Process control –––––– Central automation
Central plant control for efficient and safe production
Start
Central automation –––––– Task
Control cabinet
Fast plant start-up
Ensuring product quality Production area
Production
Increasing productivity
Production plant
Task
Solution
Added value
Interference-free communication
Outgoing goods
Contamination avoidance
Example calculation
Central automation –––––– Task
Control cabinet
Fast plant start-up The faster a plant can be serviced, the shorter the downtime. For example, the electronic teaching of new devices saves you valuable time in this respect. Production area
Ensuring product quality
Production
Increasing productivity
Production plant
Task
Solution
Added value
Interference-free communication
Outgoing goods
Contamination avoidance
Example calculation
Central automation –––––– Task
Fast plant start-up
Control cabinet
Ensuring product quality Every day of the week: Your product quality needs to be perfect. If various fluids are mixed together accidentally, you not only lose money on the contaminated batch, you also have to pay for its often costly disposal. Exact, reproducible control of the processes and their continuous monitoring are of great importance in this respect.
Production area
Production
Increasing productivity
Production plant
Task
Solution
Added value
Interference-free communication
Outgoing goods
Contamination avoidance
Example calculation
Central automation –––––– Task
Fast plant start-up
Ensuring product quality
Increasing productivity The faster a plant can be serviced, the shorter the downtime. For example, the electronic teaching of new devices saves you valuable time in this respect.
Task
Solution
Added value
Interference-free communication
Contamination avoidance
Example calculation
Central automation –––––– Solution
Operating control level
Fieldbus
control level
Fieldbus
Process
Ethernet
Control level
Diagnostics function on the device Valve open
Diagnostics function on the process control level Visualisation of the “message” on the user interface
Valve closed
Process level
Upper end position reached Lower end position reached Replacement necessary Broken wire / Short circuit
Task
Solution
Added value
Interference-free communication
Contamination avoidance
Example calculation
Central automation –––––– Added value
Replacing valves without downtime
Avoiding rejects in case of malfunctioning
Guaranteeing safety for both humans and processes
Enhancing the speed of troubleshooting
Reducing costs with interference-free communication
Task
Solution
Added value
Interference-free communication
Contamination avoidance
Example calculation
Central automation –––––– Interference-free communication
CPU/ Controller
CPU/ Controller
CPU/ Controller
Plant availability without safety functions
Plant availability with safety functions Planned maintenance
Task
Media Redundancy Protocol (MRP)
System redundancy S2 and redundancy R1
Problem: Broken cable or defective device
Problem: Broken cable or defective device
Effects: Safety function – your production continues without downtime.
Effects: Safety function – your production continues without downtime.
MRP: If the communication connection is interrupted, all devices of the ring are supplied via an alternative communication path. Max. switching time 200 ms
System redundancy S2 and redundancy R1: The Bürkert valve island with Siemens electronics can be connected to two computers via two interface modules. If a cable breaks or a module fails, the second PROFINET network is used.
Failure/Fault
Solution
Added value
Interference-free communication
Contamination avoidance
Example calculation
Central automation –––––– Contamination avoidance
CPU/ Controller
Protecting products saves costs A safe and undamaged end product is important in every industry. Even the smallest amount of mixing leads to the loss of a whole batch. But how do you protect your end product in the event of a fault? If the air is not vented quickly enough in case of malfunctioning, valves may open unintentionally as a result of the back pressure and the product mixes with unwanted substances. The check valves installed in the valve islands ensure reliable production without rejects.
Task
Solution
Added value
Interference-free communication
Contamination avoidance
Example calculation
Central automation –––––– Example calculation
In pharmaceutical production, media are not only filtered but also separated using specific processes such as chromatography. To guarantee separation of the sometimes extremely expensive media and end products, one manufacturer has, for example, modernised its plant with Robolux valves from Bürkert. If malfunctioning occurs and there are no check valves installed in the valve islands to protect the chromatography end product, it can cause enormous financial problems. Chromatography end product
1m
Loss:
10 m
euros per litre
Loss:
1 batch = 10 litres
Task
10 m
0
euros
Solution
Added value
Interference-free communication
Contamination avoidance
Example calculation
euros
euros
Central automation –––––– Added value
Replacing valves without downtime Always in operation: With the HOTSWAP technology developed by Bürkert, you can replace individual valves of the valve islands while your plant continues to run. Less downtime means higher productivity for you.
Avoiding rejects in case of malfunctioning
Guaranteeing safety for both humans and processes
Enhancing the speed of troubleshooting
Reducing costs with interference-free communication
Task
Solution
Added value
Interference-free communication
Contamination avoidance
Example calculation
Central automation –––––– Added value
Replacing valves without downtime
Avoiding rejects in case of malfunctioning If the air is not vented quickly enough when malfunctioning occurs, valves may open unintentionally as a result of the back pressure and contaminate the product. Not with Bürkert: The check valves installed in the valve island ensure reliable production without rejects.
Guaranteeing safety for both humans and processes
Enhancing the speed of troubleshooting
Reducing costs with interference-free communication
Task
Solution
Added value
Interference-free communication
Contamination avoidance
Example calculation
Central automation –––––– Added value
Replacing valves without downtime
Avoiding rejects in case of malfunctioning
Guaranteeing safety for both humans and processes The valve islands ensure peace of mind through safety-related shutdown. Bürkert solutions offer modular or channel-based shutdown – thereby preventing injuries to employees and changes to product quality.
Enhancing the speed of troubleshooting
Reducing costs with interference-free communication
Task
Solution
Added value
Interference-free communication
Contamination avoidance
Example calculation
Central automation –––––– Added value
Replacing valves without downtime
Avoiding rejects in case of malfunctioning
Guaranteeing safety for both humans and processes
Enhancing the speed of troubleshooting Particularly important for production in clean rooms: With a “safety centre” located outside the clean room, you can control system functions at any time without having to enter the clean room. This saves valuable time and money in case of malfunctioning.
Reducing costs with interference-free communication
Task
Solution
Added value
Interference-free communication
Contamination avoidance
Example calculation
Central automation –––––– Added value
Replacing valves without downtime
Avoiding rejects in case of malfunctioning
Guaranteeing safety for both humans and processes
Enhancing the speed of troubleshooting
Reducing costs with interference-free communication Valve islands from Bürkert can be connected via redundant configuration R1, system redundancy S2 or a Media Redundancy Protocol (MRP). The functions ensure interference-free communication and less downtime. Meaning: Production continues safely even if a cable breaks or an interface module fails.
Task
Solution
Added value
Interference-free communication
Contamination avoidance
Example calculation
Process control –––––– Decentral automation
Decentral plant control for high-level quality and productivity
Start
Decentral automation –––––– Task
Visual signal Intelligence Pilot control Valve
Minimising downtime
Ensuring product quality
Production
Optimising operating and maintenance costs
Production plant
Task
Solution
Added value
Plant operation and maintenance
Goods issue
Diagnostics
Example calculation
Decentral automation –––––– Task
Minimising downtime Transparent cabling speeds up error identification and prevents downtime. Should an error nevertheless occur, you can see immediately what needs to be done.
Ensuring product quality
Optimising operating and maintenance costs
Task
Solution
Added value
Plant operation and maintenance
Diagnostics
Example calculation
Decentral automation –––––– Task
Minimising downtime
Ensuring product quality Mixing various liquids due to unintentional valve switching may result in a loss of production. This will reduce profits and possibly lead to expensive disposal. Precisely and reproducibly controlled valves prevent these errors from happening. Further, the valve and the pipeline must be easy to clean.
Optimising operating and maintenance costs
Task
Solution
Added value
Plant operation and maintenance
Diagnostics
Example calculation
Decentral automation –––––– Task
Minimising downtime
Ensuring product quality
Optimising operating and maintenance costs A minimum number of hose lines reduces compressed air consumption and the risk of leakages. Since the pilot valve is located directly at the actuator being controlled, less compressed air is needed for the actual switching process.
Task
Solution
Added value
Plant operation and maintenance
Diagnostics
Example calculation
Decentral automation –––––– Solution
Industrial Ethernet
IO-Link PLC Fieldbus / Actuator-sensor communication
IO-Link
IO-Link
Intelligent heads for greater productivity
Task
Solution
Added value
Plant operation and maintenance
Diagnostics
Example calculation
Decentral automation –––––– Added value
Maximum quality, minimum rejects
Minimum maintenance effort
Reliable operation, predictive maintenance
Identifying errors quickly
Saving energy and compressed air
Excellent individual advice
Task
Solution
Added value
Plant operation and maintenance
Diagnostics
Example calculation
Decentral automation–––––– Reliable plant operation and predictive maintenance
Protection through overpressure
LED status display Contactless and continuous position detection
Hygienic design Pilot valve
Digital communication interface
Filter element compressed air supply
Integrated pilot air duct
Contactless and continuous position detection Corrosion-resistant materials
Housing design – robust and durable
Pilot valve
Task
Solution
Added value
Plant operation and maintenance
Diagnostics
Example calculation
Decentral automation–––––– Reliable plant operation and predictive maintenance
Protection through overpressure
LED status display Contactless and continuous position detection
Hygienic design Pilot valve
Digital communication interface
Contactless and continuous position detection
Filter element compressed air supply
Integrated pilot air duct
The automatic teach function for setting the end-position feedback supports reliable and long-lasting plant operation. The position of the valve is detected continuously and in high resolution, thereby enabling rapid detection of seat wear and predictive maintenance response.
Corrosion-resistant materials
Housing design – robust and durable
Pilot valve
Task
Solution
Added value
Plant operation and maintenance
Diagnostics
Example calculation
Decentral automation–––––– Reliable plant operation and predictive maintenance
Protection through overpressure
LED status display Contactless and continuous position detection
Hygienic design Pilot valve
Digital communication interface
Filter element compressed air supply
Integrated pilot air duct
Contactless and continuous position detection Corrosion-resistant materials
Housing design – robust and durable Corrosion-resistant materials make the housing durable and resistant to aggressive cleaning chemicals. An internal overpressure in the control head additionally provides reliable IP protection even in extreme ambient conditions – thus permanently ensuring reliable operation of your plant.
Pilot valve
Task
Solution
Added value
Plant operation and maintenance
Diagnostics
Example calculation
Decentral automation–––––– Reliable plant operation and predictive maintenance
Protection through overpressure
LED status display Contactless and continuous position detection
Hygienic design Pilot valve
Digital communication interface
Filter element compressed air supply
Integrated pilot air duct
Contactless and continuous position detection Corrosion-resistant materials
Housing design – robust and durable
Pilot valve To speed up work processes, operate the integrated process valve manually, if necessary, without an electrical power supply. Further cleverly designed details: The integrated, hygienically designed pilot air duct minimises the risk of failure while protecting actuator chambers and seals from environmental influences, such as moisture or chemicals. Tools are not needed to maintain the stainless steel filter element.
Task
Solution
Added value
Plant operation and maintenance
Diagnostics
Example calculation
Decentral automation –––––– Precise diagnostics
PLC
Precise diagnostics How are your process valves getting on? Thanks to intelligent diagnostic capabilities you always know the answer – and can schedule maintenance instead of having to deal with an unsuspected problem. Coloured high-performance LEDs display the current status locally. Counters with definable limit values register the number of switching cycles as well as the switching speed – and signal the next required maintenance in good time. The localisation function allows you to locate devices and to quickly put your plant back into operation after servicing or maintenance work.
Task
Solution
Added value
Plant operation and maintenance
Diagnostics
Example calculation
Decentral automation –––––– Example calculation
To switch a pneumatic process valve, both the actuator volume and the pneumatic air hose must be pressurised. This air volume can be seen as lost energy, as it does not contribute to actuator operation at all. With a decentral automated process valve, this loss of volume is completely eliminated, since the pilot valve is located directly at the process valve actuator. The example calculation below for a plant with 2,000 pneumatically actuated process valves and an average of 20 switching cycles per day visualises this:
5 l/min
(1000 m)
10 512 €/a
Less cables and hoses drastically reduce your risk of leakages. In the example, you save €10,512 a year in energy costs – and a significant amount of maintenance effort.
500
(0.5 l / Ø 10/h)
14 600 m /a 3
1752 m /a 3
40 000 m Decentral automation eliminates the route from the pilot valve to the process valve. In our example, 40,000 metres of hose lines are no longer necessary.
Task
Solution
How much compressed air volume would you save a year with 500 decentral automated process valves boasting 0.5 litres of actuator volume? With an average of ten switching operations an hour in two-shift operation, there is a savings potential of 1.75 million litres of compressed air.
Added value
Plant operation and maintenance
Diagnostics
Example calculation
Decentral automation –––––– Added value
Maximum quality, minimum rejects Faulty switching? Never! Check valves integrated in the control head Type 8681 prevent incorrect switching and thus a loss of production. If the plant switches off in the event of malfunctioning, it is possible to vent a large number of process valves simultaneously. This prevents costly rejects and ensures product quality. Thanks to the diagnostic function in the control head, you are able to reliably identify the production status even after malfunctioning. In a flash, you can determine whether product quality has been adversely impacted or not.
Minimum maintenance effort
Reliable operation, predictive maintenance
Identifying errors quickly
Saving energy and compressed air
Excellent individual advice
Task
Solution
Added value
Plant operation and maintenance
Diagnostics
Example calculation
Decentral automation –––––– Added value
Maximum quality, minimum rejects
Minimum maintenance effort Bürkert valve systems are robust and durable. This is ensured by various details, including pilot air recycling, practical IP protection, internal overpressure, integrated pilot air duct and corrosion-resistant materials. The restriction function in Type 8681 prevents water hammer phenomena, protects plant technology and reduces your overall maintenance costs.
Reliable operation, predictive maintenance
Identifying errors quickly
Saving energy and compressed air
Excellent individual advice
Task
Solution
Added value
Plant operation and maintenance
Diagnostics
Example calculation
Decentral automation –––––– Added value
Maximum quality, minimum rejects
Minimum maintenance effort
Reliable operation, predictive maintenance Bürkert decentral process valves offer extensive diagnostic functions. Thanks to digital communication with the control level, you can use them directly – for reliable plant operation and predictive maintenance.
Identifying errors quickly
Saving energy and compressed air
Excellent individual advice
Task
Solution
Added value
Plant operation and maintenance
Diagnostics
Example calculation
Decentral automation –––––– Added value
Maximum quality, minimum rejects
Minimum maintenance effort
Reliable operation, predictive maintenance
Identifying errors quickly Coloured high-performance LEDs at the control heads enable process monitoring at a glance. Even in confined spaces, you can quickly identify the type of error that has occurred thanks to the clearly visible colour. This ensures the error is identified and rectified rapidly, while product quality can be determined correctly after malfunctioning.
Saving energy and compressed air
Excellent individual advice
Task
Solution
Added value
Plant operation and maintenance
Diagnostics
Example calculation
Decentral automation –––––– Added value
Maximum quality, minimum rejects
Minimum maintenance effort
Reliable operation, predictive maintenance
Identifying errors quickly
Saving energy and compressed air The volume in the actuator of the ELEMENT (Type 8801) is extremely small thanks to the optimised product design. This saves space and, above all, energy costs, as you need less compressed air.
Excellent individual advice
Task
Solution
Added value
Plant operation and maintenance
Diagnostics
Example calculation
Decentral automation –––––– Added value
Maximum quality, minimum rejects
Minimum maintenance effort
Reliable operation, predictive maintenance
Identifying errors quickly
Saving energy and compressed air
Excellent individual advice Since we have expertise in all three automation concepts, we listen closely to what you want to achieve and analyse exactly what you need. If required, we combine intelligent concepts for a tailored solution. As a specialist for process automation, we offer decentralised and standardised solutions regardless of the selected system and the applied valve types.
Task
Solution
Added value
Plant operation and maintenance
Diagnostics
Example calculation
5
2,800 +
8.4
Systemhaus facilities
Employees
R&D share
/ Bürkert is your reliable partner for more than just the development and production of individual components. You can also rely on us as your experienced and trustworthy partner when it comes to developing individual system solutions for a specific plant. With our highly-qualified, motivated engineers and our outstanding production facilities, we can guarantee customer-specific system solutions that meet all your requirements.
/ To be able to execute complex tasks and projects in their entirety, our process organisation is geared towards bundling expertise in all divisions. This is done as flexibly as possible while observing the necessary rules and regulations. In addition, our corporate culture promotes direct internal communication and effective cooperation within our project teams.
73
Objectives and measures %
1 Independence
2 Technological and quality leadership
%
Percentage of sales outside Germany
100
36 Global subsidiaries
% Family-run business
Systemhaus Dortmund
3 Bürkert culture
Sound investments, growth
Continuous investment in innovative products and technologies
Investments in people, living our culture
Expertise Level, flow, pressure, temperature, analysis, metering, mixing, filtering, process automation
Systemhaus Dresden
Sector
Systemhaus Suzhou Systemhaus Ingelfingen
Fluid Control Systems – Industrial measurement, control and regulating technology: systems for measuring, controlling and regulating gases and liquids from individual valves, sensors or controllers to complete automation solutions and fluid systems
5
Systemhaus Charlotte
Production locations 4 in Germany, 1 in France
>100
%
Re-investment rate/year
Task
Solution
Added value
Interference-free communication
Contamination avoidance
Example calculation