Kemira, a global chemicals company serving customers in water-intensive industries, is expanding its longstanding cooperation with Bilfinger to Sweden. Bilfinger, which has been providing Kemira with various services at the Austrian location in Krems since 2001, now also assumes exclusive responsibility for maintenance and project-related services, including engineering, at Kemira’s Helsingborg location in southern Sweden from June 1, 2018. This success was preceded by a comprehensive selection procedure from which Bilfinger emerged the winner thanks mainly to the Bilfinger Maintenance Concept (BMC). The contract in Sweden runs for a period of about three-and-a-half years and has a volume of around €25 million.
“The expansion of the longstanding cooperation with an international customer like Kemira underscores our strong market position. As a leading industrial services provider, we have for decades been ensuring that our customers can focus on their core business while we optimize their maintenance costs and, at the same time, increase the productivity of their plants.”
Gerald Pilotto, Executive President of Bilfinger’s Maintenance, Modifications & Operations (MMO) Continental Europe division
In March 2018, the firm was recognized by the customer with the first-ever Supplier Excellence Award for its performance at the Kemira location in Krems. The service portfolio in Krems covers engineering and maintenance with a focus on mechanical as well as electrical and automation engineering. Bilfinger also carries out projects related to the construction and modification of plants and is responsible for material management.
In Helsingborg, where Kemira has about 300 employees and produces chemicals for water treatment as well as bleach, Bilfinger is now delivering a scope of services similar to what is provided in Krems. Helsingborg is Kemira’s largest location.
With the BMC, the company has combined and structured the comprehensive expertise it has gained from decades of experience. The objective is to be able to provide customers with the same high maintenance standard no matter where they are located. The BMC is divided into 16 modules and is based on the experience and knowledge from more than 400 maintenance analyses. The concept is precisely tailored to the individual wishes of the customer. With a consistent application, the potential for reduction of annual maintenance costs over a period of five years is up to 40 percent, while plant productivity can be increased by up to 10 percent under certain conditions.
Avoidance of production losses
With up to 20% of all bearing issues caused by incorrect installation, maintenance staff should first be properly trained and, secondly, use the right tools. For this reason, NSK provides training courses for customer maintenance departments. With the maintenance and service package AIP+, the company offers high quality, workable tools for facilitating the typical bearing tasks found in industry. The AIP+ portfolio includes mechanical and hydraulic assembly tools, as well as induction heaters.
If bearings have a tendency to fail while machines are in mid-operation, it is often because the optimal bearing type was not selected, or they have not been correctly adapted to the application and/or environmental conditions. Typical examples are machines that need frequent cleaning, such as those in the food processing sector. Cleaning with jets of high-pressure water or steam causes grease to be flushed out, and contamination to penetrate the bearings. However, these problems can be overcome by using NSK’s Molded-Oil bearings, which have the grease durably incorporated in a carrier medium.
Within the framework of AIP, the company can perform on-site inspection of both bearings and operating conditions. Company experts then make a specific proposal on which bearings to use, supporting their recommendation with a cost analysis.
A case in point can be seen at a German automotive manufacturer, where motor spindle bearings frequently required replacement in 15 identical production centres. NSK discovered that the premature failures were caused by external contamination and suggested using sealed high-precision bearings. As a result, bearing failures were reduced dramatically: service life increased from 12 months to more than 36, which in turn delivered annual savings of slightly more than €50,000 in installation costs alone.
As an alternative strategy, condition monitoring represents a more preventative approach to prolonging the service life of bearings. The company also offers this service within the framework of AIP+, whereby a company service technician first visits the site to record parameters such as vibration, temperature and the speed of machine components. Then, using a specially developed measurement technique, the technician records and analyses the data with the help of powerful software in line with a standardised procedure. The customer is provided with a comprehensive CMS report that includes a description of the current state of the bearing. Any shaft alignment or adjustment errors, insufficient lubrication, or any premature wear in the drive components, are also highlighted in the report.
Implementation of the Digital Enterprise
At the Hannover Messe 2018, Siemens will be showcasing a comprehensive series of examples which demonstrate how users can harness the potential of Industrie 4.0 by implementing Digital Enterprise solutions. The focus of the booth in Hall 9 is on industry-specific implementation of Digital Enterprise solutions over the whole life cycle. Examples from aerospace, automotive, food and beverage, electronics and machine building as well as the chemical, fiber and oil and gas industries illustrate how companies of any size and from any industry can increase their competitiveness with individual digital solutions – through greater flexibility, efficiency and quality as well as shorter times to market.
Mindsphere Version 3, concrete use cases and references from Siemens and partners such as OEMs as well as the new global user organization Mindsphere World will all be presented in the Mindsphere Lounge. Siemens will also be demonstrating how producers can already benefit now from industrialized additive manufacturing, and showcasing Sidrive IQ, the new digital platform for the Mindsphere-based evaluation of drive data. Also featured on the Siemens booth will be integrated solutions for industrial enterprises and infrastructure projects in the power utility sector, with the focus on smart energy management using Mind Apps.
At the booth, Siemens will be showing how today’s companies can increase their competitiveness through digitalization – with solutions for digital twinning throughout the value chain, the open cloud-based IoT operating system MindSphere, and the world leading automation portfolio from Siemens. Integration and digitalization of the value chain provide sustainable competitive benefits through greater flexibility, efficiency and quality in nearly every industry. It provides new opportunities in terms of added value, innovative business models, and future-oriented methods of cooperation.
Siemens will be presenting Mindsphere Version 3.0 at the exhibition, which is now available on Amazon Web Services (AWS). Version 3.0 offers a more powerful development environment with open programming interfaces (API/Application Programming Interface) as well as additional analytical features and extended connectivity. The show will also be used to introduce the new international user organization MindSphere World, which has 18 founder members. The aim of this group is to extend the ecosystem surrounding MindSphere throughout the world.
Harnessing the potential of digitalization in the discrete industries
“With the Digital Enterprise Suite we support both product manufacturers and machine builders from the discrete industries in achieving their digital transformation,” says Jan Mrosik, CEO of the Digital Factory Division. “It allows us to create a holistic virtual representation, the so-called Digital Twin, of products, production and performance. Through the knowledge gained from MindSphere, we are also able to continuously optimize the entire value chain of our customers. This applies not only to different industries and traditional producing methods, but also to new technologies such as Additive Manufacturing.” Additive manufacturing will also form a focus of this year’s trade fair presentation. Siemens is the world’s only supplier of integrated software and hardware solutions covering every phase of the additive manufacturing value chain. For users, this means that the entire digital process chain is depicted in a single integrated software environment. The tools required for engineering, simulation, product preparation and 3D printing are merged in an integrated system and can be accessed by means of a standardized user interface. This eliminates the need for data conversion and the associated possible loss of information content. This already offers users the possibility to achieve a rapid transition when scaling up from prototyping and small-series production on single machines to fully industrialized series production.
Siemens will also be showcasing a series of new apps surrounding the field of automation with Simatic systems. The new Simatic Mind Apps Machine Monitor, Notifier and Performance Monitor are special applications designed for MindSphere which allow users to tap into the benefits of cloud-based services and generate added value. The Simatic MindApps export the relevant data from producing machines or plants for analysis, process it to generate meaningful information and display it on dashboards, or use it as the basis for smart warning systems and message presentation. To ensure that this data is just as secure as the plants and infrastructure it serves, the “Defense in Depth” concept according to IEC 62443 protects against current and future cyber threats.
Siemens is launching a new soft starter generation for everything from the simplest to the most complex drive requirements in the form of Sirius 3RW5. This seamless range of devices designed to ensure a gentle startup for three-phase asynchronous motors from 5.5 to 1,200 kW can be used to implement efficient, future-proof machine concepts with the utmost simplicity and economy.
Individual entry into digitalization for verticals of the process industry
It’s time to leverage the potential and benefit from the advantages of digitalization in order to optimize the entire value chain in the process industries,” emphasizes Jürgen Brandes, CEO of the Process Industries and Drives Division. This applies just as much to new (greenfield) plants as to long-standing legacy (brownfield) plants. An important first step is to make consistent use of static and dynamic data already existing in the company to create transparency across the complete life cycle as the basis for optimization. “Thanks to our profound electrification and automation expertise, we support companies in implementing their individual digital transformation. Our offering is tailored in each case to the added value and the business models of our customers.” This is where the new Siemens “Digitalization Consulting” concept comes into its own. This entails working together with customers to sound out the digital scope of the company over the entire value chain and draw up a digitalization roadmap including a calculation of the investment needed.
The digital twin of a process production plant plays an instrumental role here. Digital twinning takes place during the engineering phase and continues to be updated and enriched by additional data over the complete life cycle of the plant. The ongoing analysis of process data and additional smart sensor data from the field level of a production plant creates a whole new dimension in terms of transparency, enabling a significant improvement in terms of maintenance and servicing. The digital twin also offers decisive benefits when it comes to commissioning. This is where Version 9.1 of the simulation software Simit enables even simpler combination of virtual plant commissioning and operator training, speeding up actual commissioning by as much as 60 percent and reducing unwanted downtime periods to a minimum, particularly during plant conversion and migration processes.
Another innovation featured at the Hannover Messe is Sidrive IQ, a new digital platform for the evaluation of drive data using MindSphere. It provides plant and machine operators with a whole new dimension in data transparency for installed drive systems, simplifying fleet management and optimizing servicing activity. The continuous analysis of data saves time and enhances plant availability, for instance by the early identification and remedy of possible error sources. These benefits make Sidrive IQ the basis for greater drive technology efficiency and productivity across the entire life cycle.
Time-Sensitive Networking or TSN is another theme featured on the booth. This permits even more robust, reliable and standardized Ethernet communication between automation devices, even under extreme network loads. Profinet network infrastructures will be gradually upgraded in future to integrate basic TSN technology. As a first step towards this goal, Siemens will be demonstrating how TSN-based OPC UA PubSub (Publisher/Subscriber) is used on the control level using the example of a robotic trade fair model.
Smart energy management
Frictionless production runs and continuous processes are impossible to imagine without a constant energy supply. The ever-increasing demand for energy from industry requires new solutions to reduce energy costs by improving efficiency, resulting in increased competitiveness. One focus of the Siemens booth in Hanover will be on the benefits of seamless interaction between reliable and safe power supply solutions, communication-capable measuring devices and sophisticated analytics. This produces the required energy transparency vital to optimum energy management. “This also includes finding smart ways of dealing with the rising flood of data which already exists in the power distribution sector today,” says Ralf Christian, CEO of the Energy Management Division. “Using Digital apps, we can offer our customers smart analytical tools for more efficient operation.” Using the Spanish automotive manufacturer Gestamp as an example, Siemens will be demonstrating how improved transparency has led to energy savings of 15 percent and to a significant reduction in CO2 emissions. The data captured is then fed to Mindsphere. The Mind App Energy Efficiency Analytics calculates the energy requirement, suggests measures to reduce the load where appropriate, and uses real-time rendering of consumption data from several locations to help to optimize the plants and manufacturing processes in order to reduce the overall energy consumption of the business. “In industry’s search for new ways to reduce production costs, in-house production of electricity is becoming more and more attractive in addition to optimized energy efficiency,” explains Ralf Christian. At Hanover, Siemens will be showing how companies can flatten their demand peaks, exploit fluctuating electricity prices, and generate additional revenue, for instance by participating in the energy balancing market. Issues such as demand response, battery storage systems and control of microgrids are part of the solution.
In addition to the main booth in Hall 9, Siemens is also collaborating closely with its partners in Hall 6 to showcase its PLM software portfolio. Visitors to the “Integrated Energy Plaza” in Hall 27 will be able to find out how the whole integrated system works – from energy production, through distribution and storage to energy demand. In this context, Siemens will be showing its electromobility highlights: Visitors will be able to discover complete solutions for the charging infrastructure and find information on components, charging management systems and complete end-to-end solutions.
PAT Data Management
Software Solutions with Advanced Process Control
Siemens and Perceptive Engineering announce a partnership which offers Perceptive’s PharmaMV and Siemens Simatic Sipat software products closely integrated to provide a versatile solution for advanced control and optimization applications in both continuous and batch pharmaceutical manufacturing. The interest to have APC integrated into a PAT platform is growing significantly within the Life Sciences Industry. Thus, the goal of this collaboration is to offer the Pharmaceutical Industry the integrated combination of technologies that have – independently from each other – established a proven track record in the past decade.
An integrated PAT Data Management system like Siemens’ Sipat has been increasingly adopted by the regulated industries, offering a 21CFR11 compliant PAT platform to monitor the end product quality in real-time while it’s been produced. This is based on the structured collection of data from spectral PAT analyzers combined with traditional process data and raw data information from e.g. a LIMS application.
Advanced Process Control (APC) with Perceptive Engineering’s PerceptiveAPC has been established in different industries, realising APC often based on process data only. Its pharmaceutical version, called PharmaMV, has been enriched with specific functionalities to comply with the requirements in a regulated environment.
The integrated approach of both software solutions provides a complete platform, for structured data collection, real time CQA calculation and multivariate modelling and monitoring, which is then combined with automated multivariable feedback directly into the process control layer to simultaneously maintain all CQA’s within the desired design space.
This combined platform has now been deployed with major Pharmaceutical partners, and at key innovation centres around the world. Perceptive Engineering, based in the UK, Singapore and Ireland can provide complimentary application support for Sipat and APC solutions worldwide.
Simatic Sipat is a scalable and modular software solution that enables companies to extend their PAT-based quality control strategies on a step-by-step basis within the scope of a Quality-by-Design (QbD) based approach. With Sipat as integrated PAT platform, product development and production processes can be monitored, controlled and optimized by measuring and calculating the Critical to Quality Attributes (CQA) of end products in real-time. This continuous monitoring of product quality can prevent deviations from specifications and therefore reduce production costs. In addition, it allows for Real Time Release Testing, so final quality inspections can be reduced or completely eliminated.
Perceptive Engineering is a leading player in the deployment of model based Advanced Process Control, APC, especially within the Pharmaceutical sector. PharmaMV is specifically designed to support development and deployment of multivariable technologies for monitoring and control within the regulated Pharmaceutical production environment. The PharmaMV platform provides modular tools to design, deploy and maintain advanced applications within a regulated environment. The Platform includes software tools to ease the transition from Development into Manufacturing, reducing the time to transfer knowledge and technology into commercial value. Advanced Process Control solutions are already available for a wide range of pharmaceutical process units, for both small and large molecules, batch and continuous processes, all now conforming to an Industry 4.0 design.