Design limited by physical trials
Pilot experiments and experience-based scaling leave efficiency, energy, and capacity decisions uncertain until scale-up.
/ INDUSTRIAL SOLUTION
21
Process Automation (PCS 7 - PLC)
Control the process with SIMATIC PCS 7 and validate decisions with a Siemens gPROMS model.
We connect SIMATIC PCS 7 and PLC-based controls with Siemens gPROMS process modelling, using the same validated model for design, commissioning and operating decisions.
Explore the solution
Don't just recognize the process when you put it into operation; see it at the design desk, constantly validate it in operation.
Surprise on commissioning.
When control strategy, adjustment and interlock behavior are first tested in the field, commissioning time and product loss increase.
Unquantified improvement potential
Energy, yield and cycle time gains cannot be justified and monitored without a validated model of the process.
Solve the process in the model;
implement it in the plant with PCS 7.
A process model built with Siemens gPROMS informs design decisions; the SIMATIC PCS 7 and PLC layers implement those decisions deterministically in the plant. After commissioning, the same model connects to live data to become a digital twin.
Model the process
Unit, flow and physical property behavior are defined in an equation-based flowchart.
→Calibrate with data
The model is validated with a confidence interval by comparing it with laboratory, pilot and facility data.
→Apply with PCS 7
Control strategy, recipe structure, alarm and interlock logic are built into the control system.
→Operate with a digital twin
The model, linked to live data, is used for monitoring, soft-sensing, and real-time optimization.
/ SIEMENS gPROMS PLATFORM FAMILYgPROMS provides
gPROMS provides
a family of platforms.
We select the modelling environment suited to your production type from platforms built on the shared gPROMS Core and gPROMS Properties foundation.
gPROMS Process
A lifecycle modeling environment for process design, dynamic simulation and optimization from concept to operation.
Review the product →
gPROMS FormulatedProducts
A drug and formulation-focused modeling environment where the product and production process are designed together.
Review the product →
gPROMS Properties
Description of complex fluid, solid and electrolytic systems with advanced physical property models including SAFT-γ Mie.
Review the product →
SIMATIC PCS 7 and PLC
Implementation of the model-validated control strategy in field instrumentation, PLC and DCS layers.
Explore the service →/ MODELLING SCOPEFrom process flowsheets
From process flowsheets
to real-time optimisation.
The scope is determined by process type, data maturity and decision objective. Each model is delivered with acceptance criteria and validity limits.
Equation-based facility model
Solve the complete plant, including recycle streams, in one system of equations for steady-state and dynamic scenarios.
High-accuracy physical properties
With gPROMS Properties, phase behavior, mixing and electrolyte systems are reliably defined.
Transient behaviour and operating scenarios
Commissioning, product transition, shutdown and failure scenarios are tested prior to production.
Multiscale unit models
Scaling in reactors and separation units is supported by distributed parametric models.
Optimization and sensitivity analysis
Design and operation variables are prioritized by MINLP optimization and global sensitivity analysis.
Soft-sensing and live optimization
Unmeasureable variables are estimated from the model; operation decisions are updated with real-time data.
/ ENGINEERING INPUTSDesign the process itself,
Design the process itself,
alongside its control system.
- 01Process definition and target
Product specification, capacity, energy and quality goals are defined in a measurable way.
- 02Data and physical property
Evaluate the available laboratory, pilot and plant data together with the scope of the physical property models.
- 03Control strategy
Regulation, recipe structure, interlock and alarm philosophy are tested on the model.
- 04Acceptance and commissioning
FAT/SAT scenarios, performance tests, and model validity limits are written into the acceptance plan.
From process objectives to stable operation, Six controlled steps.
- 01Set Scope
Which decision will be supported by the model, the expected benefit, and the validation criterion are clarified.
- 02Collect the data
Process flow diagram, operation data, laboratory results and equipment information are compiled.
- 03Build the model
Model units, physical property packages and constraints in the gPROMS environment.
- 04Validate and optimize
The model is calibrated against actual data; design and operation scenarios are compared.
- 05Transfer to the control system
The verified strategy is applied and deployed in the PCS 7/PLC layer.
- 06Operate a digital twin
A model linked to live data is monitored; deviation, performance, and recalibration are tracked.
Production environments where
process behaviour is critical.
Chemical and petrochemical
Design reaction, separation and recycle flows around yield and energy targets.
Pharmaceuticals and life sciences
Verifiable process design, scale-up and controlled operation scenarios.
Energy and utilities
Reducing fuel consumption and emissions in steam, cooling and auxiliary systems.
Food and beverage
Balance quality and energy use in core thermal processing, mixing and separation operations.
Let’s clarify your requirements
with the right engineering team.
Tell us briefly about your operation so we can establish the right next step together.
Discuss your requirements Your request is routed directly to the relevant engineering team.