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++.