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Solutions for Industry Verticals Unlock the potential with digitalization v02/10-2018 siemens.co.in
Unlock the potential
with digitalization
The World Economic Forum estimates that digital a strong ecosystem of partners. To work more closely
transformation could unlock USD 100 trillion in value with customers, we opened 20 MindSphere Application
for societies over the next decade. With government Centers at 50 locations worldwide, with four centers in
initiatives like “Digital India” and “Make in India” - India India. Each center, which specializes in a particular
has positioned itself to capitalize on the opportunities vertical market, co-creates digital applications with
of digitalization and to support continued strong GDP customers. These digital solutions are developed using
growth. MindSphere, Siemens’ open, cloud-based operating
system for the Internet of Things.
Digitalization provides the means to unlock the full
potential of an organization’s assets and operations, With the arrival of the Internet of Things in industry
to optimize performance and even create new business and infrastructure, many organizations are seeking to
models. Many organizations recognize that incorporate digital strategies into their business models.
digitalization is critical for future success but are unsure By embracing digitalization, Siemens has reinvented
where to start their digital transformation, which itself into one of the world’s top 10 software
We at Siemens, technologies to apply and often lack the capital and companies. Digitalization is at the core of our strategy
are committed to skills required. and innovation roadmap. In fiscal 2017, we invested
partnering India’s Digital transformation cannot be achieved by software around 41600 cr INR in R&D, while revenue from
software and digital services grew by 20 percent.
digital transformation and data alone. It requires a deep understanding of
We continue to expand our digital capabilities, focusing
customer needs, of specific markets, and of hardware
on disruptive technologies like additive manufacturing,
solutions. Combining our deep domain knowhow with
artificial intelligence and digital twin, to name a few,
our digital expertise and the experience of a large
that could offer customers better outcomes.
installed fleet, we are pleased to present this vertical
markets report. With a particular focus on India, We hope this report offers valuable insights for your
the report looks at key growth drivers in selected digital transformation. In the meantime, our dedicated
verticals, customer challenges and digital solutions to Vertical Market Managers are ready to assist you to
address them. chart out your customized digitalization roadmap.
The pace of technological change in the digital age
requires collaboration. At Siemens we collaborate with
Dr. Roland Busch Sunil Mathur
Chief Technology Officer Managing Director and
and Member of the Chief Executive Officer,
Managing Board Siemens Ltd.
of Siemens AG
Dear customers, Rapid technology advancement is helping us improve speed, efficiency and flexibility of our operations at an unprecedented scale. With Digitalization, we are on the cusp of a new industrial era, a.k.a. Industry 4.0. This book takes a deep look at the value chain of specific industry verticals, and the areas where Siemens’ technology can make a positive impact. This book is timely, as we are also witnessing the changing nature of customer-vendor relationships. Vendors are increasingly encouraged and challenged to act as partners in their customers’ businesses, which necessitates a better understanding of the domain, and an application of technology to achieve tangible outcomes therein. Few examples from our perspective: • How can we help a Pharmaceutical company improve compliances and their records needed for drug approvals? • How can we help a Distribution utility reduce ATC losses? • How can we help a Power Generation utility reduce coal consumption? These, and many more challenges that industries face can be resolved (and the resultant performance, improved) through Digitalization. We have described several real-life examples here in this book; where we started with a problem statement or pain point as expressed by our customer, and worked together with them to create the right solution. We are sure some of these will resonate with you as well. Details of the Siemens vertical market managers are also published on each page – do reach out to them or to me personally should you wish to start a conversation with us! One last point – what sets Siemens apart from others is our understanding of your domain, which when coupled with our deep technical knowledge of electrical, automation and industrial software systems – gives us a unique advantage to create tangible outcomes for you. Our solutions go well beyond data and visualization, to derive meaningful insights from the data and to enable impactful actions in time. We hope you will find this book useful – you may also download a soft copy from the below QR code. We look forward to a meaningful conversation with you. Warm regards, Krishnakumar Ramanathan Head – Key Accounts, Vertical Markets & Chief Customer Officer Siemens Limited r.krishnakumar@siemens.com
Digitalization is happening today
50 billion
connected devices by 2020
2.5 quintillion
bytes of data generated every day in 2017
Proliferation of use cases
90% of Indian C-suite executives
view digitalization as a
near-term strategic imperative
Know more about
Digitalization
How do I derive business value Speed Flexibility Quality Efficiency The digital transformation is gaining momentum. Companies are already unlocking this potential - by using end-to-end digitalization. Siemens has the domain expertise in industry verticals as well as the engineering and digital know-how to generate performance improvements across the entire value chain. Siemens solutions shorten time-to-market and increase flexibility, quality, and efficiency. They enable new business models while assuring highest levels of cybersecurity. Two core elements of end-to-end digitalization solutions are: • MindSphere – Cloud-based, open Internet of Things operating system • Digital Twin – Virtual representations of product and production
MindSphere
Connecting devices and applications via the cloud
MindSphere is Siemens’ cloud-based, open Internet of Things operating system, connecting real objects to the digital world. By applying
advanced analytics, MindSphere enables you to harness value from the wealth of data.
MindSphere enables the development of powerful industry applications (MindApps) and digital services to drive business innovation. Its
open 'Platform as a Service' capabilities enable a rich partner ecosystem for applications and services. To protect your company's assets
and intellectual property, MindSphere adheres to the strictest cybersecurity standards.
Applications
and services
Cloud layer
MindSphere
Connected
devices
Know more about
MindSphere
Festo – Condition monitoring services
Consumption transparency is the starting point for predictive maintenance. For Festo, the German control and automation
company, Siemens provides MindSphere solutions which gather real-time data right from the plant. Energy savings of up
to 30% compared to existing plants of similar functionality can be realized.
Digital Twin
Simulating and optimizing product and production
Digital twins allow for a complete virtual representation of both the product and the production process. These virtual representations
enable simulations, testing and optimization in the digital world, thus reducing costly and time consuming prototypes in the real world.
The transition from integrated engineering to integrated operations is an important step. We provide integrated solutions across the
entire plant lifecycle based on a common data model.
Using MindSphere, data from the actual performance are being fed back to the digital twins. Hence, these insights from the 'digital twin
performance' support continuous and fast improvement of the next versions.
Digital Twin Digital Twin Digital Twin
Product Production Performance
Insights from performance with MindSphere
Verification Validation
Real
Virtual Virtual Ideal Real
production delivery
product production Automation
product
Specification Commissioning
Continuous improvement
Collaboration platform: Teamcenter
Know more about Digital Twin
Maserati – Boosting Product Design and Development Discrete Process
Manufacturing Industries
Digitalization starts with the design of a product. Maserati uses the CAD software NX for the Digital Twin to
virtually create, simulate, and test their cars, significantly reducing the number of prototypes needed. In
combination with the collaboration platform Teamcenter, the Maserati engineers manage their project
collaboratively across various locations. The result: shortened time-to-market from 30 months to 16 months.
Siemens provides innovative solutions to meet your automation and digitalization needs
Siemens serves industry verticals in a dedicated manner
Aerospace & Defence* Automotive*
Battery Manufacturing Chemicals & Petrochemicals*
Cranes Data Centers*
Distributors Fiber Industry
Food & Beverage* Glass
Machinery & Plant Construction Marine & Shipbuilding*
Minerals – Mining & Cement* Municipalities & DSOs
Oil & Gas* Panel Building
Pharmaceuticals* Ports*
Power Utilities* Smart Cities
Solar* Transportation & Logistics*
Tyre Industry Water
Wind
*Covered in this edition
Automotive 4th
largest automotive
Reduce time-to-market and market in the world
increase manufacturing flexibility
5%
market growth p.a.
until 2021
100%
Vision of
electric vehicles
in new sales by 2030
50,000 km
of new highways by 2022
Know more about
AutomotiveReduce development time Optimize production planning
Siemens’ NX design software creates the Digital Twin of an automobile. Siemens’ Tecnomatix Digital Twin software allows to create virtual production
Together with Simcenter, the NX software simulates, tests and optimizes lines that simulate and optimize manufacturing thus shortening cycle time.
the design. Data generated in this process can also help to optimize the
manufacturing process and reduce development time by up to 50%.
Vehicle Production Production Lifetime
Production
design planning engineering services
Shorten time-to-manufacturing Improve operational efficiency Increase asset utilization
Siemens' Teamcenter and Totally Integrated Siemens' manufacturing operations management Siemens' MindSphere captures inputs from the shop
Automation (TIA) portal simulate and validate vehicle solution enables flexible manufacturing by floor and generates recommendations that can
engineering along with virtually commissioning the integrating business systems like ERP, control improve asset utilization by up to 5% and reduce
line before the start of production. This reduces systems like SCADA and design platforms like NX. energy consumption by up to 15%.
commissioning time on site by up to 70%. Production is automatically scheduled and executed
Additionally, the specialized automotive library SICAR while maintaining quality and efficiency. This
facilitates automation for e-car and battery pack solution enables higher flexibility, such that the
production. vehicle’s configuration can be changed even during
production.
Virtual commissioning Electric vehicle drivetrain and End-to-end Digitalization – Ford
charging
A leading Indian automotive company For hybrid buses from a leading Indian Ford leveraged Siemens' Digital Enterprise
plans to launch several models faster than automotive company which already operates Suite across its value chain. It enabled Ford
competitors. Siemens' Teamcenter and on Indian roads, Siemens supplied the to increase their number of models, reduce
TIA portal are enabling them to validate drivetrain solution. These buses consume factory energy cost by up to 30% and
and simulate multi-model manufacturing 30% less fuel and accordingly reduce development time by up to 40%.
on the Digital Twin of their production line. emissions. A conversion to a fully electric
drivetrain can easily be done. Siemens also
offers a comprehensive portfolio for electric
vehicle charging.
nitin.nair@siemens.com I Nitin Nair, Vertical Market Manager, AutomotivePharmaceuticals
Enhance drug quality and
yield while ensuring compliance
15%
market growth p.a.
until 2020 from today's
USD 30 billion
Government's
Pharma Vision 2020
and DPCO (Drug Pricing
Control Order) drive affordability
and aim at global sector leadership
33% cost productivity
Know more about advantage compared to US
Pharmaceuticals
Over 500
US FDA-approved
manufacturing sitesImprove yield Enhance manufacturing Process simplification Regulatory compliance
Siemens' SIPAT software enables
flexibility The XHQ operational intelligence Siemens' electronic batch record
process analytics in the development Siemens' process automation solution software aggregates, relates and solution SIMATIC IT eBR enables
and production stages. Consistent and enables batch planning, scheduling presents operational and business paperless manufacturing within
reliable quality is ensured by analyzing and overall management of the data in real-time – enabling data regulated processes. It supports
process data based on mathematical production order. It consists of transparency and continuous operational and manufacturing
models and by real-time feedback into SIMATIC PCS 7, SIMATIC BATCH and improvement of the manufacturing efficiency in both manual and highly
Preactor - interfacing with Siemens' process. Additionally, data can also be automated environments - designing,
the system. The solution can bring an
electronic batch record and also ERP uploaded to MindSphere to perform executing and approving the batch
immediate yield improvement of 1%
systems. This setup enables a more
per batch and can pay back within process analytics and generate insights record. Additionally, the increased data
flexible workflow, easier recipe
one year. to drive process simplification and integrity helps expedite regulatory
management and reduced human
intervention. This decreases batch intensification. approvals.
cycle time by up to 15%.
Primary Processing Secondary Processing
R&D
• Bio API • Chemical API • Blood fractination Drug Manufacturing
Our 'integrated engineering' and 'integrated operations' for process plants provides a foundation for digital twin, simulation and analytics on MindSphere
Personalized vaccines –
Process Analytical Technology Electronic batch recording
BioNTech
Siemens' SIPAT solution enabled a leading A leading Indian manufacturer simplified its The German company develops personalized
Indian pharmaceutical player to bring processes by deploying Siemens' eBR therapies for cancer and other diseases.
‘quality by design’ into their formulation solution. It was implemented in running For manufacturing of personalized vaccines
plant. The solution correlates process data plant without disrupting operations. at optimized cost, they implemented an
with quality parameters, thus, predicting The manufacturer was able to further automated factory powered by Siemens MES
quality deviations ahead of completion. improve its data integrity and expeditiously solutions. It allows for vaccine production of
This enables process adjustments to ensure address all regulatory requirements. lot size of one by direct inputs from the ERP
consistent batch quality. system and production with minimal human
intervention.
samson.samuel@siemens.com I Samuel Samson, Vertical Market Manager, PharmaceuticalsFood & Beverages
Enable flexible manufacturing and
increase operational efficiency
6th
largest food market globally
60 agriculture
export zones
USD 33 billion
investment expected over
the next decade
Know more about
Food & beverages
Increasing need for
customized
variantsReduce time-to-market for bakery Reduce commissioning time for dairy Increase uptime and reduce cost for
Siemens' SIMATIC IT R&D suite enables defining and SIMATIC PCS 7 and the Totally Integrated consumer packaged goods
optimizing new product compositions by taking Automation(TIA) portal flexibly and efficiently The fleet management application of MindSphere
supply chain constraints and consumer expectations handle the electrical and automation design provides transparency on machine performance
into consideration. Specialized modules like with integrated engineering. Engineering efficiency metrics. Data captured translate into insights for
regulatory management help to automatically is increased for the production process as well preventive and predictive maintenance of critical
generate nutrition profiles and allergen declarations. as for bottling and packaging through integrated assets. Siemens' Energy Analytics solution captures
Additionally, Teamcenter NX creates the Digital Twin workflows. Virtual commissioning enables validation utility data like electricity, water, and gas of a factory
of the package for stress testing along with real-time and simulation before start of production, thereby correlated to production helping reduce energy
collaboration to create an appealing product design. reducing commissioning time. consumption thereby optimizing cost.
These solutions help in reducing the time-to-market.
Product Production Production Production Services
Design planning engineering
Optimize factory design for confectionery Improve operational efficiency for softdrinks
Siemens' COMOS and Tecnomatix facilitate simulation and optimization of SIMATIC IT Preactor enables planning and scheduling of production orders based
a confectionary factory through Digital Twin. Simulation of the production on cost, energy consumption as well as availability of material, equipment,
processes, material validation and bottleneck identification helps to optimize employees and other process related constraints like cleaning in process.
the factory design in the virtual world. This helps optimize capital investments. Additional solutions based on line balancing algorithms minimize downtime and
increase operational efficiency.
Simulate packing lines – LoeschPack Fully automated dairy plant – Rajkot Dairy
The leading packing OEM leveraged Siemens' Tecnomatix portfolio Siemens’ dairy automation solution based on SIMATIC PCS 7 and TIA
to simulate and optimize their packing lines. LoeschPack can test their integrated the Intelligent Motor Control Center, production machines,
machines on the Digital Twin facilitating a faster feedback loop. laboratory PCs and weighbridge with the control room. The solution
This approach identifies bottlenecks and overcapacities, improves enabled Rajkot Dairy, a member of AMUL, to set an ambitious target
production parameters, and optimizes packing systems. of producing 0.6 million liter of milk per day plus an option to
expand output by another 30%.
abhijit.wavhal@siemens.com I Abhijit Wavhal, Vertical Market Manager, Food & BeveragesAerospace & Defence
Increase throughput and enable flexible manufacturing
5th largest defence
budget globally and pioneer in
space launches
30%
domestic value-add
mandated under the FDI rules
Indian companies to buy
civil aeroplanes worth
USD 290 billion
Know more about over the next 20 years
Aerospace & Defence
Government's UDAN
program driving affordability
and regional connectivityReduce time-to-market Reduce lifecycle cost of marine vessels
Siemens’ software solutions create the Digital Twin of the product and the Siemens’ SINAVY solution provides electric and hybrid propulsion systems
production. Products can be modeled and optimized on NX CAD and CAM, and for surface vessels and submarines. The solution consists of an automation
manufacturing processes can be virtually simulated and commissioned on platform, generators, as well as propulsion motors and drives. The transition
Tecnomatix. Improvements in productivity of up to 40% can be realized using from diesel to electric or hybrid propulsion can save up to 30% in lifecycle costs
these digital solutions. while Siemens’ global service network ensures maximum uptime of the vessel.
Product Production Production Production Services
Design planning engineering
Enable flexible manufacturing Reduce operational cost
Siemens’ SINUMERIK TRAORI feature in CNC increases manufacturing flexibility Siemens’ Analyze MyCondition solution, powered by MindSphere, captures
and throughput. This feature can be installed on any 5-axis simultaneous milling machine data and processes them in the cloud to prevent machine failures and
machine to optimize the tool path and reduce switchover time between support disturbance-free machine operations, thus, improving machine
specifications. productivity.
Throughput increase – Electric propulsion lab – Electric aircraft –
MTU Aero Engines Indian Navy Siemens and Airbus
The German aircraft engine manufacturer Siemens has set up the medium voltage Siemens has developed extremely efficient
aimed at precision manufacturing of blisks and electric propulsion lab at INS Valsura, motors to power electric aircraft in
of lot size one. The SINUMERIK TRAORI Jamnagar. This one-of-its-kind setup collaboration with Airbus and further
solution across all CNC control boxes in facilitates the Indian Navy’s modernization partners. Currently, the 50kg motor delivers
their production line enabled optimized plans of adopting energy-efficient electric an output of 260 kW – five times more than
tool motion, shorter switchover time and propulsion systems. The lab offers hands-on a conventional drive system and propels the
automatic compensation of errors during training and simulation of electric aircraft to top speeds of 340 km/h. The aim
machining. This digital solution enhanced propulsion and MV systems for the Naval is to produce new regional aircraft powered
the production from 500 to 3500 blisks per officers and sailors. by hybrid-electric propulsion systems in the
year without additional hardware. near future.
shankar.narayanan@siemens.com I Shankar Narayanan, Vertical Market Manager, Aerospace & DefenceData Centers
23%
Improve power utilization effectiveness market growth p.a. until 2020
and optimize lifecycle cost
Co-location revenue of
USD 2 billion
by 2019
Telecom, e-commerce
& financial inclusion
programs driving investments
Push towards higher
data localization
Know more about
Data CentersIncrease data transparency Reduce energy costs
Siemens’ data center infrastructure management The computational fluid dynamics module in the
solution Clarity LC offers a comprehensive view of Asset Clarity LC solution reduces energy cost by analyzing
the data center. Seamless integration with the management Cooling heat patterns and dynamically adjusting the air flow.
building management system Desigo Control Center The solution can also simulate and optimize layout
enables increased transparency and facilitates design for new data centers, thus, maximizing
smarter decision making. This leads to reduced energy efficiency.
power consumption and optimized lifecycle cost.
Fire Reliable
protection power
Security
Minimize operational disruptions Ensure building security Increase system availability
Siemens' end-to-end fire management solution Siemens' data center security solution includes Siemens Total Integrated Power solution ensures
offers accurate early smoke detection, automatic perimeter protection, intrusion detection, access efficient and reliable power supply to maximize
alarm release by Fire Finder and timely extinguishing control and intelligent video surveillance solutions. system availability and safeguard critical data.
by Sinorix. The silent discharge nozzle technology The integrated control room enables increased The integrated portfolio includes products and
ensures quiet and effective extinguishing, visibility and prompt response facilitating business services across voltages and throughout the project
minimizing the risk of data loss due to hard disk continuity. life cycle.
failures.
Data center infrastructure Integrated power solution –
Building management system
management – Atos Digital Realty
A leading Indian data center provider Siemens' Clarity LC solution enabled Atos The world's largest full-scale data center
implemented Siemens' Desigo Control with an intelligent dashboard of its IT and provider commissioned Siemens to address
Center to increase transparency on energy facility infrastructure. The solution at its data its power requirements. The solution
consumption per rack and temperature center facility with 490 racks and 960kW consists of fully pre-assembled electrical
footprint. The solution enabled operators facilitates increased power consumption rooms with the complete power distribution
visibility, simulate ‘what if’ scenarios and equipment as well as fire safety and
to improve the power utilization
accurately generates invoices from over lifecycle services. The integrated approach
effectiveness by 10% from 1.67 to 1.5. 7 million power readings per month. helped reduce implementation time by
more than 30%.
kunjumon.francis@siemens.com I Francis Kunjumon, Vertical Market Manager, Data centersMinerals
Reduce cost in cement and
mining production processes
2nd largest cement
and 4th largest iron
producer globally
99 cities
selected under
the smart city mission
USD 15 billion
investment in roads until 2020
Know more about
Minerals
Housing
for all by 2022Improve stockyard operations Increase operational efficiency
Siemens’ MAQ solution for stockyards supports safe and reliable management Siemens’ scalable Manufacturing Execution System connects business systems
of bulk materials. It enables material tracking, quality monitoring, real-time like ERP with shop floor systems, across geographies and factories. Data-driven
inventory management, as well as autonomous machine operations. The 3D insights from the solution enable enhanced manufacturing responsiveness,
visualization of the stockpile facilitates precise blend control. improved supply chain efficiency and production optimization.
MINING
Refining
Beneficiation
agglomeration
Excavation Transport /
Material handling
Grinding and
Clinkering
finishing
CEMENT
Our 'integrated engineering' and 'integrated operations' based on COMOS provide a foundation for digital twin, simulation and analytics on MindSphere
Enhance energy efficiency Optimize manufacturing performance
Siemens’ kiln and mill control systems, KCS and MCS, enable optimization of SIMULEX enables visualization and simulation of the dynamic process behavior of
closed loop controls with CEMAT and advanced process control. Input parameters cement plants. Comprehensive training to plant operators is provided in a
like heat and vibrations are analyzed in real-time to dynamically adjust the set running plant environment, without posing risk to product quality, equipment,
points and optimize the process. This stabilizes operations, improves product personnel or production. Thereby, performance is optimized under varying input
quality and reduces energy consumption by up to 8%. conditions.
Kiln and mill optimization – Manufacturing Execution Automated stockyard –
Wonder Cement System – Vale Boxberg Lignite
Siemens' kiln and mill optimization solution Following several acquisitions, the Brazilian At the Boxberg power plant in the German
improved productivity for Wonder Cement's mining company had 23 different legacy IT state of Saxony, a fully-automated stockpile
greenfield project. The CEMAT automation systems across its supply chain. Siemens management system ensures uniform lignite
with KCS and MCS enabled automatic and deployed an MES solution across 38 quality. The system also allows for unmanned
hands-free operation of many loops. locations and created a unified dashboard operation of the stock-yard machines based
Optimized set points provided to the to handle real-time data. Increased labour on the 3D model of the stockpile. Increased
automation system regulated kiln productivity, higher system uptime, and data transparency has led to higher
temperature, reduced mill vibration, and lower IT cost are expected to deliver USD performance, full utilization of the stockpile
stabilized input feed. 70 million of savings until 2020. area and optimized energy consumption.
ashish.sareen@siemens.com I Ashish Sareen, Head (Solutions Business), Mining & MineralsOil & Gas
Generate data-driven insights
to reduce lifecycle cost
3rd
largest consumer of oil
and gas products globally
Government's vision
to reduce India's oil
and gas imports
by 10% by 2022
620 million
tonnes of crude oil reserves
Know more about
Oil & Gas
70 bcm gas
to be consumed by 2022
up from today's 50 bcmReduce offshore platform lifecycle cost Maximize pump uptime Improve plant efficiency
Siemens’ Topside 4.0 solution enables the creation of the Digital Critical Electric Submersible Pumps (ESP) in Siemens’ XHQ platform enables fact based
twin of a topside facility. Optimized design, integrated simulation oil fields can be monitored and analyzed via decision by capturing operational and
with 3rd party control systems and virtual commissioning can save a MindSphere application. The predictive business data from a refinery and presenting
engineering cost by up to 30%. Real-time facility data can be maintenance AI solution uses past failure them in an intuitive dashboard. The XHQ
processed on MindSphere for predictive analytics. For a mid-sized patterns of ESPs and data such as pressure portfolio offers applications like performance
Floating Production Storage and Offloading unit cycle time can be and temperature. Thus, upcoming incidents analytics or performance management to
reduced by 3-9 months as well USD 10-15 million of CAPEX and can be detected early to implement timely improve productivity by up to 30%.
more than USD 100 million over 10 years in OPEX can be saved. countermeasures and to increase production
uptime.
Upstream Midstream Downstream
Improve power efficiency of the pipeline Reduce construction lead time
Siemens’ smart pumping technology enables real-time performance monitoring Siemens’ E-House is a prefabricated power supply solution - consisting of
on MindSphere to reduce power consumption. The solution actively manages components such as switchgears and transformers. This plug-and-play approach
production to reduce stress loads that can occur during batch changes, thus, reduces construction lead time and can save up to 20% of the total cost of
increasing asset life and decreasing forced outages. For a typical 1300 km ownership.
pipeline with 18 pumps, powered by smart pumping technology, the payback
period is estimated to be under a year and savings up to USD 60 million during
the 40-year lifecycle of the pipeline can be realized.
Real-time operations management Digital offshore solutions – Aker BP
Siemens' XHQ solution enabled one of the largest refineries in India At a new North Sea facility, the Norwegian oil exploration company
with end-to-end data transparency of their operations and business implemented a suite of Siemens' digital solutions - including Topside 4.0.
processes. Real-time operation tracking and seamless integration with The suite provides process simulations for virtual testing and training
the ERP system has facilitated faster decision making, minimized and an onshore operation center for remote condition monitoring.
downtime and reduced operational cost. Aker BP was able to save about 30% of cost, reduce the workforce on
the platform and stabilized operations within one week.
vikrant.sankhe@siemens.com I Vikrant Sankhe, Vertical Market Manager, Oil & GasPower Utilities
Enable efficient generation and
smart grids
3rd
largest power generation
capacity globally
6% growth p.a. of electricity
demand until 2021 with increasing
share of renewables
INR 1.1 trillion
investments in power generations
until 2022
Know more about
Power Utilities
UDAY and
Government's
Electricity for All
programs drive investmentsReduce lifecycle cost Increase grid availability Reduced operational cost
Siemens offers a comprehensive power generation Siemens' digital substation portfolio captures Siemens' Energy IP Meter Data Management
portfolio of gas and steam turbines based on latest substation data from digitally enhanced assets to software facilitates reduction in OPEX and service
technology with best in class efficiency and facilitate grid automation, maintain power quality improvement by capturing, processing and
environmentally friendly solutions. Additionally, our and prevent asset failures. Data can be securely analyzing load data from smart meters.
digital fleet center solution connects power units transferred to MindSphere for generating insights The solution, used by over 75 utilities and
with the highest security standards to a remote for better grid availability, reliability and improved 75 million devices globally, communicates with
control center for continuous monitoring and efficiency. the meter and receives notifications when outages,
diagnostics. Electricity producers can avoid up to tampering or other events occur. It also integrates
40% of forced outages and take corrective measures with other IT systems like ERP and billing systems.
for an additional 20% of forced outages. This increase
in plant availability reduces the lifecycle cost.
Generation Transmission Distribution
Reduce spare part lead time Improve operational efficiency
Siemens’ additive manufacturing technology facilitates rapid prototyping, Siemens' closed loop automatic generation control regulates the power output
manufacturing and advanced repairs. The solution builds components from CAD from multiple plants by remotely monitoring grid parameter like frequency and
models up to 40% faster than conventional manufacturing along with complete interchanges. With more and more renewables feeding into the grid, the
flexibility in design. solution enables smooth ramp up and ramp down of conventional sources
without any manual intervention, thereby, reducing losses.
Remote monitoring and Additive manufacturing – Closed loop automatic
diagnostics – Vedanta JSW Steel generation control
Siemens' digital fleet center solution Siemens produced its first 3D-printed Siemens' closed loop AGC was the first of its
connects three power plants of Vedanta industrial steam turbine replacement part kind to be implemented in India. The solution
across India to a monitoring station globally for JSW Steel. The solution consists enables automated increase and decrease in
enabling predictive maintenance. of two oil rings printed from metal and generation with a quick response time. It's
The solutions reduce unplanned outages, enables us to meet our customer’s success has influenced the Central Electricity
increase availability of power assets and requirements much faster. Regulator Commission to mandate closed
optimize costs. loop AGC across all load dispatch centers in
the country.
beryl.lopez@siemens.com, girish.p@siemens.com I Beryl Lopez (T&D) and Girish P (Generation), Power UtilitiesPower Utilities - Services
Digitalization and innovative solutions improves flexibility,
efficiency, and productivity in power plant applications
Electricity Generation in India:
1200 Billion
Units in FY17-18
Conventional Power - As on year ended March 31, 2018
Estimated Growth of 7%
CAGR in energy generation till FY23
Investment potential of
Know more about ~USD 1 Trillion
Power Plant Services across value chain
Renewable Integration and
per capita consumption increase
to drive investmentsPower Plant Services focus on supporting efficient, reliable and sustainable power generation through parts, repair, servicing, retrofits, modernization, engineering
solutions, digitalization and asset management across the power island, electrical & control systems and balance of plant such as coal and ash handling systems.
Condensate throttling, based on Siemens’ Frequency Siemens Topsides 4.0 is a digital lifecycle approach Siemens is utilizing state-of-the-art AM technology
Control Solution, is used for immediate generation to rotating equipment and electrical and automation to pave the way for greater agility in steam turbine
of additional power for frequency control. In the systems, underpinned by secure communications. component manufacturing and maintenance and to
current regime of renewable energy integration into It is designed to enable digital project management set new benchmarks for industrial power plant
the power grid, this technology provides flexibility and manufacturing, virtual testing and services. The additive manufacturing technology
to the thermal power plant unit. Plants with AGC commissioning, and delivery of an intelligent “digital significantly reduces the lead time to produce spare
technology can regulate the generation variation twin” of a topsides facility, which can be used by parts and will help meet high-end customized
automatically according to the grid parameter operators for decision-making support and asset requirements of the Industry more quickly.
conditions, thus leading to reliable power, stable optimization.
power grid and boosting integration of renewable
energy into the grid.
Primary Frequency Additive Remote Thermodynamics
and Automatic Topsides 4.0 Manufacturing Operation Center Monitoring
Generation Control
Siemens is developing the Remote Operation Center (ROC) to help customers Siemens has developed a unique online performance monitoring solution for
meet strategic and operational goals with the focus on performance calculation a combined cycle power plant, which includes the boiler feed pumps, condensate
and operation optimization to improve efficiency. The services include advanced pumps and circulating water system. These performance monitoring calculations,
big-data analysis, diagnostic capabilities, optimal economic dispatch, reliability which are part of the SPPA-T3000 platform, are designed to provide unit
centered maintenance and a role-based working center to match digital performance information and assist in the immediate detection of the reduced
instructions to each users’ specific role. efficiency of any monitored plant component or overall plant performance
degradation.
NTPC Dadri OOEM Services SGT-700
Siemens Limited commissioned India’s first Siemens has a full-fledged and well-trained Siemens developed the world’s first 3D printed
condensate throttling-based Primary team to provide quality service, repair and burner for SGT-700 gas turbine which has
Frequency Control Solution at National modernizations solutions for other OEM successfully completed one year of operations
Capital Power Station (NCPS), NTPC Dadri machines. Successful service overhauls and in a running power plant. In 2017, Siemens
(Stage 2, Unit 6). Condensate throttling on-site repair activities were completed in began printing gas turbine burners using
is one of the most advanced and efficient record time for 4 oOEM machines (300 MW) selective laser melting technology and they
methods which can be used to rapidly at JSW Ratnagiri. Similarly, the HP module were the first burners produced by Siemens’
activate stored energy enough for unit load of a 500 MW BHEL make turbine was intelligent burner manufacturing (IBUMA)
support for a few minutes. refurbished indigenously at our Vadodara program in Finspång, Sweden. Each burner
facility resulting in increased efficiency and head is manufactured in one piece compared
performance. to traditional methods that required 13
individual parts and 18 welds.
nk.wadhwani@siemens.com I Naresh Wadhwani, Vertical Market Manager, Power Plant ServicesChemicals and Petrochemicals
Reduced costs, agile production flexibility
and increased plant availability
3rd largest producer
of chemicals by volume in Asia
and 6th by output in the world
Chemical as an Industry is
a key contributor to Indian economy,
accounting to 2.11% of GDP
By 2025, the Indian chemical industry
Know more about
Chemicals and
is projected to reach US$403
Petrochemicals billion
3rd largest consumer of polymers
and agrochemicalsControl Performance Analytics Valve Monitoring
Siemens Control Performance Analytics is a cloud-based service that collects The Valve Monitoring Solution is a central platform devised for critical assets
control loop data in an anonymized form with enabled secure data connection such as valves, pumps etc. It uses existing diagnostics and process data for
and provides detailed reports and suggestions for implementation It results in anomaly detection and predictive maintenance. The monitoring systems are fully
Increased product quality, minimized equipment utilization, increased integrated with MindSphere ready cloud- based application resulting in reduced
throughput and reduced operator work load. downtime and optimizing asset maintenance.
Improve Process OPERATIONS Ensure Asset Uptime
Design and Maintenance
Engineering Petrochemical Base Chemical Specialty Chemical Fine Chemical and Service
Continuous Process Batch Process
Reduced time to market Asset Performance Management
Shorter innovation cycles, reduced time to market and, above all, plant and Solutions such as SIMATIC PCS 7 and COMOS MRO (Maintenance, Repair &
project data terabytes all pose major challenges for plant designers and Overhaul) support in with efficient planning, implementation, and analysis of
operators, even as early as the planning stage. The COMOS software solution maintenance activities – including the connection of portable devices for
for plant lifecycle management consistently implements the complete remote services. With COMOS MRO, all aspects of the management, planning,
integration of all processes – during both the engineering stage and the operation and maintenance, including plant documentation, are carried out
operation/ maintenance stage. In addition the powerful COMOS Walkinside in a single system. This means that any changes to the plant due to service and
3D visualization software realistically presents highly complex plant models maintenance processes are also immediately available in the engineering system.
based on 3D engineering data.
Advance Process Control Mass customization Virtualization enables
at Ineos, Phenol and reduced costs global cooperation
Time-dependent dynamic model as basis New Dulux plant in Merrifield has focused A multi-national who has R&D and
for calculating the future process behavior on the end-to-end digitalization of all Engineering team based out in India installed
in order to ensure consistent phenol processes for production of approximately a virtual setup for Engineering, Simulation &
concentration and product quality. 75 million liters of paint each year. testing of global projects. Siemens virtual
Use of new Model Predictive Control Simulation platform SIMIT enabled early platform of SiVAAS based on PCS 7
module integrated into SIMATIC PCS 7 comprehensive tests and virtual comprising of Emulated controllers, SIMIT
process control system without additional commissioning of automation applications for simulation and the Flow-net library to
hard- and software. Load switch of process even before the real startup. Paperless build process models was used as part of the
plant in automatic mode. Benefits - production, achieved through SIMATIC IT set-up. This platform enables global
Increased throughput, improved process eBR software. collaboration & deployment between the
reliability, optimized energy and raw teams for standardization of engineering &
material use. testing, thus providing shorter development
& commissioning time.
km.sundaram@siemens.com I KM Sundaram, Vertical Market Manager, Chemicals and PetrochemicalsSolar
Innovative PV eBoP (electrical balance of plant)
solutions for efficient, smart & reliable evacuation
of clean energy to the grid
Target of 100 GW
installed solar capacity by 2022
India is endowed with a rich solar
radiation of 5.5 kWh
per square meter per day
India 3rd
largest solar market in the world
Cumulative solar
Know more about
capacity is 25GW
Solar
World’s largest solar park named
‘Shakti Sthala’
was launched in Karnataka
in March 2018Universal Solution Reduced Engineering Hours Centerpiece of the Medium-Voltage
The Solar Tracking Control System from Siemens is The SINACON PV inverter is used in medium and Station
the universal solution for dual- and single-axis solar large utility scale photovoltaic power plants to The MV-inverter station is a comprehensive
tracking systems. Our SIMATIC S7-1200 control unit achieve high efficiency. It is equipped with 3-level plug-and-play solution with highest power density
and special software jointly control the duel axis IGBT modules for input voltages of up to DC 1500 V for extra-large PV plants. Three high-performance
tracking of a solar unit. It controls movement in to maximize energy efficiency. The integrated DC components from the Siemens portfolio work
azimuthal and zenithal directions, independent of and AC distribution makes the SINACON PV inverter together perfectly: central inverter, transformer,
whether the requirements are for a photovoltaic cost efficient. Standardized interfaces for easy plug and RMU (Ring Main Unit). It enables maximized
(PV) or a concentrated solar power (CSP) facility. and play reduce engineering hours. cost reduction coupled with Open outdoor elements
for efficient cooling.
Siemens has also developed sleek AC distribution
boxes with integrated metering for rooftop solar
projects.
Universal Tracker Optimized
Power Grid Energy
Automation Power
Conversion Management Analytics
Solutions Evacuation
Integrated Energy & Storage Systems Intelligent Use of Data
With its EMS/ SCADA systems, Siemens offers an innovative, scalable process-visualization system with Siemens EnergyIP DEOP provides a powerful
numerous high-performance functions for monitoring automated processes. IoT-platform for management of data from millions
Siemens energy storage system is based on lithium-ion batteries. This system enhances grid stability while of distributed assets in near-real time. It has
also enabling integration of higher volumes of power from renewable energy sources and exchange of scalability for monitoring multiple asset types
active power between the battery storage system and the grid. (Eg: multiple PV plants, storage, building data) and
the unique gateway can collect data from multiple
Energy storage is the most responsive and flexible solution available for Renewable Integration that can protocols (Eg: IEC-61850). The data can be accessed
neutralize the volatility caused by renewables in the grid and enable better availability & utilization of by a web-based app available on desktop, tablet,
renewable energy. smartphone etc.
M/s Fluence (A Siemens and AES company) is our storage partner company which has technology platforms
of Siestorage, Advancion & SunFlex depending on the project requirements.
AC Power evacuation New generation of Photovoltaic Medium Voltage Inverter
for ReNew Power (PV) Central Inverters Stations - Brazil
Siemens provided a turnkey solution for AC Siemens India launched with Sinacon PV a The engineering firm Quebec Engenharia
electrical balance of plant for a 48 MW solar new generation of photovoltaic (PV) central is building a solar farm with a total capacity
PV plant for ReNew Power at a remote site inverters with an output up to 5,000 kVA. of 38 MW in northeastern Brazil. Siemens
in Telangana. Siemens’ Reliable & robust Solar PV inverter converts the variable direct has supplied seven inverter stations for
substation solution enables efficient solar current (DC) output of a photovoltaic solar connection to the local distribution grid.
power evacuation to the grid. panel into a utility frequency alternating These stations consist of a 4.36 MWac
central inverter, the transformer and the
current (AC) that can be fed into a
medium-voltage switchgear.
commercial electrical grid or used by a local,
off-grid electrical network. The Sinacon PV
is equipped with 3 level IGBT modules, has
an outdoor design for harsh environments
with fluid cooling and can operate up to
60°C ambient temperature.
bidyut.mazumder@siemens.com I Bidyut Mazumder, Vertical Market Manager, SolarMarine and Ship-Building
Electrical propulsion & Digitalization solutions -
Enabling greener and efficient global fleets
Indian Coast line of
7500+Kms, guarded by
250+ Naval/Coast Guard Vessels
Indian Shipping fleet has
500+ Vessels,
making it one of the largest fleet
among developing nations
(Ranked 14th Globally)
Know more about 20+ shipyard - Naval
Marine and Ship-Building
and Commercial Ship construction
14% annual growth from
2014-18 in Coastal shipping in IndiaDigitalization of the marine business is creating new SISHIP/SINAVY IMAC Automation system provides In today’s marine industry, ship owners and
possibilities to increase efficiency and reduce costs a comprehensive solution for seagoing ships operators face a wide range of daily challenges.
while meeting environmental regulations. Siemens integrating all the products and services operator Invariably, they all share the same goal – to keep
PLM solutions ranging from integrated design, needs for sustained maximization of performance. their vessels operations safe and reliable. High-level
digital construction to ship service and support Horizontally it improves ship’s operations, Vertically operability is always uppermost on their minds.
enables shipyard to design, engineer, build better it integrates the ship’s information and end-to-end After all, only a working vessel generates revenues.
and more affordable ships. security management, facilitating better decision That’s what SISHIP and SINAVY life-cycle
making. At the same time, it is designed for optimal management (LCM) modules and services are all
ship specific maintenance over the whole life cycle
about – optimizing the operability of vessels over
ensuring exhaustive and sustained plant productivity
the long term.
in their very core.
Ship Design Electric/Hybrid Electrification Life Cycle
Digitalization
and Construction propulsion and Automation Management
Integrated Solution from Siemens SISHIP/BlueDrive PlusC, Electric/Hybrid Siemens’ web based data application SISHIP EcoMAIN solution provides real-time
propulsion family provides a reliable, sustainable and environmental friendly monitoring and analyzing of the entire energy flow on board. A tailored app
propulsion solution for ships in Naval, Commercial and Offshore sector. They are helps to optimize energy consumption and emissions by making the right
clearly superior, both technically and in operation to normal diesel drive systems decisions, addressing power generation, propulsion, trim, waste heat and HVAC
in almost all areas. Thanks to their flexibility and versatility, these propulsion (Heating, ventilation, and air conditioning). It provides on board and shore-based
systems are customized to meet the widest range of demands. Extremely quiet system with a user-friendly, easy-to-operate graphical user interface (GUI). The
and low in vibration, they are excellently suited for use on board a wide range of graphical user interface shows all applications in a unique layout providing the
ship types. customized information required for decision making by a fleet owner/operator.
Siemens PLM for Naval Zero Emmission All-electric Digitalization –
shipbuilding in India ferry, Norway Fleet Management
Marching towards establishing industry 4.0 The world’s first all-electric drive carry ferry With 60+ installed references SISHIP
standards, Mazagon Dock Shipbuilders AMPERE powered with Siemens SISHIP EcoMAIN is providing an exhaustive Marine
Limited kicked off implementation of BlueDrive PlusC electric propulsion solution, 4.0 solution for a wide range of customers -
Product Lifecycle Management (PLM) makes 34 runs of 20 minutes each day, and from leading global cruise line operators
system, first time in the history of recharging its batteries from the local power to largest container fleet owners. The
shipbuilding in the country. MDL, along grid. Powered by a pair of 450 kW motors and established references shows fuel saving
with the many firsts being introduced in 10 tons of lithium batteries built by Siemens combined with evidence for compliance to
Project 17A, has added another new feature Norway, the lightweight all-aluminum ferry emission regulations. The App-principle
in the project by adopting the PLM solutions can carry up to 360 passengers and 120 allows an open and customized system – this
from Siemens. vehicles across Sognefjord. is a Marine 4.0 answer for every vessel type.
manav.gandhi@siemens.com I Manav Gandhi, Vertical Market Manager, Marine and Ship-BuildingPorts
Integration of real and virtual worlds
for increased port productivity
16th
Largest coastline in the world –
spanning, 7516.6 km contributing
95% trading volume through
maritime transport
Target 2020
From 1,806.8 MT to 3,130 MT
port capacity
INR 8.5 trillion
Know more about Investment in Ports
Ports
Govt. of India’s Sagarmala
Programme, a key investment
driver aims to promote port-led
development in the countryDigitalization & Big Data Simulation Remote Control Operation System
Siemens offers a complete Digitalized infrastructure A digital twin enables to evaluating scenario’s and a RCOS allows for automatic crane operation. Crane
for Ports to improve productivity, safety and reduced development time. Corresponding solutions operators supervise the process from a remote
efficiency. The integration of real and virtual worlds can be pre tested leading to an accelerated location. To ensure safe, trouble-free unloa-ding
helps in maintenance, optimization of crane and commissioning time on site. The main advantage processes, the interplay between control and
block performance, timely delivery, logistic include assessment and performance analytics even monitoring components is vital. Remotely monitored
planning, commissioning etc. before the system is delivered. Also during the unmanned cranes automatically handle 90% of the
operation customers can make best use of data and containers.
predictive maintenance.
Terminal
Digitalization Remote Control
Simulation Supervisor Safety
& Big Data Operation System System
Terminal Supervisor System Safety
Terminal Supervisor System, which monitors all operations in the port area, is used Sensors like camera or laser systems help with target control, positioning and
to centrally supervise all operations in the terminal, report disruptions, and ensure collision prevention. The gathering of operational data via Crane Management
high productivity in the terminal area through optimal control of the processes. Systems enables the customer to optimize operations, service and maintenance
The Terminal Supervisor System assists to efficiently handle the high volume of and thus driving down the cost.
moves, the ship-to-shore and horizontal transport. The system controls a large
amount of information enabling quick action when there is a deflection of activities.
Africa’s first automated The Jawaharlal Nehru Port PSA Singapore
container terminal Trust (JNPT)
Siemens is supplying electrical systems used Siemens has installed state-of-the-art Siemens Cranes implemented electrical and
in 12 remote-controlled double trolley Remote Control Stations (RCS) and port automation systems for 56 Automated Rail
ship-to-shore cranes (STS). This order was equipments at DP World-operated Nhava Mounted Gantry Cranes to PSA Singapore
placed by the Chinese Zhenhua Port Sheva (India) Gateway Terminal (NSIGT) Terminals, for the Pasir Panjang terminal
Machinery Company (ZPMC), one of the at JNPT, Navi Mumbai. The Remote Control Phases 3 and 4 developments. These
world’s biggest crane builders for APM Stations comprises of ergonomically SIMOCRANE cranes -as tall as a 5 story
building - can stack containers about 20m
Terminals MedPort Tangier. The terminal, designed desks and operator chairs with
high. 56 cranes are controlled by only 6
to be opened in 2019, will be the world’s necessary controls to control the
Operators from a centralized control room.
first transshipment hub featuring an end movements of the crane, monitors for
loading yard concept. visuals, remote I/O interface with
communication to the server PC.
sourav.sadhukhan@siemens.com I Sourav Sadhukhan, Vertical Market Manager, PortsYou can also read
