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MediaService Digital Industries Newsroom

Think big - Largest pipe manufacturing facility in the world completed using Siemens automation

Tenaris is one of the world’s leading manufacturers of steel pipes and has created the largest and most comprehensively automated pipe manufacturing facility in the world at its site in the USA using solutions from Siemens’ automation portfolio.

One of the technical highlights that came out of the new facility in Texas is the fact that Tenaris placed the largest bill of materials in the world for this project in the Siemens TIA (Totally Integrated Automation) Portal engineering framework. This bill of materials included 124 programmable logic controllers (PLCs), 1,620 drives, 4,000 network nodes, 156 HMIs (Human Machine Interfaces), and 50,000 I/Os (Input/Outputs). At the same time, the plant employees’ safety had to be guaranteed at all times which required a comprehensive safety model. To achieve this, Tenaris used the Simatic S7-1500F fail-safe controller with integrated safety features. These existing features not only relieve Tenaris of the cost of separate safety controllers but also reduce commissioning times by approximately 20 percent. The controller is supplemented by the Simatic ET200 distributed I/O modules and user-friendly Simatic HMI panels and mobile HMI panels. Communication is via a vast Profinet (open industrial Ethernet standard) network with components from the Siemens Scalance, Profisafe, and Profienergy portfolio. This efficient network communication and the risk reduction to Safety Integrity Level 3 means the plant meets the strict quality management requirements.

Simulation and virtual commissioning save time

The plant engineers paid particular attention to efficiency as well as safety considerations. This included maximizing the use of assets, high production output, and optimum production transparency. To achieve this, Tenaris used simulation tools such as Simit to check every element of the plant in advance through a virtual commissioning process. “Siemens and TIA Portal allowed us to create a 3D model of the plant and to test it through simulations. This saved us a significant amount of commissioning time (30 percent, editor’s note) and allowed to open the plant on time,” remembers Pablo Fushimi, Project Senior Director at Tenaris.
MediaService application reports may be based on previously published Siemens technical articles.


Ursula Lang

Siemens AG

Gleiwitzer Str. 555
90475 Nuremberg

+49 (911) 895-7947