Type of plant:

PV Crystalox Solar Silicon GmbH

Customer:

PV Crystalox Solar Solicon GmbH / Siemens AG

Project site:

Bitterfeld chemical park

Project description:

 

 

 

 

 

PV Crystalox Solar AG is a globally leading manufacturer of solar-grade silicon in the form of ingots and wafers for solar panels. The group has specialised in crystalline technology and was one of the first to develop this technology on an industrial scale. 

At the Bitterfeld chemical park, one of the largest chemical production sites in Europe, a new production facility for high-purity silicon – PV Crystalox Solar Silicon GmbH – has been constructed. This investment completes the entire solar value chain from the production of silicon up to full-fledged systems. Actemium was awarded the contract for the automation technology, including the MES system as well as erection of the instrumentation and control systems, and played an instrumental role in this investment. Responsibility for fulfilling the contract lay with the Halle/Leipzig BU.


Automation technology
Actemium was responsible on behalf of Siemens for the software engineering of the PCS 7 Version 7.0 process control system. Within the scope of software preparation, system-specific modules were configured into a higher PCS 7 version with consistent standardisation and simple migration capabilities. The high safety requirements of the process necessitated the use of failsafe controls. These were configured and visualised with the help of the engineering tool “Safety Matrix”. To ensure efficient maintenance of electrical, instrumentation and control systems PCS 7 Asset Management, including PDM and PACTware 3.0 SP5 with Pepperl & Fuchs firmware was used.


I&C erection
PV Crystalox’s contract for Actemium included supply and erection of the complete I&C installation for the solar-grade silicon plant as well as the neighbouring Poerner and Evonik plant components. The scope of supply also included I&C equipment cabinets, instrument air diffusers and marshalling cabinets. In total, over 90,000 m of cable and piping were laid including bus cables, conventional and fibre optic cables. On completion of the assembly work, loop checks were carried out for approx. 1,400 loops from field equipment to terminal.

 

Technical highlights:

 

 

 

 

 

 

 

 

Scope of systems/technology:

  • 3500 I/Os
  • 21 automation systems
  • 1 redundant server pair
  • 12 clients
  • Profibus PA
     - I/O signals partly in potentially explosive areas
     - MCC tie-in
     - 20 S7 controls

Manufacturing Execution System MES
In order to meet the high production data requirements in the management information area, the Simatic IT MES system was used.


Simatic IT Historian serves in this application to:

  • Display process values outside the production levels
  • Promptly calculate production indicators from current process values
  • Transfer these KPIs to the ERP system


Through the use of client applications, the stored values can be displayed on PCs not directly linked to the production network. This system permits prompt calculation of values that can be transferred for further processing to an ERP system. The complete system was installed and configured on three servers in a modern server system. To ensure enhanced availability and safeguarding against failure, parts of the system were configured as redundant featuring special back-up functions.

 

Vinci