Siemens Engineering Pakistan Co. Ltd.

Internship Report
Industry Automation
Syed Abdullah Ahmed

Summer 2012

Preface
During the summer of 2012, I was granted the unique opportunity to be employed by Siemens Engineering Pakistan Co. Ltd. as an Internee. Under the supervision of Industry Automation Division department, I was lucky enough to undertake 3 weeks internship that expanded my horizons and my way of thinking. Siemens has been active in Pakistan since 1947, and holds leading positions in its Industry, Energy, City and Infrastructure and Healthcare Sectors. Siemens IT Solutions and Services operate across all three Sectors. Siemens is the countrys Number One supplier of high-voltage grid stations, switchgear products and systems, power distribution and power transformers, and network consultancy. My main project was based within the Electronics discipline and primarily involved practical understanding basic theories under the supervision of concerned Engineers.

Acknowledgement
The whole praise is to Almighty Allah, creator of this universe. Who made us the super creature with great knowledge and who able me to accomplish this work. I feel great pleasure in expressing my deepest appreciation and heartiest gratitude to the staff of Siemens Engineering Pakistan Co. Ltd. for their guidance and great help during the internship period. I would like to express my deepest affection for my parents and my friends who prayed for my success and encouraged me during this internship period. I appreciate and acknowledge the patience, understanding and love provided by employees of Siemens Pakistan. A token of special thanks to Ms. Sadia Kazmi who had been very friendly, co-operated throughout my internship period in Industry Automation Department and made it possible for me to learn and gather information. In spite of her busy schedule she took time out to explain to me the procedures and ethics of work in the organization.

Table of Contents
1. Introduction a. Historical Background b. Siemens Pakistan c. Quality policy d. Principles

2. Structure a. Industry b. Energy c. Healthcare d. Infrastructure Cities 3. Industry Automation Division 4. Quality Management Services 5. Programmable Logic Controller a. Introduction b. Characteristics c. Advantages d. PLC Design 6. SAP 7. Conclusion

Introduction
Historical Background Siemens was founded by Werner von Siemens on 12 October 1847. Siemens AG is Europe's largest engineering company and is a global powerhouse in electronics and electrical engineering Siemens' International Headquarters are located in Berlin, Munich and Erlangen, Germany. AG stands for Aktiengesellschaft which is a German term that refers to a corporation that is limited by shares, i.e. owned by shareholders, and may be traded on a stock market. The term is used in Germany, Austria, and Switzerland. Siemens is an integrated technology company with activities in the fields of industry, energy and healthcare. It is organized into five main divisions: Industry, Energy, Healthcare, Infrastructure & Cities, and Siemens Financial Services (SFS). Siemens and its subsidiaries employ approximately 360,000 people across nearly 190 countries and reported global revenue of approx 71 billion Euros for the year of 2011. Siemens AG is listed on the Frankfurt Stock Exchange, and has been listed on the New York Stock Exchange since March 12, 2001.

Siemens Pakistan Siemens Pakistan history dates back when Werner Von Siemens made the Indo European telegraph line between Calcutta & London come true, he also laid the foundations for trans Continental Cooperation between Pakistan and his company that was to last till this day. Siemens actual operations in the Indo-Pak subcontinent actually started in 1922 when Siemens opened its first office in Lahore. Siemens (Pakistan) Engineering Co. was founded as Private Limited Company in 1953. Since then Siemens has played an active & vital role in the countrys economy and is one of the countrys largest multinational company. Being a subsidiary of Siemens AG, the products produced in its factory in Karachi are manufactured under license from Siemens AG. Siemens first office in Lahore (Pakistan) opened in 1922. The Siemens Pakistan Engineering Company Ltd. was founded in 1953 as a private company and was later recognized as public limited company in 1963. Siemens enjoys a leading position in the Pakistan in power generation, transmission and distribution, automation and control, industrial and infrastructure solutions, medical solutions, transportation and information technology solutions. It operates in four segments: Energy segment which mainly relates to supply and installation of transformers, switchboards, and other related power generation, transmission, and distribution equipment and related services. Rotary machines segment which includes diesel generating sets, motors, alternators and drives. Industry automation and services segment which includes designing, engineering and construction services in electrical field, mechanical field and information technology services and other operations which includes supply and services of health care equipment, monitoring and security, solar power and home appliances. Siemens Pakistan has the following product manufacturing facilities at its factory in Karachi:

Power Transformers Distribution Transformers Switchgears Motors and Alternators

QUALITY POLICY OF SIEMENS Siemens Pakistan designs, develops, manufactures, markets and provides services of a wide range of technologically advanced Electrical and Electronic Products and Systems, including Construction Projects and Software which benefit business, industry and society. Quality is an integral part of our mission and strategy. The Customer is a focal point in our thinking and action. We, therefore, align ourselves to the needs and expectations of the Customers in a manner that result in their Satisfaction, our Business profitability and Stakeholders benefit. We create a challenging and rewarding work environment with a proactive management that encourage our employees to work with pride, enthusiasm, commitment and high sense of ethical and moral values. We are alive to the dynamics of the fast changing cycle of technology and continuously strive for innovation. We therefore train and groom our workforce accordingly. We build a relationship of cooperation and support with our suppliers resulting in improved products and services for mutual benefit.

OUR PRINCIPLES
We strengthen our CUSTOMERS - to keep them competitive

Our success depends on the success of our customers. We provide our customers with our comprehensive experience and solutions so they can achieve their objectives fast and effectively
We push INNOVATION - to shape the future

Innovation is our lifeblood, around the globe and around the clock. We turn our people's imagination and best practices into successful technologies and products.
We enhance company VALUE - to open up new opportunities

We generate profitable growth to ensure sustainable success. We leverage our balanced business portfolio, our business excellence and synergies across all segments and regions.
We empower our PEOPLE - to achieve world-class performance

Our employees are the key to our success. We work together as a global network of knowledge and learning.
We embrace corporate RESPONSIBILITY - to advance society

Our ideas, technologies and activities help create a better world.

Structure
Siemens is divided into 4 main sectors: Energy Industry Healthcare Infrastructure & Cites

Infrastructure & Cites

Mobility & Logistics Smart Grid Low & Medium Voltage

Healthcare
Imaging & Therapy Cilinical Products

Sectors
Energy
Fossils Renewables Oil & Gas Service Transmission

Industry
Industry Automation Drive Tecnologies Customer Services Regional Sales

Industry Industry Sector is one of the leading suppliers of manufacturing, transportation, building and lighting systems. Siemens technologies are helping industry and infrastructure customers compete more effectively and reduce their environmental footprint by optimizing their profitability, efficiency and flexibility. Departments under industry sector are; Drive Technologies Automation Technologies Building Technologies Mobility Market Specific Solutions Lighting (OSRAM) Financial Solutions IT Solutions and Services Communication Networks

Energy Energy Sector is a leading supplier of a wide range of products, solutions and services in the field of energy technology. Siemens enable its customers to generate, transmit and distribute electrical power at the highest levels of efficiency. It also help them produce, convert and transport the primary fuels oil and gas. Its exceptional solutions expertise is particularly striking in the area of interfaces: for example, in plant-to-grid connections, grid integration technologies and smart distribution systems linking grids to consumers. Energy sector covers following departments;

Power Generation Power Transmission Power Distribution Automation, Controls, Protection & Electrical Compression, Expansion & Ventilation Mechanical Drives Services

Healthcare Healthcare Sector is one of the largest providers to the healthcare industry. Siemens specialize in medical solutions based on our core competencies and innovative strengths: on the one hand, diagnostic systems and therapeutic technologies; and on the other, knowledge processing including information technology and systems integration. To leverage our market and growth potential even further, Siemens is reorganizing its activities into five Divisions: Clinical Workflow Solutions Diagnostic Imaging and Therapy Healthcare Infrastructure Hearing Instruments Laboratory Diagnostics Financial Solutions IT Solutions and Services

Infrastructure Cities The new Infrastructure & Cities Sector will manage the company's global business with cities and infrastructures from Munich, Germany. Siemens is bundling its competencies and business activities in one unit in order to offer cities solutions for mobility, environmental protection and energy saving. The new Sector, with around 87,000 employees, will contain the Mobility and Building Technology Divisions from the Industry Sector, as well as the Power Distribution Division and Smart Grid business from the Energy Sector. By forming the new Sector, the company plans to be a leading participant in the dynamic growth of cities and infrastructure investments; Building Technologies Mobility Power Distribution Smart Grid Lighting (OSRAM)

Industry Automation Division

Industry Automation formerly known as Cross Industry Business Unit, a part of Siemens Industry Sector, is involved in the following projects from Design and engineering to the services.

Portfolio

Design & Engineering Services Engineering Process Industries Water Technologies Instrument and Control System

Design & Engineering Services Engineering activities include preparation of basic design philosophy, system sizing, detailed engineering, technical specifications & detailed drawings. Engineering Siemens provide the systems and products for industry solutions. It has its own-built software and hardware accessories. Some may include:

CEMAT Totally Integrated Solutions for Cement industry SIMATIC PCS7 Human machine interface - Scada System Drive Systems MIS Light For archiving plant data Object Linking and Embedding Process Control Simatic Industrial Network

Process Industries Siemens is also a global provider of solutions, systems, products, and services for the Process industry. With solutions and services for entire plants and individual products, its portfolio covers each aspect of

plant lifecycle from automation, drive engineering, and energy to infrastructure, communication, and Enterprise Resource Planning. Their offering profile includes Batch Process, Basic, Continuous, Infrastructure and water industries.

Water Technologies Siemens also offers cost-effective solutions for industrial and institutional water plants for water treatment or wastewater purification.

Instruments & Control Systems Cross Industry Projects Business Unit also has competencies of Supplies, Calibration, Installation and Testing& Commissioning of Instruments.

Field Devices, Bus Systems Process Control Systems SCADA Systems, SIMATIC, PCS-7etc. Telemetry Communications Systems Emergency Shutdown Systems Analytic Systems Protective Systems Measuring Instruments for Temperature Measuring Instruments for Pressure Flow Meters Level Instruments

Quality Management Services

Purpose To define a systematic procedure to ensure that:

Customers as well as applicable statutory and regulatory requirements are determined. Requirements are reviewed at appropriate stages of order processing. Effective arrangements for communication with customers are implemented. Scope Applies to Design order/contract of BU. Definitions Requirement: Need or expectation that I stated, generally implied or obligatory. Generally implied: Customs or common practices of the Organization, its customers, other interested parties & stake holders. Engineering and Execution of each

Customer Satisfaction: Customers perception of the degree in which the customers requirements have been fulfilled. Project: Unique process, consisting of a set of coordinated & controlled activities with start & finish dates. Undertaken to achieve an objective.Conforming to specific requirements including the constraints of time, cost & resources. Procedure: Specified way to carry out activity or a process. Specification: Document stating requirements. Verification: Confirmation through the provision of objective evidence, that specified requirement have been fulfilled. Validation: Demonstration that the design and engineering output fulfills specified requirements. Review: Activity undertaken to determine the suitability, adequacy & effectiveness of the subject matter to achieve established objective. Customer Focus: Organization depends on their customers & therefore, should understand.

Programmable Logic Controller

INTRODUCTION: The first PLC systems evolved from conventional computers in the late 1960s and early 1970s. These first PLCs were mostly installed in automotive plants. Traditionally, the auto plants had to be shut down for up to a month at model changeover time. The early PLCs were used along with other new automation techniques to shorten this change over time. One of the major time consuming changeover procedures had been the wiring of new or revised relay and control panels. The PLC keyboard reprogramming procedure replaced the rewiring of a panel full of wires, relays, timers and other components. The new PLCs helped reduce reprogramming time to a matter of a day or two. A definition by National Electrical Manufacturers Association (NEMA) Digital electronic device that uses a programmable memory to store instructions and to implement specific functions such as logic, sequence, timing, counting, and arithmetic to control machines and processes. Or in other words A PLC (Programmable logic controller) is a user friendly, microprocessor or microcontroller based, specialized computer that carries out control functions of many types and levels of complexity.

Characteristic Functions of a PLC: It is field programmable by the user. This characteristic allows the user to write and change programs in the field without rewiring or sending the unit back to the manufacturer for this purpose. It contains preprogrammed functions. PLCs contain at least logic, timing, counting, and memory functions that the user can access through some type of control-oriented Programming language. It scans memory and inputs (I/O) in a deterministic manner. This critical feature allows the control engineer to determine precisely how the machine or process will respond to the program
.

Advantages of PLCs: The following are the some of the major advantages of using PLCs: Flexibility Ease of Reprogramming Commissioning with Simulation Large Quantity of Contacts Easy Troubleshooting Speed Reliability Documentation Security

PLC DESIGN (COMPONENTS OF PLC): 1) Power Supply Module: The power supply module converts the input voltage in to a voltage required by the electronic modules of the PLC. 2) Central Processing Unit: The CPU is the brain of the PLC. It executes the control program stored in the memory and scans the individual inputs of the controller for the presence and absence of voltage. The more powerful the CPU you choose, the shorter is your program execution time and the larger the user memory. 3) Input and Output Modules: The I/O Modules transfer information between the CPU and peripherals like sensors, actuators & transducers. The voltage signals coming in from the sensors are connected to the terminals of the Input Modules. The processor of the CPU scans these inputs and depending on the state of the inputs and on the program in the memory, directs the Output Modules to switch voltages to the connectors of the output terminals 4) Bus Units: The bus units connect the CPU to I/O Modules. 5) Interface Module: Interface Module is used to assemble the PLC system in a Multi tier configuration. 6) Standard Mounting Rail: The PLC System is mounted on a standard Mounting Rail. 7) Intelligent I/O Modules: Used to perform critical jobs like counting rapid pulse trains, measuring time & speed etc. The central processor of a programmable controller cannot execute such jobs fast enough in addition to its actual control task.

SAP
Definition SAP is a German multinational software corporation that makes enterprise software to manage business operations and customer relations. It provides interactive snapshots of business processes along with simulations, data reporting and growth analysis. SAP Solutions Siemens Learning Center is providing comprehensive SAP solutions for the best run businesses of an organization that helps in increasing efficiency, enabling the company to stay competitive and grasp the timely opportunities. There is a wide range of SAP solutions to empower every aspect of business operation. Namely:

Functional Modules Financial Accounting Managerial Accounting Human Capital Management Procurement Order Fulfillment Production Planning / Manufacturing

Technical Modules

Programming / ABAP Business Intelligence System Administration

SAP Implementation SAP implementation is a six step procedure which is:

Project Preparation Business Blue Realization Final Preparation Go Line Support

Business Intelligence Outside the system, analytical reports are prepared that access data from SAP and non-SAP to compare between the two. This powerful and comprehensive tool, that provides analytical environment, helps to monitor and analyze business growth.

Conclusion
I believe working at Siemens was among the best commercial working experience that I have ever had in my life. This four week internship was very gainful for me. I believe Siemens has a long way to go in its quest for the leading industry in terms of power innovation and production of technical expertise in this country. Without the advice and conviction of Ms. Sadia Kazmi and their staff, I would have surely never learnt all this in four weeks.