In this revamping project we transformed an obsolete installation, based on hard-wired logic and legacy PLCs, into a modern, safe and efficient architecture. We started with reverse engineering of the existing system so that no process function would be lost.
Power and control panels: from hard-wired logic to the new cabinets with an S7-1500 PLC and HMI
Furnace control desk: from analogue indicators to a WinCC Unified HMI screen
What we did
- Replacement of the old power and control panels
- Migration of two PLS 511 PLCs to a Siemens S7-1500 with a SIL zone
- Complete renewal of the field boxes in accordance with ATEX regulations
- Drawings produced in EPLAN, with all documentation updated
- Two new HMI screens in TIA Portal WinCC Unified, with standardised libraries
- Safety fencing with interlocks at the furnace access
Results
- Greater reliability and availability of the installation
- Regulatory compliance in functional safety (SIL) and ATEX
- Simpler, standardised operation from the new HMIs
- Greater safety for people around the furnace