Production Plant – Replacement of the Control System
Description:
Three Siemens TI505 controllers in the control system of a production plant were scheduled for replacement with two Siemens S7-400 controllers and the software used for the TI controllers was slated for transfer to PCS7. A further step was the installation of a new CIP station with CIP panel and the integration of the functions into the present control system using a new S7-400 controller. The entire modernization process took place over four phases. All conversions were carried out during the company’s non-production time. The overall conversion included the construction of ten new control cabinets, modifications to 41 previously installed control cabinets, and the dismantling of ten control cabinets.
Scope of performance:
- Electrical planning
- Read-out of the software from the current TI505 controllers
- Preparation of function specifications
- PLS software creation
- Function test of the software in a FAT
- Operational startup and implementation of the SAT
- Preparation of documentation in accordance with as-built and GMP requirements
Supervision, management, and integration of:
- Control cabinet construction
- Wiring
- Electrical installation
Software:
- SIMATIC PCS 7
Project duration:
- 30 months (with interruptions)
Number of employees involved in project:
- 8