CONTROL AND INFORMATION MANAGEMENT
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New Production Facility Control System

Background

    This project involved the installation of a new production control system implemented on an integrated Siemens solution, which includes WinCC Pro SCADA and S7 1500 PLCs.

Technology

  • Siemens TIA
  • WinCC Professional
  • S7-1500
  • PROFINET
  • ATEX ET200 iSP I/O
  • Stahl Thin Clients
  • Virtualisation
  • Sartorius Weigh Scales

Implementation

  • The new control system controls the processes in the following utility areas:
  • • Purified Water Storage and Distribution
  • • Waste Treatment Storage
  • • Scrubber Control
  • • Environmental Monitoring
  • The new control system controls the manufacturing processes in the following production areas:
  • • Reactor Control
  • • Temperature Control Units Interface / Control
  • • Vacuum Unit Interface / Control
  • • Filter Dryer Interface / Control
  • • Drum Booth Control
  • • Glove Box Interface / Control
  • The main components of the control system are as follows:
  • • 2 Physical Dell ESXi Host Servers
  • • Virtualised redundant TIA WinCC Pro SCADA servers
  • • 5 Virtualised SCADA clients (3 Stahl Production Area HMIs, 2 Dell Desktop Thin Clients)
  • • 8 Siemens KP8 PROFINET networked push-button modules
  • • Dedicated Network Attached Storage Server
  • • 2 Siemens S7-1500 PLCs (1 standard, 1 Fail Safe) with SIMATIC ATEX ET200 iSP Remote I/O (including safety I/O)
  • • 1000 I/O (physical I/O excluding spares for utilities and production areas) – note that soft I/O used for interface signals to/from third party equipment
  • • 4 Serial Sartorius Weigh Scales (communications via gateway)
  • • 9 PROFINET Sartorius Weigh Scales
  • • 7 PROFINET Vacon VSD’s
  • • Interface with third party equipment:
  • – PROFINET interface to Variable Speed Drives
  • – PROFINET (via PN/PN Coupler) interface to Filter Dryer
  • – PROFINET (via PN/PN Coupler) interface to Temperature Control Units
  • – PROFINET (via PN/PN Coupler) interface to Glove Boxes
  • – PROFIBUS interface to Vacuum Unit
  • – Serial interface (via ethernet gateway) to multiple Weigh Scales
  • – OLM (PROFIBUS to PROFIBUS via fibre optic) interface to other plant facility
  • – Signal splitter interface to BMS

  • The system was delivered to site in stages to coincide with mechanical and electrical completion.
    The system was commissioned and fully validated (FAT, SAT, IQ and OQ).
    The project successfully delivered in line with client requirements.