to extreme time and cost pressure, we can provide support in the form of efficient engineering tools, modular and scalable products. We can also help to minimize your business risk during operation of your plant through the optimization of the processes and the general reduction of operating costs. 3
The benefits of integrated solutions Totally Integrated Automation (TIA) covers products and solutions from the field level through the production control level to the company management level. Based on Totally Integrated Power (TIP), our power distribution concept ranges from the medium-voltage supply system to the socket. The merging of TIA and TIP and the optimum interaction of all the components used offers technical and economic benefits: Central engineering, operation and monitoring of field technology as well as the motor control center and switchgear with one system provides an integrated view of the production and electrical processes Increasing plant availability and reducing maintenance requirements through integrated asset management functionalities and revolutionary online diagnostics Low installation costs through the use of bus technology allows you to add devices quickly and easily Lower engineering costs due to comprehensive software tools Reduced commissioning time through flexible automation solutions Increasing transparency through automatic archiving and reporting of process and plant information Reduced total cost of ownership and competitive advantage because of the high reliability to your electrical energy utilized in the facility Quelle: GreyLogix GmbH, Lübeck Integrated solutions With Totally Integrated Automation (TIA), Siemens is the only provider of a comprehensive range of products and systems for the automation of biogas plants. Based on Totally Integrated Power (TIP), Siemens also provides integrated, economic and safe solutions for energy management. 4
Sustainability during the installation and operation of your plant The high level of integration of TIA and TIP and the optimum interaction of all the components used enable quick commissioning and the problem-free, profitable operation of your biogas plant. In automation, our offer ranges from the field level to the management level. For energy management, it is optimally complemented by a wide scope of solutions: from transformers, low- and mediumhigh voltage systems through individual control cabinets, power monitoring to compact container solutions. Cost-optimized solutions throughout the entire life cycle Hardware and software from a single source as well as preconfigured and pretested components not only ensure faster commissioning of your plant, they also provide a single resource for global support and the long-term success and availability of your plant. You will also benefit from a reduction in the total cost of ownership (TCO) and can therefore considerably improve your return on investment (ROI). The use of state-of-the-art bus technology also reduces installation costs dramatically in this context, for example. Comprehensive software tools lead to a decrease in engineering effort and associated costs. Our flexible solutions and many years of project management experience minimize the commissioning time for new plants. In existing plants, you can benefit from online monitoring, automated archiving and reporting as well as concepts for preventive maintenance, secure remote monitoring and support and thus reduce your operating costs over the entire life cycle of your plant. Consequently, operational analysis and economic viability calculations are greatly simplified and make it easier to fulfill the required documentation. Automation concepts for varying requirements From an automation point of view, biogas plants differ greatly in the way they further process raw biogas. The process for transforming raw biogas into processed biogas is far more complex in plants which supply the biogas to the natural gas grid than in plants in which the raw biogas is simply cleaned or desulfurized prior to combustion in combined heat and power plants. Depending on the process and the required efficiency level, a biogas feed-in plant involves far more instrumentation and automation than basic raw biogas production. According to the plant type and requirements quantity structure and functionality we can offer the right products and solutions for your automation concept. 5
Scalable automation systems Our modular automation solutions are based on hardware and software components from our comprehensive SIMATIC product range which are designed, engineered, sold and supported by our team. At its heart is the SIMATIC PCS 7, our innovative distributed process control system. The solution can be tailored to particular requirements. Customized parameterization The automation level of a biogas plant must be configured depending on the requirements and the relevant concept. We offer scalable solutions and different graphical configuration tools either integrated directly in SIMATIC PCS 7 or using WinCC flexible. This enables the efficient parameterization of field devices and setup of electrical components. Thanks to open stateof-the-art communications standards, all control commands and diagnostic data as well as the necessary operating faceplates and function blocks are available as a function block library. Communication-capable components such as I/O modules and controllers use the fast PROFIBUS DP or PROFINET system. This means that remote I/O modules can be distributed to the various areas of the plant, leading to shorter cable paths to the field devices and therefore reducing installation costs and commissioning time. Safety integrated as standard In biogas plants, reliable explosion protection is a fundamental factor for the safe operation of the plant. For comprehensive explosion protection, the distributed SIMATIC ET 200iSP I/O system can be installed via a remote PROFIBUS connection in Class 1 Zone 1 or Division 2 areas. This system is the most cost-effective solution for the hazardous area. The intrinsically safe and modular I/O system is particularly flexible and requires little effort in terms of engineering, assembly, space and cabling. For safety-instrumented functions up to level SIL 3, only the required safety components must be added to the standard components to provide scalable solutions. In addition, the SIMATIC Safety Matrix tool can be used to create a simple and clear cause-andeffect matrix of protection functions. This tool offers considerable benefits during project engineering, operation and maintenance because of its simplied approach. You only need to program your interlocks in the Safety Matrix and your configuration logic, change management, testing, operator environment and system documents are generated automatically. Savings potential through plant optimization Depending on the plant size and automation solution, there are various options for increasing the productivity of your plant. Special concepts for online and remote monitoring can be used to reduce your TCO considerably. The use of TIA and TIP provides the full range of diagnostic options, because all field devices, automation and drive components are monitored. Mechanical components such as motors, pumps, valves, or heat exchangers are also supervised. If you decide in favour of a SIMATIC PCS 7 process control system, you can benefit from integrated advanced process control functions, which can be used to implement effective measurement and control concepts, for example to increase output. Further potential can be realized through the use of simulation tools in the control system for engineering change management and for training plant operators. Local control and operation without archiving process data PROFIBUS DP Operator Panel SIMATIC S7-300 Controller Gas analyzer Gas flare CHP Local control and operation with automatic archiving PROFIBUS DP SIMATIC PCS 7 Box SIMATIC ET 200M with weighing system Gas analyzer Gas flare CHP 6
Local control and operation with remote access Central Control Plant A Plant B OS Single Station OS Single Station DSL SIMATIC PCS 7 Box Industrial Ethernet SIMATIC S7-400 Controller SIMATIC ET 200M with weighing system SIMATIC ET 200M with weighing system Gas analyzer Gas analyzer PROFIBUS DP Gas flare PROFIBUS DP Gas flare CHP CHP Central control and monitoring of several biogas plants with web-based local operation Central Control Plant A Plant B Ex-client Web Server Industrial Ethernet SIMATIC PCS 7 AS RTX Controller SIMATIC S7-400 Controller Central Archive Server SIMATIC ET 200M with weighing system SIMATIC ET 200M with weighing system SIMATIC PCS 7 OS Server DSL Gas analyzer Gas analyzer PROFIBUS DP Gas flare PROFIBUS DP Gas flare CHP CHP 7
Comprehensive instrumentation A large volume of measuring data has to be processed during operation of a biogas plant. Integrated in the process automation, this forms the basis for a problem-free production sequence and ongoing optimization of processes. We support the economic production of biogas and its supply into the natural gas grid with a wide range of products, both for explosion-proof areas and for other less safety-critical plant units. 8
Weighing technology for every task The SIWAREX weighing and proportioning system can be used to perform weighing tasks accurately, for example when weighing raw materials and by-products. It also offers calibration and verification capabilities. Precise level meters The SITRANS L device family provides a selection of measuring procedures for continuous level measurement. Especially in the fermenter, the level of liquids and sludge can be measured by radar with the rugged SITRANS LR 200. Point level switches with comprehensive diagnostics Pointek sensors are used to recognize limit levels in order to detect overfilling in tanks or foam. They also provide a wide range of diagnostic data, which enables the early detection of encrustation and maintenance requirements. Intrinsically safe temperature measuring instruments In a biogas plant, temperature monitoring is required at various points, such as in the fermenter or for the quantity of heat produced after the combined heat and power plant. Siemens offers high-precision, intrinsically safe sensors and transmitters, e.g. SITRANS TH, with all the usual approvals for combined temperature measurement. Pressure measuring instruments for maximum economic efficiency Regardless of the point where the pressure has to be measured, be it the gas bubbles in the fermenter or the flow volume of generated gas in the pipeline using a metering orifice, the SITRANS P device family can be used to ensure economic and high-quality operation of the biogas plant. Flow meters that can be calibrated The SITRANS F device family can be applied to perform all usual flow measurements, e.g. magnetic-inductive measurement for precise substrate measurement in pipelines. For heat supply after the CHP, a heat measuring system with calibration capability is available for custody transfer application. Positioner with simple operator control For valve control, the SIPART PS2 intelligent positioner is available for linear and part-turn actuators. Its simple operation, numerous diagnostic functions and low air consumption can help insure successful and efficient operation of your valves. Gas analysis for constant quality Continuous gas analysis with ULTRAMAT 23 enables the monitoring and control of the fermentation process and thus contributes to the quality of the generated biogas. In order to supply the processed biogas into the natural gas grid in accordance with official guidelines, the gas composition and the calorific value and density of the gas must be known. SITRANS CV is the ideal analyzer for determining the calorific value. 9
Flexible power management We offer a broad portfolio of medium- and low-voltage components including power monitoring. Connecting them to the process control system, the world s largest installed fieldbus PROFIBUS provides universal integration in the electrical infrastructure and in the communications standard. The selection of drives for pumps, agitators or heat exchangers ranges from standard motors through energy-saving motors in accordance with EFF1 up to explosion-protected motors for Ex zone 1 / Class 1 Division 1. 10
Transformers and medium-voltage systems When it comes to transformers, we offer the choice between commonly used oil distribution transformers up to 2,500 KVA and GEAFOL cast-resin transformers up to 16,000 KVA, which do not require facilities for oil retention. GEAFOL cast-resin transformers are largely maintenance-free. You can also choose between air-insulated medium-voltage systems (up to 24 KV, type 8BT1) and gas-insulated medium-voltage systems (up to 24 KV, type 8DH/J). The latter are compact, maintenance-free, and can be used in all climates. Communication-capable SIPROTEC overcurrent relays and motor protection can be used to determine the causes of any system incidents quickly and conveniently as they are programmable to protect your equipment and avoid outages. Low-voltage distribution SIVACON switchgear comprises the lowvoltage distribution and the function of the motor control center (MCC). SIVACON is available in withdrawable, plug-in or fixed-mounted versions. TIASTAR, our lowvoltage motor control center for the Americas, offers rugged, safe and efficient designs. For simple switching technology, circuit breakers, overload relays and local switches, etc. are available. When controlling and monitoring low-voltage motors with constant speed using SIMOCODE pro, e.g. on pumps, slides or valves, in addition to the motor control all diagnostic data such as switching status, operating hours, phase currents, motor temperature and electrical active power are transmitted to the automation system via PROFIBUS. Our electronic soft starters for AC motors up to 1,200 kw at constant speed ensure soft startup and ramp-down and therefore reduce the electrical and mechanical load considerably. Frequency converters for all requirements Compact MICROMASTER 440 and SINAMICS G120 frequency converters cover the power spectrum up to 250 kw. They are fully integrated in SIMATIC via PROFIBUS DP and predefined faceplates are ideal for use in agitators, particularly for fermentation. For low power ratings, the converters can be placed directly in the motor control center. Flexible power management In larger plants, power management is essential for economic plant operation. Energy-intensive loads can be identified and effective measures implemented for optimized energy consumption. Highly efficient tools are available for plant-wide visualization, dimensioning of the power distribution and for assessing any modifications: e.g. software add-ons such as SIMATIC PCS 7 powerrate and b.data power management, as well as the SENTRON PAC3200 power monitoring device. They use the fully integrated SIMATIC PROFIBUS DP connection and predefined faceplates for easy operation. Modular solutions for rapid commissioning Biogas plants can be constructed and commissioned more quickly and economically if the components are installed as preconfigured, ready-for-use units individually. We offer modular systems, from the compact control cabinet to the complete E-House in a container. Systems are installed according to functional areas, e.g. biogas generation and gas processing, and with Siemens devices according to customer requirements. The only work required on site is the connection of interfaces and field devices. 11
One partner worldwide With branches in 190 countries around the world, we are a genuine global player with a long experience in this industry sector. We are, therefore, the perfect partner for planners and operators of biogas plants. We support our customers on site from the planning phase through installation and commissioning up to servicing during the operating phase. For many years, we have been providing optimally coordinated, modular solutions to address automation, instrumentation, drive technology and power distribution for the biogas industry and we can guarantee the availability of spare parts and professional on-site support over the entire life cycle of your plant. Benefits for plant constructors Lower installation costs, reduced engineering effort, shorter installation times and the lowest possible environmental impact are all major factors in the successful implementation of projects. With a global network of experts in this sector, we can concentrate on the specific requirements of our customers and meet the high demands in the market Benefits for plant operators We are the leading manufacturer that can offer a complete range of integrated products, systems and solutions for the field of automation and energy management. We offer you modular concepts for operational analysis and optimization which you can use according to your specific requirements. Together with a worldwide service team we offer the ideal basis for efficiency and profitability of your plant both now and in the future. 12
Thinking globally, acting locally In the fields of automation and electrical engineering, as in other sectors, international business requires globally active solution partners with excellent knowledge of local conditions. For this reason, a partner like Siemens is therefore a great advantage present worldwide and with a network for service and support. In addition, Siemens is familiar with national standards, guidelines and regulations and offers an appropriate product portfolio for IEC and NEMA. This helps greatly in the problemfree implementation of global projects and ensures that the system meets all the operator s expectations from the start. Solid knowledge of the industry As a well-known provider of automation and energy management solutions for various industries, we have built up a wealth of expertise over the years. This also greatly benefits our customers in the biogas industry. During both planning and commissioning, we synchronize the activities of all partners, be it for a small farm, medium-sized cooperative or large industrial plant. And at the same time we work very closely together with plant builders and system integrators. 13
Experienced Industry Partner We have been providing solutions for the biogas industry for many years. The reason for our significant role in this sector is the seamless integration of automation, drive technology and power distribution, which is also demonstrated in the numerous projects that we have implemented successfully. Medium-sized farm-based biogas plant The privately owned biogas plant in Weyberhöfe produces biogas from liquid manure and renewable raw materials (e.g. corn and grass). To increase the reliability and efficiency of the plant, it was modernized with the compact SIMATIC PCS 7 Box process control system. For the system integrator, Sigma Engineering GmbH, the economic and compact process control system provides exactly the right solution for a medium-sized plant with 500 kw power. Large agricultural biogas plant One of the largest biogas plants in Europe has been installed in Jessen by Agratec AG with the system integrator HEROS Anlagenautomatisierung GmbH. Since 2008, silage and grain has been used to generate power and heat as well as organic solid and liquid fertilizer as a by-product. Apart from own consumption, the supply of heat and steam from the plant is used by local companies. Following expansion in a second building phase, 5.3 MW of power and 5.1 MW of heat will then be generated in four CHP s. The plant is equipped with Siemens drive and switching technology and the SIMATIC PCS 7 automation system. Various field devices are connected via PROFIBUS PA and two gas analysis stations are connected via PROFIBUS DP. For servicing, remote diagnostics and the ACC alarm system for text and voice messages are integrated. 14
Waste disposal plant In the biomechanical waste treatment plant in Lübeck, biogas is generated from organic waste and sewage sludge. The dried digestate is processed into a substrate that is suitable for landfill in accordance with waste disposal regulations. The gas technology of the plant comprises a gas storage facility, a compressor system and two CHP s with 1.9 MW of power and 2.3 MW of heat. Together with our longterm partner Haase Energietechnik AG, we supplied drive and control technology from our product family. Haase also performs ongoing diagnostics, maintenance and emergency servicing during operation. To ensure that no time is lost during critical operating states, the fast delivery of information as text message and remote diagnostics to remove failure is extremely important. Industrial biogas plant The biogas plant in the Höchst industrial park offers disposal options for organic waste. 310,000 m 3 of sewage sludge and 190,000 m 3 of organic waste are processed every year and 45,000 m 3 of biogas is produced every day. The plant operator, Infraserv GmbH & Co. KG, fed in about 5.1 MW of power and 3.9 MW of heat to the heat and power supply system of the industrial park. In this project, we took on responsibility for the PLS engineering to automate the biogas plant. The plant is controlled using SIMATIC PCS 7, integrated field device technology and pump drive systems from Siemens. Full service provider Schmack Biogas is a full-service provider for biogas plants and biogas processing. The company relies on Siemens products for the equipment of their vertical market plant systems as well. For the safe plant operation, amongst others, drive technology with motors and MICROMASTER frequency converters, automation components such as SIMATIC S7 or process instruments of the SITRANS family is being used. Continuous recording, monitoring and visualization of all process-relevant parameters are of decisive importance for cost-effective operations. The result: added value that can be noticed. 15
Siemens AG Industry Sector Industry Automation P.O. Box 4848 90327 Nuremberg GERMANY Subject to change without prior notice 09/12 Order No.: E20001-A80-T111-V1-7600 WS 09120.0 PDF Siemens AG 2012 The information provided in this brochure contains merely general descriptions or characteristics of performance which in case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners. siemens.com/biogas