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One of the largest drinks production sites in Scotland required a system upgrade to their Case Conveyor and Palletisation Cell due to obsolete Siemens S5 equipment. Due to the critical production nature of the site, it was imperative the solution provided would result in a smooth migration, be thoroughly tested, and involve minimal production downtime.
Kigtek have significant experience delivering Siemens solutions, and as an Approved Siemens Solutions Partner have completed numerous S5 upgrade projects. Kigtek have a robust methodology for S5 to S7 Conversions, utilising OEM hardware, migration tools and our expertise in control system engineering.
Objectives
Kigtek worked with the client to develop a comprehensive solution meeting the following objectives:
Services Provided
Migration Strategy
Kigtek utilised Siemens S5 to S7 Migration Strategy and Guides which provided a range of advantages as follows:
The Migration Process
A key component and integral part of the project was the up front survey work, review of existing electrical information and obtaining of existing PLC/SCADA backups. This allowed our engineers to have a full understanding of site operations and their system before we commenced any work.
Kigtek used the standard S5 to S7 Conversion Components which included a mounting frame to accommodate the replacement PLC/IO Racks and secure the conversion harnesses, and Siemens pre-assembled and tested conversion harnesses. A software review is completed by our engineers to develop detailed migration documentation for approval from all parties to ensure no areas are missed out. As part of the installation process, as much non invasive enabling works is completed ahead of the planned shutdowns to reduce plant downtime
As the area is comprised of 5 interconnected S5 PLC systems the changeover stage of the project was completed over 5 weekends. An implementation methodology was agreed and communicated to site via a break-in and commissioning matrix for each stage. This methodology was repeated and allowed for an efficient process reducing downtime across the 5 weekends
Due to an understanding of potential risks of migrating from S5 to S7 Kigtek built in a 'confidence check' as part of the break in tasks. This enabled the team to check the new software connected to the existing IO following the changeover, creating an additional layer of protection and limiting any start up issues.
The S5 equipment that was removed was retained as critical spares which the site were in need of, minimising any wastage.
The project was a great success for both Kigtek and our client, leading us on to continued success for S5 to S7 conversions.