SOLUTION PARTNER PRESENTATION: CONSULTA TECHNOLOGIES PVT. LTD.

Transcription

1 Siemens Process Automation Conference (SPACe) 2013, Mumbai, India SOLUTION PARTNER PRESENTATION: CONSULTA TECHNOLOGIES PVT. LTD.

2 Consulta Group About us INTRODUCTION Formed in 1997 under the leadership of Mr. Ashok Hinge The Key Contacts Head office in Bandra East, Mumbai 6000 sq. ft. Technical Center in Belapur, Navi Mumbai Fully equipped training facilities and laboratory setup A young team of professionals : Average age - 28 years Ashok Hinge Santosh Ajgaonkar Page 2 Ashish Atre Santosh Ahinave

3 Consulta Group About us IN HOUSE FACILITIES Siemens PCS7 controller S CPU 417 training kit Siemens PCS7 redundant controller S CPU 416-5H training kit Siemens S7 testing & training kits for Logo, S7-200, 1200 & 300 Siemens Softwares WinCC/ WinCC Flex / S7 / PCS7 / Cemat Intelligent MCC Modules Simocode Training Kit Energy Management System Meters Test Kit with Sentron PAC 3200,CONZERV, SOCOMEC meters Page 3

4 Consulta Group About us OFFERINGS Process Automation Process Optimization Sentron power Manager WinEMS Energy Optimization Services Energy Management Solutions Automation Panels IO/CPU Panels MCC / PCC Panels Drive Panels Control Desks Electrical Switchgear Automation Equipment Field Instrumentation Supply / Trading CONSULTA Engineering Cable Engineering Hook Up Diagrams Panel Engineering Termination plans in EPLAN / AUTOCAD Technical Training Training Reporting Batch Reporting Field Services Historian Solutions Web CCR Page 4 Supervision Electrical, C&I Commissioning AMC Services Teleservice & Remote Support ERP Integration A One-Stop-Shop for all your needs!!

5 Consulta Group About us INDUSTRY PRESENCE Industry Spectrum Cement Steel Power Pharmaceutical Water treatment Textile Ceramics Chemicals Page 5

6 Consulta Group About us OUR ESTEEMED CLIENTELE NATIONAL CEMENT COMPANY, YEMEN Page 6

7 A brief introduction A part of the Kesoram Group of Industries Four Cement Lines located at Sedam, Gulbarga District, Karnataka Started Line 1 operations in Automated with Coros LSC + S5 + Cemat v2 in Year 1991 Started Line 2 operations in 1995 with Coros LSB + S5 + Cemat v3 Upgraded Line 1 in Year 2000 Coros LSB + S5 : Cemat v3 Started Line3 operations in with PCS7 + Cemat v6 Started Line4 operations in with PCS7 + Cemat v7 Page 7

8 Why Migrate? Capacity/Efficiency Enhancement Plans Maintainability Productivity Roller Press for Cement Mill (L1) Non-availability of spares Non-homogenous at systems at CCR leading to increased man power for operation ESP to Bag House Conversion (L1 & L2) Integration of Material Handling Sections Modifications for Energy Efficiency Addition of VFDs, SPRS/GRR Increased failures due to ageing Lack of trained manpower maintaining old systems Time required for modifications using old systems was very high Increased dependence on specific personnel maintenance New features Improved diagnostic capabilities, Alarm Management, Trending Page 8

9 Migration Strategy Consulta partnered with Vasavadatta Cement to lay down comprehensive roadmap for automation system migration Key propositions: First phase to migrate Operator Station to latest PCS7 platform retaining the old controllers and I/Os to bring in operation comfort and addressing immediate operation needs. Providing upgrade plan vis-à-vis the process upgrade to synchronize stoppage availability. Identifying areas for IO upgrade to generate spares for other sections. Finalizing modality of IO rewiring to ensure minimum disturbance to errors and field cabling. Extensive planning of installation activities resulted in first time right results avoiding any rework during shutdown. Use of SIEMENS Migration Tools to ensure error free migration. Minute detailing of interfaces and software interlocks ensured quick and trouble free changeover. Simulation and Training plan. Page 9

10 Migration Strategy OS Migration Convert COROS LSB to PCS7+CEMAT OS similar to Line 3 & 4 IO Upgrade Section wise IO upgrades Shutdown based. New S7 IOs for additional sections e.g. Roller Press CPU Upgrade Replacement of S5 CPUs with PCS7 CPUs Page 10 Line 1 Line 2 Sections Panels Rewired at Site IO Handled Servers OS ES Raw Mill Coal Mill 18 ~ Kiln Raw Mill Coal Mill Kiln 33 ~ Cement Mill 1 Cement Mill 2

11 System Configuration at start of migration LINE 1 : COROS LS-B Hosts ES LINE 2 : COROS LS-B Hosts ES Ethernet H1 Ethernet H1 SIMATIC S5 155U cpu RAW MILL KILN & COOLER COAL MILL RAW MILL KILN & COOLER RAW MILL CEM MILL 1 CEM MILL 2 Page 11

12 System Configuration : Migration Phase 1 : Conversion of COROS to PCS7 OS Line 1: Multi- Clients Engineering-Station Line 2 : Multi- Clients Engineering-Station OS-Server PCS7 + CEMAT OS v7 OS-Server Ethernet H1 SIMATIC S5 155U CPU S5 100U IOs RAW MILL KILN & COOLER COAL MILL RAW MILL KILN & COOLER RAW MILL CEM MILL 1 CEM MILL 2 Page 12

13 Faceplates : Migration Phase 1 : Conversion of COROS to PCS7 OS Cemat V7 connected to V3 AS Cemat V7 connected to PCS7 AS Page 13

14 System Configuration : Migration Phase 2 : Addition/Modification of IOs Line 1: Multi- Clients Engineering-Station Line 2 : Multi- Clients Engineering-Station OS-Server PCS7 + CEMAT OS v7 OS-Server Ethernet H1 SIMATIC S5 155U CPU S5 100U IOs RAW MILL KILN & COOLER COAL MILL RAW MILL KILN & COOLER COAL MILL CEM MILL 1 CEM MILL 2 Page 14 ET 200M IO on Profibus

15 System Configuration : Migration Phase 3 : Upgrade of Clinkerisation Line 2 Line 1: Multi- Clients Engineering-Station Line 2 : Multi- Clients Engineering-Station OS-Server PCS7 + CEMAT OS v7 OS-Server Ethernet H1 SIMATIC S5 155U CPU PCS7 CPU 416-3DP S5 100U IOs Page 15 RAW MILL KILN & COOLER COAL MILL RAW MILL KILN & COOLER COAL MILL CEM MILL 1 CEM MILL 2 ET 200M IO on Profibus

16 System Configuration : Migration Phase 4 : Upgrade of Cement Mills to PCS7 Controllers Line 1: Multi- Clients Engineering-Station Line 2 : Multi- Clients Engineering-Station OS-Server PCS7 + CEMAT OS v7 OS-Server Ethernet H1 SIMATIC S5 155U CPU PCS7 CPU 416-3DP S5 100U IOs Page 16 RAW MILL KILN & COOLER COAL MILL RAW MILL KILN & COOLER COAL MILL CEM MILL 1 CEM MILL 2 ET 200M IO on Profibus

17 System Configuration : Migration Phase 5 : Upgrade of Line 1 controllers to PCS7 Line 1: Multi- Clients Engineering-Station Line 2 : Multi- Clients Engineering-Station Ethernet H1 PCS7 CPU 416-3DP OS-Server PCS7 + CEMAT OS v7 PCS7 CPU 416-3DP Phase 5 : Upgrade OS-Server of Line 1 controllers to PCS7 Successfully commissioned by our team on 30 th May 2013 Page 17 RAW MILL KILN & COOLER COAL MILL RAW MILL KILN & COOLER COAL MILL CEM MILL 1 CEM MILL 2 ET 200M IO on Profibus ET 200M IO on Profibus

18 System Configuration : Final : Actual Snapshots from plant OS Page 18

19 Line 1 Plant Mimics Page 19

20 Line 2 Plant Mimics Page 20

21 VASAVADATTA SIEMENS CONSULTA Changeover within planned outages Maximum utilization of existing assets Minimization of yearly CAPEX outflow Better utilization of human resources Ready for future process improvement plans CEMAT migration philosophy Comprehensive reference for PCS7 + CEMAT Reaffirmation of the Solution Partner concept Customer Retention Platform for demonstrating competence Customer confidence Industry wide reference Increase in business volume Page 21 A Win-Win situations for all parties involved!!!!!

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