Nord Stream Baltic Sea Pipeline – SCADA-Migration During Ongoing Operation

 

The Nord Stream AG operates two gas pipelines from Russia to Germany through the Baltic Sea. The two pipelines with a total length of approximately 1200 kilometers are protected with the landfall stations in Lubmin and Portovaja Bay (Vyborg, Russia). Both stations are monitored and operated from the headquarters in Zug (Switzerland), where the supervisory control and data acquisition (SCADA) is carried out as well. Just like every other technical system, this system is also subject to a continuous life and maintenance cycle. A particularly critical and demanding challenge was the SCADA migration to its latest release during operation, which was successfully carried out by Bilfinger GreyLogix GmbH.

As the facility’s operator, Nord Stream AG benefits from the update of the hardware and software in particular through the increased safety of the facility and additional new functions within the controls. Migrating to a virtualized system furthermore increases the flexibility of the facility. Optimizations to the software design also significantly enhanced the structure and transparency.

With the know-how and the process knowledge of the engineers of the BU Oil & Gas at Bilfinger GreyLogix, we were able to demonstrate to the customer even in the early project phase to which extent he will benefit from the update of his facility. But that is not all: As the experts of Bilfinger GreyLogix carried out their work during operation, the downtimes caused by maintenance and works on the plant were reduced to a minimum. This allowed the customer to fully focus on the operation of his plant.

In order to offer the typical „GreyLogix Service“ to our customer even after the project, service locations have been set up in St. Petersburg and Lubmin. There, experienced technicians and engineers of Bilfinger GreyLogix will assist the customer in order to ensure a continuous, safe, and economical plant operation.As the customers need to focus more and more on their core competencies and cannot maintain staff outside of this area, Bilfinger GreyLogix has strongly developed this service area to provide optimal support to its customers.

Bilfinger GreyLogix foodtec Makes Spray-Drying Safe

 

Many products in our daily lives are produced by means of spray drying. These reach from milk powder over instant coffee up to vaccines. The manufacturing process is very complex, though: simply put, concentrated products are pushed through a sprayer or a jet and dried with hot air intake. The resulting product is a dried powder with a long shelf life. However, the high temperatures can cause fires or even explosions in the plant during the drying process. The relatively high age of many plants increases this risk even more.

Against this background, Bilfinger sees great business opportunities in this field and has now founded its own department with 20 employees within the subsidiary GreyLogix foodtec. This department deals with all safety-related aspects concerning spray drying and at the same time promotes technological developments. „Safety and safety technology are playing an increasingly important role“, says Matthias Buch, general manager at Bilfinger GreyLogix foodtec. „We have recognized this and have developed a comprehensive package with many simple and ingenious solutions. In addition, we will invest further in new developments.“

For a safety-related upgrade the age of a plant is not the only decisive factor. The legal safety requirements also have steadily increased in the past years. Hence, modernization is required. Bilfinger offers a comprehensive bundle for the safety of the spray drying plant – from the analysis of the current situation over the concept for improving the safety coordinated with the authorities up to the installation of the components. Furthermore, the company also provides comprehensive services like maintenance, if desired.

The safety team at Bilfinger GreyLogix foodtec consists of experts in plant engineering as well as engineers from the process technology. The package resulting from this wealth of experience comprises different modules, which significantly increase the safety during production. The great advantage: The individual components are compatible with each other as well as with many third-party systems. The companies, which are using the innovative Bilfinger safety solutions in milk processing, include Uelzena, Rücker, and Deutsches Milchkontor.


Employees of the Safety Technology team of Bilfinger GreyLogix foodtec GmbH

An innovative module of the portfolio is the carbon monoxide (CO) detection system „Detex“ for the spray drying, which has ensured a safe production of milk powder for three years by now. It monitors the spray dryers for glowing embers, which, in the worst case, can lead to an explosion in the plant. Detex is fitted with a two-channel analysis module. The benefit: The absolute measurement values of both the air intake and the exhaust air are available at any time. Thus, it is possible to clearly recognize interferences outside the process and minimize unnecessary production stops.

In case a plant needs to be shut down immediately and cooled down to a non-critical temperature range, the cooling system „Vertex“ comes into play. Vertex prevents superheating of the air intake flowing to the drying chamber independently from the mains supply voltage and cools the air down in a controlled manner. The basic principle is based on evaporative cooling, which is achieved by a fine spray of water into the air intake duct of the drying chamber. The energy removed from the hot air through this process reduces the air’s temperature to a non-critical value – without damaging the powder present in the drying.

Despite all precautions, the chance of fire or even an explosion can never be fully ruled out. In order to ensure greatest possible protection even in such cases, Bilfinger has explosion protection systems to offer, as well as tailor-made fire extinguishing systems.

Even when working in the plant itself, the safety can be increased in a highly effective way. Bilfinger offers an innovative key transfer system for maintenance holes. This ensures that the closed holes remain locked until it is safe to open them. In the same manner, it prevents dangerous operating conditions to occur when the holes are open. For this, a locking mechanism is installed at each maintenance hole, which can be opened only with a key specifically designed for this mechanism. When the plant is in operation, the keys are in a key board, which has an electronically monitored slot for each key. If a key is removed, the plant will be locked against unsafe operating conditions and will be shut down in a controlled manner.


Internal training of the safety technology team of Bilfinger GreyLogix foodtec GmbH

Lünendonk list 2017: Bilfinger once again leading industrial services provider in Germany

 

When it comes to industrial services, Bilfinger is far and away the top choice for companies in Germany. For the ninth consecutive year, the company has taken first place in the industrial services sector according to the renowned Lünendonk List 2017, published annually by Lünendonk & Hossenfelder GmbH. With domestic sales of over €1 billion last year, the Group generated revenues of roughly a quarter more than the second placed company.

Tom Blades, Bilfinger CEO: “I am delighted that we have been at the top of the list for almost a decade. We enhance the efficiency of plants while reducing maintenance costs – something our customers appreciate. Especially in the field of digitalization, we apply predictive maintenance approaches that are setting standards in our industry.”

Advancing digitalization has provided a huge boost in the development of predictive maintenance. With a strict set of standards and best practices, Bilfinger’s Maintenance, Modifications & Operations (MMO) segment offers its customers the most modern maintenance available.

Bilfinger’s pilot project with Münzing Chemie is one example of how predictive maintenance works. Bilfinger digitally records the technical information on an existing power
plant and for two chemical reactors. Bilfinger’s new digital MMO platform will also collate and comprehensively assess maintenance and production data.

Information about the plant can be accessed with just a few clicks on the integrated Bilfinger MMO platform. All engineering, maintenance, production, environmental and energy data recorded during the lifecycle of the plant is also systematically collated and analyzed. The aim is to use the existing data portfolio to tap new potential for the enhancement of plant efficiency and availability.

Bilfinger GreyLogix is now RosTechNadzor certified

 

СВЕРШИЛОСЬ! Twelve Bilfinger GreyLogix employees are now RosTechNadzor certified in Russia.

RosTechNadzor Surveillance Authority

RosTechNadzor is a federal technical controlling authority in Russia, similar to the German TÜV. RosTechNadzor (RTN) stands for „Russian Technical Surveillance Authorities“. When employees are involved with the planning, developing, commissioning, operation, or maintenance of an industrial plant in Russia, they must be certified accordingly. No work at the plant may be carried out without the corresponding certification. At the same time, this certification means the individual’s information must be entered into the state register, a database of the surveillance authority.

Bilfinger GreyLogix Stands for Innovation

Before the RTN certifications could be issued, negotiations were held with Russian authorities to verify numerous documents, diplomas, and certificates. Through the RosTechNadzor certification, professional employees from Bilfinger GreyLogix are officially authorized to conduct work on plants and carry out their activities in Russia. Since Bilfinger GreyLogix continues to expand its range of activities and is committed to fulfill requirements for ongoing projects, such certifications will be carried out in a targeted manner. These nuances give Bilfinger GreyLogix an edge over the competition and promote intercultural understanding among its team of experts.

On Behalf of the Customer

Bilfinger GreyLogix relies on professionalism while fulfilling all necessary legal requirements to maintain good customer relationships — whether in Germany, Russia, or other countries around the world. By employing specialists with management backgrounds and experience in engineering fields, such as hardware, software, and SCADA, Bilfinger GreyLogix satisfies these requirements. It is Bilfinger GreyLogix‘ goal to work towards continuous improvement and provide the best possible performance for its customers.
Gas, Industrial plants, Quality, RosTechNadzor, Russia, Certification

Bilfinger GreyLogix foodtec and SiccaDania secure important contract from DMK for a complete infant formula powder plant.

 

Bilfinger GreyLogix foodtec and SiccaDania are pleased to announce the contract award of a new spray dryer for infant formula production for DMK in Strückhausen, Germany. The contract was an outcome of several months of intensive work in understanding the possibilities for either upgrading a 30 years old spray dryer or to install a new spray dryer in the existing building on site at DMK Strückhausen production facilities. The dryer will produce a number of high quality infant formula powders and lives up to today’s strict requirements for manufacturing a safe and nutritional product. Bilfinger GREYLOGIX foodtec as the general contractor will supply the complete liquid milk processing area, the overall electrical and automation system and the safety equipment and SiccaDania will supply all drying equipment including installation and commissioning. The main driving key performance indicators for this contract award is the delivery time and quality of the product, as DMK has a strong requirement from the market for their infant formula products. SiccaDania sees this order as a strategic very important order to verify our abilities within the infant formula industry.

About the DMK GROUP

The DMK GROUP is backed by over 8,300 active dairy farmers and around 7,500 employees. DMK now processes 6.7 billion kilos of milk at 17 dairy factory sites. A further eight sites are available for the manufacture of baby food, ice cream and health products. The DMK GROUP also has an administrative facility in Bremen. With brands such as MILRAM, Osterland, Oldenburger, Humana, intact, sanotact, hansal and NORMI, the DMK GROUP is an established name for retailers and consumers in Germany and around 100 other countries all over the world. The company generates a turnover of 4.6 billion euros, making it one of Europe’s leading dairy companies.

Visit www.dmk.de »

About SiccaDania

SiccaDania is a global supplier for evaporators and dryers. We offer innovative and cost-effective solutions to the global dairy and food processing industries, ranging from small individual evaporators or dryers to turnkey installations. SiccaDania also supports its customers with modifications of existing plants, i.e. upgrades to improve safety, capacity, hygiene, new product adaptability etc. SiccaDania prioritizes technical focus, intense attention to customer requirements and above all: flexibility in our approach to our customers. SiccaDania is a Danish owned and managed company. We have offices in Denmark, France, China and New Zealand.

Visit www.siccadania.dk »

About Bilfinger GreyLogix foodtec

Bilfinger GREYLOGIX foodtec GmbH is the Bilfinger Group’s specialist for the food and beverage industry. With our experienced team of nearly 100 engineers and technicians, we realise green and brown field automation and process technology projects from planning, engineering all the way to assembling and commissioning. As part of Bilfinger GREYLOGIX with more than 500 engineers and technicians, we are able to handle orders of all sizes safely and reliably. And as member of Bilfinger, we can offer our customers the security of a major group with the flexibility of a medium-sized company.

Visit Bilfinger GreyLogix foodtec »

Strong Partners: Siemens, HanseWerk Natur and Bilfinger GREYLOGIX together on the SPS IPC Drives 2016

 

Together with HanseWerk Natur, we will present the project “The Unmanned Control Center” on the SPS IPC Drives 2016. You can convince yourself of the idea, away from the typical hustle and bustle of the exhibition in the Siemens SCADA Lounge. Bilfinger GreyLogix proves with the Unmanned Control Center that the unmanned control of a decentralized plant in a heating network is a viable solution; a secure and efficient solution.

This state-of-the-art development by Bilfinger GreyLogix and HanseWerk Natur is right in the main area of interest of the exhibition.
For more information about this event, please visit the website of our partner Siemens.

We are looking forward to meeting you at the exhibition!

Process control technology for refinery upgrading – Bilfinger GREYLOGIX establishes foothold in Iran

 

IRAN-Unterzeichnung_webNow that most of the economic sanctions against Iran have been lifted, the country has become an interesting partner for German industry. Bilfinger GREYLOGIX has now secured its first order there: one of Iran’s largest refineries is being upgraded and Bilfinger GREYLOGIX is delivering the entire process control system for the project.

The system will be designed, built and programmed in Germany. Following testing and customer acceptance, it will be shipped to Iran. The order has a volume of several million euros, though the parties agreed not to disclose the exact amount. The contract was signed during a visit of the Iranian delegation to Bilfinger headquarters in Mannheim.

“Our engineering services made in Germany are an international seal of quality. I am delighted that we will be able to contribute our quality and reliability to the ambitious project in Iran,” says Tom Blades, CEO at Bilfinger SE. “Iran has a great deal of pent up demand when it comes to the modernization of its industrial facilities and Bilfinger can make a contribution here in cooperation with Iranian companies.”

The refinery in the city of Esfahan is operated by the Esfahan Oil Refining Company (EORC). It went into operation in 1979 and has a processing capacity of up to 370,000 barrels per day. The refinery will be upgraded through the addition of a so-called Diesel Hydro Treatment plant which will be used to produce environmental friendly diesel in accordance with the Euro 5 norm.

Iranian company Nargan, which was commissioned with the engineering and procurement of the plant, selected Bilfinger GREYLOGIX as supplier for the process technology including the safety systems.

The order volume does not include commissioning of the plant, which Bilfinger GREYLOGIX will carry out in the country. In addition to Bilfinger’s Engineering Solutions division, other renowned German companies have also been selected as suppliers for this project.

CAMiX – Awarded for Industry 4.0 Innovation by the Ministry of Economic Affairs and Energy

 

„CAMiX is a great idea!“ is our sentiment echoed by our customers and now shared by even more fans.

The German Federal Ministry for Economic Affairs and Energy and the Federal Ministry of Education and Research have found CAMiX to be so valuable that it has now a place in the national portal “Platform Industry 4.0”.
This platform focusses the innovative driving forces of German companies, allows mutual exchanges and secures the position of Germany as an industrial nation.
For more information, see http://www.plattform-i40.de/I40/Redaktion/DE/Anwendungsbeispiele/361-bilfinger-grey-logixs/beitrag-bilfinger-greylogix.html (only in German)

 

 

Hockenheimring – Bilfinger GREYLOGIX smashes own records!

 

The annual BASF FIRMENCUP (Company Cup) on the legendary Grand Prix track Hockenheimring lets runners, inline skaters and Nordic walkers compete either on their own or with their respective company’s team since 2003.
Once again we were part of the over 17,000 athletes and 820 participating companies and had enthusiastic fans cheering us on. All of our athletes beat their last year’s final result and reached their personal goals! Maybe the ferocious thunderstorm just before the start of the race gave them this special edge.
Next year we will compete again with an even stronger team.

Gasunie relies on MCCs by Bilfinger GreyLogix

 

The engineering and service company Bilfinger GreyLogix GmbH has successfully concluded a framework contract with the Dutch energy supplier Gasunie for the replacement and maintenance of control systems of 50 gas turbines. The contract volume is over € 20 mio.

Bilfinger GREYLOGIX will develop a new, standardized control system for the gas turbine compressor units of all suppliers of the entire pipeline system of Gasunie in the Netherlands. The systems will be replaced over the coming years gradually. In addition to the system replacement, the contract covers the maintenance and repair of the control technology.