- 30+Siemens PCS 7 systems implemented
- 6,000+signals in a single project
- 20+in-house programmers
- V6.1–V10every PCS 7 version
As a Siemens Solution Partner for SIMATIC PCS 7, with more than 30 PCS 7 systems implemented, we deliver complete distributed control and safety projects: engineering, programming, cabinets, installation, commissioning and maintenance, with our own team and a single point of contact.
We work in continuous process plants —oil and gas, chemicals, food and desalination—, both on new systems and on migrating existing systems to PCS 7, in Spain and internationally.
PCS 7 projects from the last 10 years
01
SWRO desalination plant in Taiwan
PCS 7 control architecture with around 4,000 I/O signals, OT cybersecurity, redundancy and sized infrastructure (servers, SAN and NAS).
02
Bunge: migration from Quantum/Premium to PCS 7
Around 4,000 I/O signals, more than 50 drives and soft starters replaced, operator training with SIMIT and a one-month shutdown with 49 people on site.
03
Bunge Cartagena: SIMIT simulation and OTS
Complete automation on PCS 7 with more than 4,000 signals, APL libraries, Safety Integrated and Virtual Commissioning with SIMIT and OTS before commissioning.
04
SWRO desalination plant in Sri Lanka
Redundant PCS 7 V9.1 with around 3,000 signals, DMZ, Process Historian and automatic reports.
05
Greenfuel biodiesel plant
Migration to PCS 7 V8.2 of the system implemented in 2007, with safety functions in S7 F Systems and automation of the glycerine tricanter.
06
ASK Chemicals: paint and resin plants
Three phases on PCS 7: paint system (2016), resin system (2019) and extension of the paint system with an upgrade to redundancy (2021).
07
LPG terminal and filling plant
Two independent PCS 7 systems with an Emergency Shutdown System, safety matrix, ATEX CCTV, fire detection and extinguishing, and access control.
08
Migration of a crude oil pumping control system
From SMAR and Foundation Fieldbus to PCS 7 with redundant S7-400H, ET 200iSP and CFU in an ATEX zone, new drives and an ESD to IEC 61508.
09
Winoa Ibérica: redundant PCS 7 system
PCS 7 V9.0 with a redundant CPU 414-5H, 20 ET 200M stations with fail-safe modules, redundant OS servers, 13 clients and Safety Matrix: around 3,300 I/O channels.
What we do with Siemens PCS 7
Safety: functional safety
Safety instrumented systems (SIS) with Safety Integrated, Emergency Shutdown Systems and cause-and-effect matrices with Safety Matrix, to IEC 61508 and IEC 61511, in projects up to SIL 2/3.
Engineering and architecture
Redundant architectures with S7-400H controllers, ET 200SP HA and ET 200iSP I/O (also in ATEX zones), Profibus and Profinet networks, servers and DMZ.
Programming with standard libraries
Control logic and graphics with the Siemens APL, IL and PAC libraries, for a consistent system that is easy to maintain.
SIMIT simulation and OTS
Virtual process model connected to PCS 7 to validate the logic before start-up and train operators.
Migrations to PCS 7
From Schneider Quantum and Premium, SMAR and Foundation Fieldbus, with reverse engineering when documentation is out of date and the work concentrated in the shutdown.
OT cybersecurity
Segmentation, secure remote access, SINEC NMS and monitoring in PCS 7 architectures, including sizing of servers and storage.
Integration with the plant
MCCs, drives and soft starters, instrumentation, analysers and third-party systems, with cabinets built in our own workshop.
Data and reporting
Process Historian and automatic reports to make use of process data.
How we work
- 01
Engineering
Architecture, signal list and system documentation.
- 02
Programming and simulation
Programming with standard libraries and testing on SIMIT.
- 03
FAT
Cabinets and software tested at our facilities.
- 04
Installation
By our own 50-person installation team.
- 05
Commissioning
Loop checks, start-up and operator training.
- 06
Maintenance
Support, modifications and system backups.
Siemens PCS 7 track record since 2005
We have worked with every version of PCS 7, from V6.1 to V10, and with its redundant controllers (CPU 414-5H, 417-4H and 410-5H), in energy, oil & gas, chemicals, environment and industry. In many of these projects we do not only program: we design the industrial control system (ICS) architecture and its cybersecurity, supply and install the MCCs, control panels and instrumentation, and carry out commissioning. Some of those systems we have later migrated to newer versions.
- V6.1
- V7.0
- V7.1
- V8.0
- V8.1
- V8.2
- V9.0
- V9.1
- V10
Oil & Gas 5
- PCS 7 V8.1 · 2016–2018Dolphin Energy, Ras Laffan (Qatar) · Veolia (HPD)KHI removal unit: PCS 7 control with redundant CPU 410-5H, SIS engineering, safety PLC and SIL verification to IEC 61511; 1,500 signals.View project →
- PCS 7 V8.1 · migrated from V6.1Oil refinery in the Caribbean: distillationTwo CPU 417-4H systems with 4 OS servers, Process Historian and Information Server.View project →
- PCS 7 V7.1 SP4Oil refinery in the Caribbean: catalytic crackingCPU 417-4H with redundant OS and CAS servers and an MES with OpenPCS 7.View project →
- PCS 7 V7.1Oil refinery in the Caribbean: plant 1CPU 417-4H with redundant OS servers, CAS and an OPC server.
- PCS 7 V7.1 SP2Oil refinery in the Caribbean: boilersCPU 417-4H with redundant OS servers and Maintenance Station.View project →
Energy 5
- PCS 7 V8.2 · migrated from V7.0 · 2007 and 2022Greenfuel biodiesel plant, BadajozCPU 416-2 and 10 ET 200M stations, integrated with S7-300F, Omron and Danfoss drives.View project →
- PCS 7 V7.1 · 2010–2012Lointek: 9 PTC solar thermal plants (Spain, Mexico and South Africa)Steam generation control: supply and installation of MCCs, control panels and instrumentation, programming and commissioning.View project →
- PCS 7 V7.0 SP2 · 20098 MW biomass plant, Villacañas · Biomasa BerkesWood-fired steam boiler (40 t/h) for an 8 MW turbine: CPU 416-2 and 8 ET 200M stations, with around 1,450 I/O channels.View project →
- PCS 7 V6.1Cuenca biodiesel plant (with Alfa Laval)Three controllers (CPU 416-2 and 414-3) with ET 200M and ET 200S I/O.View project →
- PCS 7 V6.1 SP1Ocaña biodiesel plant (with Técnicas Reunidas)CPU 416-2 with 6 ET 200S stations and a web server.View project →
Chemicals, industry and environment 2
- PCS 7 V9.0 SP1 · 2015Grupo Otua, Legutiano (Álava) · Veolia (HPD)Control unit of a mechanical evaporation unit at a salt crystallisation plant.View project →
- PCS 7 V8.0 SP2 · 2013–2015Elytt Energy · Neureus: VPI impregnation (3 systems)Three identical systems for vacuum pressure impregnation, with CPU 414-3 and 10 ET 200SP stations.View project →
Frequently asked questions
What does a turnkey PCS 7 project include?
System engineering and architecture, programming with standard libraries, cabinets built in our own workshop, FAT, installation by our own team, commissioning, operator training and subsequent maintenance, with a single point of contact.
Can a plant be migrated to PCS 7 with a limited shutdown?
Yes. Field data collection, pre-installation, engineering and programming are done beforehand, and the on-site work is concentrated in the shutdown. At Bunge, the migration of around 4,000 I/O signals was carried out in a one-month shutdown.
What does SIMIT simulation add?
It lets us test logic, sequences, alarms and failure scenarios on a virtual model of the process before going on site, and train operators (OTS). Errors are found earlier and commissioning is shorter.
Do you also deliver safety systems on PCS 7?
Yes. We integrate safety functions into PCS 7 itself with Safety Integrated (fail-safe controllers and modules), Emergency Shutdown Systems and cause-and-effect matrices with Safety Matrix, to IEC 61508 and IEC 61511. We have applied it, among others, at an LPG terminal and filling plant (SIL 2/3), at a crude oil pumping station and at Winoa Ibérica.
Do you also work with PCS neo?
Our SIMIT simulation connects both to PCS 7 and to PCS neo, the new generation of Siemens’ process control system.
Ask us about your PCS 7 project. Tell us whether it is a new system or a migration and what you need to solve, and we will propose the scope.