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Digitalization prepares the way for Integrated Engineering, Integrated Operations, and comprehensive plant management leading to Industry 4.0. Software tools and one common data base offer seamless planning, virtual commissioning and ensure efficiency during operation and maintenance.
From Integrated Engineering to Integrated Operations
What if you could detect future outages at your plant today already? What if engineering and operational data could be used intelligently for your maintenance, and even plant performance could be centrally optimized at all sites? That would mean that you’d be enjoying the opportunities of progressive digitalization today already. Processes are becoming more transparent and productive thanks to the end-to-end integration of plant design and engineering for the commissioning, operation, and maintenance as well as the constant optimization of processes on the basis of one data platform. We can support you with Integrated Engineering and Integrated Operations solutions over the entire lifecycle of your plant.
Shorter innovation cycles, reduced time to market and, above all, plant and project data terabytes all pose major challenges for plant designers and operators, even as early as the planning stage. Our COMOS software solution for plant lifecycle management consistently implements the complete integration of all processes – during both the engineering stage and the operation/maintenance stage. This close interconnection between the individual stages and the uniform data platform contribute significantly to increased plant availability and security. Thanks to the interplay between COMOS and our innovative SIMATIC PCS 7 process control system, you can benefit from a seamless integration of plant and automation engineering and a consistent bidirectional flow of data. At the touch of a button, the entire plant structure is generated in the control system from the engineering data and plant data is available in real-time.
Formerly, plant behavior was tested on prototypes. Today, software tools are increasingly used for simulations. A plant’s behavior can be simulated even before completion, and errors can be detected and resolved at an early stage. This opens up the possibility of virtual commissioning before the actual factory acceptance test. Putting plants or plant units into operation more quickly requires an optimized workflow on the engineering and automation side as well as the shortest possible setup, testing, and commissioning times. Our SIMIT simulation software enables real-time simulation and emulation, allowing for an extensive review of components and automation solutions. You can thus perform virtual commissioning simply and flexibly. In addition, SIMIT simulation software allows you to provide safe and efficient training in a virtual environment (Operator Training System). Staff can therefore be optimally familiarized with the plant before it’s even started up.
The XHQ Operations Intelligence platform creates the foundation for continuous optimization. It visualizes operating processes at chemical plants in real-time. XHQ thus creates the basis for concrete and well-supported decisions and helps you to increase your performance and reduce operating costs by up to 8%, as well as to increase production by up to 10%.
Intelligent use of data
The systematic monitoring of plant components directly prolongs their service life, prevents unscheduled downtimes, and thus significantly increases plant availability.
Solutions such as SIMATIC PCS 7 and COMOS MRO (Maintenance, Repair & Overhaul) support you with efficient planning, implementation, and analysis of your maintenance activities – including the connection of portable devices for remote services, also in Ex zones. With COMOS MRO, all aspects of the management, planning, operation and maintenance, including plant documentation, are carried out in a single system. This means that any changes to the plant due to service and maintenance processes are also immediately available in the engineering system. And the Maintenance Station integrated into SIMATIC PCS 7 provides a complete status overview of all plant components, thus offering effective diagnostics, service, and maintenance of the plant. Then there’s the powerful COMOS Walkinside 3D visualization software, which realistically presents highly complex plant models based on 3D engineering data. Your benefits: maximum efficiency in planning and monitoring, operator training, and the forward-looking planning, simulation, and implementation of maintenance and servicing work.
Whether it’s the online monitoring of remote parts of a plant, predictive maintenance, energy data management, or resource planning – digital services are growing in importance. Fact-based decisions can be made based on data from the process, thereby increasing plant reliability and, thus, productivity.
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Whether our systems are implemented in new plants or introduced to current operations: Our solutions and services enable more efficient and more intelligent production throughout the world. Learn all about our comprehensive industry expertise and customized solutions in our references.
Building a new digital factory in Haiyan by creating a virtual factory for full-range simulation of the new facility, supported by manufacturing execution system (MES) and intensive training sessions.
The Siemens MES, fully compliant with ISA-95, is able to reduce costs of integration with the ERP and work with the product lifecycle management software teamcenter for more manufacturing flexibility.
Complete drive intelligence (SINAMICS S120), embedded in the control units, deployment of an energy management and monitoring system for annual savings of 20% in water and 10% in electricity.
Integration and linking of 2D and 3D information with COMOS and the Bentley tools
Integrated planning and maintenance of plant and engineering data throughout the entire lifecycle
The interface has laid the groundwork for creating a digital twin of process plants
The Solvay/Butachimie chemical factory in Chalampé, France, is one of the world’s largest facilities specializing in the manufacture of polyamide 6.6 and its intermediary products.
Investments in future-proofing their facilities resulted in the changeover of all production facilities to SIMATIC PCS 7.
To simplify the migration and further optimization, the real plants were tested before their actual commissioning – as a sort of “virtual twin” – using SIMIT simulation software.
The Ineos Group AG, a group of global chemical companies, relies on a new planning system for computer-aided engineering (CAE) at its Cologne site.
With additional tools, it manages over 100,000 documented process control points.
Including safety equipment and over 3,500 piping and instrumentation diagrams.
Sisseln in Switzerland is one of the largest production sites of the Dutch company DSM.
In one of the key plants there, electrical engineering and automation were planned using the COMOS engineering software.
A significant increase in plant performance was achieved.
Whether you’re planning to optimize maintenance strategies or expand your plant, whether you want to improve performance or reduce operating costs – we’re here to support you.