Project Details
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 Domain  System Upgradation
 Project Name  Dairy Plant Migration of From S5 PLC system to PCS7
 Client  Siemens, Kalwa
 Consultant  
 Project Highlights Migration of Existing S5 PLC Systems to PCS7 in a running plant with minimum shutdown time
System Configuration
1 PLC/Drives : AS-417-4 – 4 Nos
2 HMI : PCS7-OS
3 Communication Protocol : Profibus-DP, Profibus-PA, Ethernet
4 IO Count : 2500 S5 IOs linked with PCS7-AS using IM-463 & IM-314
5 Software : PCS7-ES/OS V6.0, PDM V6.0, Special PCS7 Dig-Device Library.
Project Synopsis

Migration / Upgradation of existing Simatic S5 system to PCS-7 systems in a running dairy plant.  All areas of the plant have been upgraded.

  • Reception of Raw milk Storage
  • Skim Milk Storage
  • Pasteurized milk Storage section
  • Milk Processing Section
  • CIP of whole dairy plant
  • Butter & Cream storage section
  • Milk Powder Evaporator & Dryer Section
  • Utility section of Dairy plant
  • Aseptic Milk Packaging Plant Section

Project Highlights:

  • Use Of S7-400 CPUs stations with old S5 IO Modules using IM-463-2 & IM-314 Module.
  • Data Transfer  between 4  PCS 7 AS stations using Industrial Ethernet Communication Link.
  • Use of standard PCS-7 Library & Dig-device Library to reduce the development time.
  • Use of Import-Export assistance for creation of CFCs using standard Modules developed in CFCs.
  • Development of Standard SFC for repetitive Steps Sequence Logic.
  • Development of faceplates & Function Block as per client requirement.
  • Development of function logic apart from PCS 7 Library.
  • Development of Standard Function-Blocks, which is suitable for OLD S5-IO System.
  • Use Process Object View for interlinking CFCs by direct IO or Textual Inter-connection between CFCs charts.
  • Use of AS, OS & ES concept in this projects.
  • Use of Client/Server concept in PCS-7 OS Stations.
  • Use of Alarm-Logging concept , which gives whole Process-Wise Logs, Section wise Logs, Process Operating activity logs.
  • Use of Trend-Logging concept  for Online Trends, Archived Trends & online configuration Trends from PCS-7 OS Stations.
  • Use of Recipe Management concept for CIP.
  • Process Recipe, which have total 52 routes each having 14 programs with 80 parameters.
  • Use of Report Management for Process data shift-wise, month-wise & Day-wise.
  • Connection of PCS-7 database to Client Oracle Database Server through OPC-Connectivity (Only OPC Connectivity part handled).
  • Use of PCS-7 database for Report Generation using Visual-Basics & Visual-C++.