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  • Smart energy management in the chemical industry

    TIP Chemical industry

    Industry 4.0 makes high demands on the chemical industry: Through digitalization, the markets are changing rapidly and new technologies, lack of power quality, and grid reliability represent major challenges for companies. This leads not only to new conditions and high technology requirements. Increasing electricity prices also require more efficient production. These requirements stand vis-à-vis to insecure grid reliability and fluctuating power quality as well as increasing complexity of the power  grid. Our Totally Integrated Power (TIP) portfolio meets the highest safety standards and is perfectly tailored to the needs of the chemical industry – for a reliable, economical, and secure power supply.

     

    Securing the power grid of a plant

     

    Because petrochemicals plants in particular are often located in remote areas, they are dependent on a reliable and stable power supply. For this reason, only products which operate reliably under extreme conditions may be used. Generator switchgear with vacuum switching technology reduces maintenance costs together with GEAFOL cast-resin transformers, increasing the profitability of the plant.

    Further problems in remote locations include the lack of grid reliability and fluctuating power quality. The combination of centralized and decentralized energy generation also requires advanced energy management processes. This results in a great amount of data that must be processed.  Comprehensive Big Data analyses are therefore essential in order to convert this quantity of data into relevant and valuable information.

     

    Varying conditions and high demands

     

    The shift in market dynamics and the use of alternative technologies are changing the chemical industry. It is therefore important that the power supply is integrated seamlessly into the process automation and building automation system to make it possible to react quickly and flexibly to market changes.

     

    Because energy prices are rising, cost-effective energy management also plays a major role. Intelligent software and hardware products make electricity consumption and efficiency transparent. CO2 emissions are increasing worldwide, and the extraction of fossil fuels is becoming more difficult. Companies must therefore use resources efficiently. With our efficient microgrid management and our portfolio of concepts for renewable energy, we help them to make production more sustainable.

     

    A turn-key solution for success

     

    Solvay Indupa S.A., one of the largest PVC producers in Argentina, uses our comprehensive portfolio to be independent from the public power grid. To do this, the company expanded its own power generation and transmission capacity. The core component of our turnkey solution is a GIS system with SIPROTEC protective devices and panel control units, a substation automation system, and a protective device. Improved monitoring of the substation, the modern protective device, and the effective remote control system provide greater reliability in the power supply and higher profitability thanks to grid infeed: Because Solvay requires only part of the 120 KW produced, it can feed the rest into the public power grid – and thus increase its sustainability.

     

     

     

    Our Totally Integrated Power (TIP) Portfolio is relevant to many industries. In the next blog articles, read about how companies from the automotive and construction industries benefit from a reliable, flexible, and secure power supply. In addition, find out more about cyber-security, which plays an ever more important role in times of increasingly networked businesses.

     

     

    Here you can find more information and references on the topic of Totally Integrated Power:

    http://w3.siemens.com/powerdistribution/global/EN/tip/references/Pages/overview.aspx​

     

     

    Come see us at our booth in Hall 9 at Hannover Messe 2017 and find out how industries can benefit from Totally Integrated Power when it comes to intelligent power supply.

     

     

    To be sure you’re always up to date, follow us on our Twitter channel @siemensindustry or on LinkedIn. And for energy related topics, follow our Twitter feed Siemens Energy and our LinkedIn showcase page.

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  • Kristina Dotzauer 02/03/2017

    On the way to a smart power supply in the automotive industry

    TIP Automotive

    Some 70 million cars are produced annually worldwide – and the number is steadily increasing. For each car, it is not only necessary for thousands of items to be manufactured; the customization due to customer requirements is also increasing. The automotive industry is therefore dependent not only on flexible production but also on transparent and available data. The prerequisite for this is a flexible and integrated power supply. TIP allows companies to flexibly and efficiently manufacture while minimizing costly downtime.

     

    The automotive market is highly competitive. Companies need to face market- and network-specific as well as economic challenges. Faster time to market for larger production volumes, international standards, and growing electricity demands are just some of the requirements. Digitized manufacturing is also needed to remain competitive in the era of Industry 4.0. And with increasing automation, the amount of data that is produced in an industrial plant is also increasing.  That’s why flexible, integrated solutions are the key to a smart power grid.

     

    Cost pressure requires greater efficiency

     

    To save costs, full transparency of data is important at every stage of the manufacturing process in the automotive industry. Intelligent software and hardware products ensure optimal transparency of energy consumption and greater energy efficiency. To increase the efficiency, reliability, and safety of electrical distribution equipment, we offer integrated planning to automakers. Our TIP Consultant Support includes software tools, tender texts, planning and application manuals, and professional advice from experts. This also includes individual concepts for all plants and requirements.

     

    Availability around the clock

     

    Due to globalization and companies that operate worldwide, times to market are shorter, the models are changing ever more quickly, and the level of customization is increasing. To remain competitive, automotive plants need to operate around the clock and minimize downtime. This makes integrated and customizable power distribution indispensable. Assisting in this, Sivacon switchgear systems distribute energy simply and safely. Thanks to their flexible modules, the system can be adapted to any requirement. The products are constantly being further developed and are therefore always on the cutting edge of technology. In times of building management systems that are becoming ever more complex, Sivacon 8PS busbar trunking systems offer an adaptable solution. Compared to cables, they are easier to install and also have better fire protection. They also require less space when bridging longer distances.

     

    Safe and environmental friendly

     

    For the power range between 50 kVA and 50 MVA, Geafol cast-resin transformers have excellent electrical, mechanical, and thermal properties. Unlike liquid-filled transformers, the insulation made of a mixture of epoxy resin and quartz powder makes the windings maintenance-free, moisture-proof, flame-retardant and self-extinguishing. Temperature-independent controlled cross-flow fans increase performance by up to 50 percent. With a lifespan of more than 30 years, the transformers are particularly environmentally friendly: Upon disposal, only 4% of the material is thermally recycled. 2% is suitable for landfill and 94% flows back into the raw materials cycle.

     

    An automotive plant for Mexico

     

    The South Korean carmaker Kia Motors, part of the Hyundai Kia Automotive Group, was looking for an opportunity to further develop manufacturing capabilities easily for its new plant in Pesqueria, Mexico. FC low-voltage miniature circuit breakers, 3WL air circuit breakers, Sentron molded case circuit breakers, protection, control, and monitoring equipment, and UL switchboards ensure reliable and energy-efficient operation. The versatility of the entire system with cast-resin transformers and air-insulated medium-voltage switchgear NXAIR enables efficient production with the latest technology for Kia.

     

    “In the phases of procurement, delivery, and installation, Siemens S.A. Mexico has added great commitment to the game. We wish to emphasize that the quality delivered and the implementation of the project have been met with our fullest satisfaction.”

    Kim Bo-hyun of Hyundai Engineering Mexico

     

     

     

    The Totally Integrated Power (TIP) portfolio is relevant to many industries. In the next blog articles, learn about how companies from chemical and construction industries benefit from a reliable, flexible, and secure power supply. In addition, find out more about cyber-security, which plays an ever more important role in times of increasingly networked businesses.

     

     

    More information about Totally Integrated Power at KIA Motors:

    Kia Motors Mexico, a complete power solution

     

    Here you can find more information and references on the topic of Totally Integrated Power:

    http://w3.siemens.com/powerdistribution/global/EN/tip/references/Pages/overview.aspx​

     

     

    Come see us at our booth D35 in Hall 9 at Hannover Messe 2017 and find out how industries can benefit from Totally Integrated Power when it comes to intelligent power supply.

     

    To be sure you’re always up to date, follow us on our Twitter channel @siemensindustry or on LinkedIn. And for energy related topics, follow our Twitter feed Siemens Energy and our LinkedIn showcase page.

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  • Kristina Dotzauer 02/03/2017

    Smart power grids require a new, integrated approach: Totally Integrated Power

    Totally Integrated Power

    By 2035, the global demand for electrical energy will rise by another two-thirds. Electricity is the basis for a sustainable energy supply in private households as well as for cities and industry. For a reliable, safe, and efficient supply, it is therefore important to individually exploit the full potential of an integrated power solution.

     

    Increasing digitalization and automation are also changing the energy system: Simple structures are becoming complex networks. The requirements of the various sectors are as diverse as their applications. While the automotive industry emphasizes shorter product rollout times, the safety of personnel and the plant is most important for the chemical industry. The power supply must therefore be flexible, adaptable, and transparent.

     

    Efficient and safe power distribution

     

    Each technical system depends on a reliable power supply, and high-, medium- and low-voltage switchgear and equipment must guarantee maximum availability.In addition to transformers and line contactors, knowledge of the local distribution network plays an important role in continuous improvement and security of the power supply. That’s why solutions for network monitoring, power quality recording, fault recording, and time-synchronous (pointer) measuring devices are essential. Power quality and measurement support electricity suppliers and consumers with solutions for accurate recording and reporting of information to determine, adjust, and improve power quality.

     

    The development of smart networks thus requires a new, integrated approach to provide appropriate information and operator technology solutions. These are to meet the requirements of a smart, networked, and distributed energy system. Network controllers and applications play an equally important role as planning, simulation and Big Data Analytics.

     

    Efficient and environmentally friendly

     

    The Siemens Totally Integrated Power (TIP) portfolio offers software and hardware products, systems, and solutions for all voltage levels for efficient energy management.

     

    The Totally Integrated Power products can be used modularly and fit into any system. The portfolio includes turnkey high-voltage substations as well as low- and medium-voltage power supply solutions that are tailored to individual requirements. To supply industrial processes, we provide safe and economical solutions from a single source: from process-oriented planning of power systems to the selection and design of products and plant operation. This enables an energy and cost-efficient as well as environmentally friendly infrastructure. The close association of TIP with systems of industrial and building automation Totally Integrated Automation (TIA) and Total Building Solutions (TBS) allows users to exploit the entire optimization potential of these solutions: digital planning, monitoring, and control of all processes.

     

     

    TIP is relevant to many industries. In the next blog articles, learn about how companies from the automotive, chemical, and construction industries benefit from a reliable, flexible, and secure power supply. In addition, find out more about cyber-security, which plays an ever more important role in times of increasingly networked businesses.

     

     

    Here you can find more information and references on the topic of Totally Integrated Power:

    http://w3.siemens.com/powerdistribution/global/EN/tip/references/Pages/overview.aspx

     

    Come see us at our booth in Hall 9 booth D35 at Hannover Messe 2017 and find out how industries can benefit from Totally Integrated Power when it comes to intelligent power supply.

     

    To be sure you’re always up to date, follow us on our Twitter channel @siemensindustry or on LinkedIn. And for energy related topics, follow our Twitter feed Siemens Energy and our LinkedIn showcase page.

     

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  • Andreas Milbradt 01/03/2017

    Optimization, integration and the future of the fertilizer industry

    Chemie

    After meeting with experts of numerous leading fertilizer companies from around the world at the recent Nitrogen & Syngas conference in London, it is now time to follow up on the ideas and insights gathered and the contacts made at the event.
    The market is faced with competition, process optimization and capacity adjustment. Solutions to increase safety, to simplify complexity, to improve performance and maximize production efficiency continue to generate great interest. One subject, however, that influences all is smart data and intelligent decision making.

     

    Today’s fertilizer production plants find themselves having to manage huge volumes of data and managing increasingly complex operations. Being able to quickly and flexibly respond to customer needs and market developments involves being “fully in the know” at all times, at each process step. Effective data management is indispensable for everything from increasing plant performance and availability to improving production quality, output, process safety, resource management, systems maintenance, energy efficiency and much, much more – in other words, for gaining and maintaining a competitive advantage. Turning a profit in today’s tight markets requires a high degree of process integration over the entire lifecycle – from the planning phase up to dismantling.

     

    Making the most of your resources

    By investing in innovative technologies designed to get the most out of the available assets and resources, companies can still harvest significant gains over the long term – even in highly competitive market environments. Siemens has a comprehensive portfolio of process automation, instrumentation, safety, monitoring and analyzing technologies, it also has the broadest and most innovative offerings of motors, converters, compressors, single shaft horizontal and vertical turbomachinery for energy savings in ammonia and urea plants. Finally, the digitalization solutions, the analytics and field services for the fertilizer industry are outstanding.

     

    With its future-oriented portfolio of, for example, highly efficient Dresser-Rand centrifugal and reciprocating compressors or the natural gas analyzer SITRANS CV or SIPROCESS GA700, Siemens is well positioned to assist customers in achieving efficiency.

     

    In the areas of predictive maintenance, energy data management, and resource optimization for fertilizer plants, MindSphere, our cloud-based, open IoT operating system, provides a solid foundation for applications and data-based services from Siemens and third-party providers, for example in the areas of predictive maintenance, energy data management, and resource optimization.

     

     

    Interested in learning more about our digitalization portfolio for the fertilizer industry? Visit us online at siemens.com/fertilizer.

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  • Andreas Milbradt 23/02/2017

    Leveraging production efficiency and process transparency in the fertilizer industry

    Nitrogen & Syngas conference and exhibition, now in its 30th year, will be held in London.

    Investing in a new plant, revamping an existing plant, or maintaining your plant to achieve optimal production, safety and environmental performance, Siemens has solutions designed to reduce complexity and improve the total cost of ownership by increasing safety of fertilizer plants, the boost in production quality, performance and efficiency. Even the next technological evolution rapidly transforming the entire industry, frequently referred to as Internet of Things or Industrie 4.0, is already incorporated in the portfolio with the topic of “Digitalization”.

     

    Plant operators find themselves confronted with steadily changing production requirements and ever increasing cost pressures, reliability, safety and environmental protection to keep plant productivity high. At the same time production processes become increasingly digitalized. Plants all over the world generate enormous volumes of data requiring efficient information management. Consequently, process automation, control technologies, transparency and operations intelligence play an increasingly important role in maintaining a competitive edge over the long-term.

     

     

    Continuous monitoring and analysis is key

    The massive volumes of data needing to be effectively collected and managed in today’s ammonia and urea plants continue to grow exponentially.

    Data from temperature or pressure sensors, from analyzers for gazes and emissions as well as compressor performance or energy consumption of turbomachinery are well monitored and managed.

    Highly automated processes generally lead to greater data complexity. The key question here is: How can the collected data from the field be consolidated in such a way to provide decision makers with only the relevant information they need in any particular situation? The answer is digitalization. A common data management platform over the entire lifecycle from engineering to maintenance and innovative process analytics technologies provide an appropriate answer for reducing overall data complexity and for improving production monitoring and flexibility.

     

    Always the right data at hand

    The seamless integration of plant engineering, operation and maintenance will not only help to speed up the engineering times of new plants or revamps. SIMATIC PCS 7 DCS, COMOS plant engineering, SIMIT virtual training and simulation help accelerate plant setup and commissioning times as well as facilitate operator training, plant control, regularly maintenance, documentation and updates. XHQ Operations Intelligence efficiently filter out “smart data” from “big data” in one management cockpit, helping users to utilize assets at its best and make well-informed decisions.

     

    Interested in learning more? Visit us at Nitrogen + Syngas 2017 (Booth 30 ), 27 February - 2 March at Hilton London Metropole, London, UK or online at www.siemens.com/fertilizer

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  • Bernhard Neumann 23/02/2017

    Switchboards as a rich source of data

    In the process industry, other matters tend to take second place as long as systems are running. It is not uncommon for a lot of data, like that supplied by a modern motor management system, to remain unused. But it doesn't have to be that way: OPC UA communication turns switchboards into useful data providers commensurate with the aims of Industrie 4.0 without having to intervene in process technology.

     

    There is a huge mass of control, process and measured data in the process industry. Most of it originates from motor management systems such as Siemens' Simocode pro (www.siemens.com/simocode). These devices feature integrated control, switching and protection functions and provide data on dozens of different variables such as current, voltage, phase, temperature, operation, symmetry, energy, diagnostics, etc.

     

    OPC UA as a dedicated communication channel for bulk data

    The trick is to analyze this flood of information in a targeted fashion so that it can be used to optimize production systems. With the OPC UA (Unified Architecture) communication standard – also known as the IEC 62541 standard – this can now be done without elaborate engineering and without having to interfere in the existing process control system. The motor management system directs the flow of data via Ethernet right to where it is processed.

    That can be an MES, ERP or energy management system or even a Cloud with corresponding facilities for analysis and documentation. In this way, switchboards and motor control centers (MCCs) are turned into rich sources of data that contribute to process optimization. Saving, analyzing and visualizing these enormous amounts of data is particularly straightforward in centralized computer systems such as the Siemens "MindSphere" Cloud (www.siemens.com/mindsphere).

     

    Secure and straightforward process optimization using the Cloud

    Using such a low-cost and scalable Cloud platform as an open operating system for the Internet of Things (IoT) creates many benefits for the process industry – like a Platform as a Service (PaaS), so to speak. Predictive maintenance, energy data management and resource optimization are just a few examples showing how information obtained at field level can be put to good use. MindSphere provides a development environment in which users can integrate their own applications and services.

    And of course Ethernet-based OPC UA communication based on TCP/IP delivers the benefit of fulfilling key additional tasks such as tamper protection (security). For example, the direct dialog between the field level and subordinate control systems – which works without the actual process control – is protected by appropriate encryption mechanisms.

     

    Sustainability supported by "communicative" switchboards

    To sum up, the control, switching and protection functions the Siemens Simocode pro motor management system with OPC UA communication not only ensure smooth-running production processes, they also enable improvements to be made without having to intervene in process control. Furthermore, the devices possess features such as teleservice, network integration and Web capability, thus creating an environment in which switchboards and MCCs are able to act as valuable sources of data lending long-term support to the process industry.

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