A step-by-step, budget-optimized approach to top performance. Migration of existing systems. Industrial Services

Transcription

1 A step-by-step, budget-optimized approach to top performance Migration of existing systems Industrial Services 1

2 The challenge: Making older plants more competitive again Our migration solutions offer attractive alternatives to complete modernization or construction of a new plant. In a step-by-step process, we update your electrical systems to ensure that they are state of the art. We do this in a prioritized sequence, based on the changes that will bring the greatest improvements while preserving your investment in your plant s engineering. Thanks to our comprehensive approach, every migration step is integrated into a long-term modernization strategy. Sooner or later, every older manufacturing plant requires modernization investments in order to remain competitive. When modernizing a plant, the focus is less on mechanical systems and more on electrotechnology and automation engineering owing to their short innovation cycles. It doesn t take long for an existing system to fall far behind state-of-the-art technology whether in the speed and quality of controls, the operating philosophy, or the integration with quality management processes. The result is declining productivity and availability, accompanied by higher downtime costs. And as equipment is discontinued, spare parts and systems expertise become rare. Nevertheless, because of their technical complexity and high investment costs, complete upgrades are often not the ideal solution. What is needed is an alternative that promptly addresses the most critical issues while staying within a reasonable budget and protecting existing investments in a plant s engineering. 2

3 Migration with Siemens: Integrated into a long-term modernization strategy Migration with Siemens means migrating within the framework of a comprehensive solution that is optimized with regard to time, financial commitment, and technology. Our ability to analyze the electrotechnology as a whole enables us to generate a future-oriented migration plan. Your benefit: Plant performance and investment needs can be designed for the long term. With this long-term strategy, we also take into account links to the next migration step. Your benefit: Avoidance of expensive temporary steps and stopgap solutions. We prioritize migration steps based on their impact on productivity: The production segment with the most far-reaching impact will be upgraded first. Your benefit: Optimum deployment of investments. Thanks to Siemens concept of Totally Integrated Automation, interfaces for instance to drives are safeguarded from the very beginning. Gateway solutions allow for mixed operation throughout each stage. Your benefit: High productivity with no start-up issues, along with long-term investment protection. Part of the comprehensive strategy is the opportunity to tie in a manufacturing execution system (MES). Your benefit: Coordinated expansion with a focus on more effective business management. Reliable migration for all production segments Regardless of the technology involved, we provide you with an integrated, interface-optimized migration solution including analysis of your specific plant configuration, complete implementation, and services that ensure optimum performance. Drive systems: In many cases, we recommend upgrading to the latest open- and closed-loop controls rather than a complete replacement. These increase performance and efficiency while keeping investment costs under control. Our migration services cover a range of open- and closed-loop controls: SIMOVERT A, C, D, P SIMOREG (DC drive systems) Analog open-loop controls: SIMADyN C/D, MODULPAC C, and TRANSIDYN B Automation and process control systems: Building on your existing basic automation systems, we migrate process controls and control systems to the future-oriented Totally Integrated Automation platform. This approach applies to older Siemens systems as well as third-party systems such as: COROS LS-B/LS-C SIMATIC S5 AEG Modicon 350/500 TELEPERM M ABB Contronic P ABB Advant ABB Melody Honeywell TDC 3000 Other systems in the planning stage

4 Experience and successes: Migration at work Witten waterworks Customer: Wasserwerk Witten, owned by Wasserwerke Westfalen GmbH : Seven AS 220 automation systems Our solution: The projection data of the TELEPERM systems was converted to SIMATIC PCS 7 using the MigraSafe conversion tool. MigraSafe allows data to be converted even without concrete knowledge about the customer s plant. After performing a system test in which the functionality of the new data was tested and optimized, the automation systems were replaced. Thanks to a solid backup strategy, the customer always had the option of reactivating the former TELEPERM system. Success: The customer was highly satisfied and placed an order to convert an additional waterworks facility. ARA Rhein Customer: : Our solution: Success: ARA Rhein AG s water treatment facility in Pratteln, Switzerland SIMATIC S5 and the IS300 information system The WinIS developed by Siemens Industrial Solutions was selected as the process information system. WinIS receives all process data directly from the SIMATIC PCS 7 via a standard interface. Thanks to this solution, all process and archive data can be clearly and conveniently processed. The customer was highly satisfied and placed two additional orders with Siemens I&S. Scheufelen paper mill Customer: Papierfabrik Scheufelen GmbH & Co. KG in Lenningen, Germany : Four SIMATIC S5 systems and a warehouse management computer Our solution: The latest SIMATIC S7-400 systems replaced the existing film-packaging controllers. Like the new warehouse management computer, they are connected to the main computer system via TCP/IP. The main systems display is monitored by SIMATIC WinCC. All conveyors were equipped with SIMATIC ET 200X and frequency converters. Success: Performance of the entire plant was substantially increased, and visualization and operating potential were improved. INEOS Phenol Customer: : Our solution: Success: INEOS Phenol in Gladbeck, Germany ABB Contronic P The user s 32 Contronic processor stations were automatically converted using a migration tool newly developed by Siemens, and replaced by eight AS-417 systems. Operation and monitoring are handled by 13 multiclients. In addition, fail-safe functions and column-pressure monitoring (originally HIMA controllers) were integrated into the AS 417 HF systems. The migration was executed during normal operations with no production outages. Production output was increased and plant downtime was reduced. 4

5 Our solution: Step-by-step optimization tailored to your budget We offer a step-by-step migration of your drives, automation, visualization, and process control systems, up to and including integration into a manufacturing execution system (MES). Compared to a complete upgrade, this scalable approach offers three important advantages: it is easy on your budget, forecasted system data is safeguarded, and retrofitting is executed quickly. Step-by-step migration step-by-step financing The more complex a retrofitting project, the more uncertain the break-even point. Performing a migration in several phases makes the amortization period manageable and allows cost forecasting that aligns with the budgeting process. Investment protection for system data By the time installation begins, considerable funds have already been invested in the project planning for your system data. Our approach uses a tool-supported transfer of data to the new system platform, thus protecting past investments. This method enables us to deliver a new level of quality in error-free integration of data. Rapid conversion rapid return to production Based on our experience in modernizing systems, we have developed largely standardized solutions that can be adapted to your requirements. As a result, downtime is reduced to an absolute minimum. In fact, for automation and display systems, there is often no downtime at all, with conversion taking place during normal operations. 1 2 MES 4 3 n 1. 1st Jahr year 1 Examples: z. B. Migration COROS migration COROS PCS Modernisierung 7 modernizationpcs 7 SIMATIC Migration S5 migration SIMATIC S5 DCS 3 Visualization 1 1 Automation Drives Field nd Jahr year 2 3 Service Examples: New project z. B. Neuprojektierung S5 planning for the S5 Migration AEG Modicon AEG Modicon A350 migration A350 Modernis. SIMOVERT P SIMOVERT P modernization z. B. Migration S5 Examples: S5 migration Modernisierung SIMOREG SIMOREG modernization Modernisierung AC-Drives Modernization of AC drives Erweiterung Sensorik Expansion of sensor technology Austausch DCS- DCS system replacement 3. 3rd Jahr year 4 Expansion Erweiterung of sensor Sensorik technology Modernization Modernisierung of sensor Sensorik technology Installation Installation of an MES- system 5

6 For further information, please contact: I&S IS E&C P.O. Box Erlangen Germany The information provided in this brochure contains merely general descriptions or characteristics of performance which in actual case of use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. Order No.: E10001-T480-A91-V Printed in Germany Dispo No.: K No.: GB C-ISEC5207M07 PA Subject to change without prior notice Siemens AG All rights reserved.