We implement several Siemens Step 7, WinCC and PCS 7 version upgrades.
These are some of the major projects we have completed:
Cadisa is busy developing a scanner system to visualise and monitor the profile of material on a belt.
The control system of a Paper Winder was developed using Cadisa's sectional drives software library. The control system was implemented on virtual machines using VMware.
A new batching control system was developed and commissioned using our custom written PCS 7 APL blocks. The PLC recipe management provides an interface to the site's MES system.
The control system software was developed using Cadisa's process plant library, based on PCS 7 APL. The process was fully simulated in the software in order to test the system thoroughly and allow extensive operator training. Cadisa also supplied and exported the PLC panel and automation system computers.
The plant is located in Europe. Commissioning was completed in July 2021.
A custom PCS 7 APL library was developed for a client with very specific requirements. Since the plant MCCs were also gradually being upgraded, Control Module Types were designed to make changing the PLC program easier as and when the MCC buckets were upgraded.
Cadisa worked together with Siemens to renew the control and drive system of a Paper Machine. Cadisa's sectional drives software library was used to implement the automation and drives software.
The paper machine was successfully commissioned during the annual shut.
Cadisa wrote PCS 7 interface drivers for WEG and Danfoss VSDs for Profibus and Profinet protocols.
The control system software was developed using Cadisa's process plant library, based on PCS 7 APL. The key features of this library are:
Extensive messaging and diagnostics to record abnormal events, including detailed reasons for stopping and interlocking. This reduces fault finding time and provides easy investigation into previous problems, even long after the event occurred.
Time delayed interlocks are displayed clearly, to warn an operator that a possible interlock stop is pending.
Group controllers which show dynamic checklists of required states for groups of devices and controllers. The group controller can be used to quickly establish the state and condition of a group, and allow easy fault finding if an abnormal condition occurs.
The control system software was thoroughly tested by simulating devices and the process, which greatly reduced commissioning time on site and allowed for comprehensive operator training.
Cadisa did the hardware design for the PLC, Server and Remote IO panels and attended the manufacturer's FAT to ensure the panels were built according to the design.
The automation software of a large paper machine was upgraded to the new SiPaper PCS 7 APL version. This is the Siemens pulp & paper software library for paper machine control. We use this library for larger paper machines.
Cadisa worked together with Siemens to renew the control and drive system of an aluminum tension levelling line. Cadisa's sectional drives software library was used to implement the automation software.
Yet another furnace control system was developed in a short period due to the similarity and experience gained from the previous furnace control system upgrades.
An existing furnace control system was replaced with Siemens PCS 7 using the Advanced Process Library (APL) as well as custom written blocks (using APL concepts) for furnace operations.
The control and drive system of a Paper Winder was replaced with a Siemens PCS 7 platform and Siemens VSDs. Cadisa's sectional drives software library was used for the implementation of the winder software.
The winder was successfully commissioned during the 2018 annual shut.
The control software for a furnace gas cleaning plant, including the furnace pressure control, was designed and written using Siemens PCS 7 and the Advanced Process Library (APL).
An existing furnace control system was replaced with Siemens PCS 7 using the Advanced Process Library (APL) and plant specific custom written blocks.
The control software was rewritten for RMH, Batching and the Gas Cleaning Plants using Siemens PCS 7 APL and required custom written blocks. The Batching software allows for batching from either batching plant to either furnace depending on demand and the availability of conveyors, which provides a very high plant availability.
A control system for a refiner was designed and developed using Cadisa's DCS software library.
A control system for a small Chemical Mixing Plant was designed and developed using Siemens automation software.
A protocol converter was designed and manufactured to enable a tag reader to communicate with a material handling system's PLC. The details of the protocol converter are shown here.
The automation software of a large material handling plant was upgraded and changed to incorporate detailed material tracking and interfacing with the plant's new MES systems. Cadisa engineers previously developed the full automation software for this material handling system, which includes Automatic Guided Vehicles, High-Bay Cranes and several conveyor systems.
An existing furnace control system was replaced with Siemens PCS 7 using the Advanced Process Library (APL).
Customised control functions were implemented on the Siemens platform according to the APL concepts so these have the same look and feel as the APL functions. Emphasis is placed on designing clear, uncluttered SCADA screens, as well as minimising nuisance alarms and prioritising relevant ones.
The control system interfaces with Simocodes, Micromasters and Sinamics via Profibus, which can be parameterised from the Engineering Station. The control system also interfaces to devices from other manufacturers such as the Schneider PowerLogic ION meters via Modbus TCP and ifm AS-i Gateways. Legacy devices on DeviceNet interface to the control system via gateways. Driver blocks were developed to obtain diagnostic information from connected devices so signal statuses obtained from these devices could be structured according to the PCS 7 APL process value and status data structure. A signal's measured value as well as its status can be evaluated and reacted upon by the PLC and is also displayed on the SCADA.
The control system of a Paper Winder, was replaced with a Siemens PCS 7 platform and integrated into the existing Paper Machine's control system.
A detailed analysis of all existing IOs and subsystems of the Paper Winder was done and all control was consolidated into one PLC. Careful planning allowed for an efficient replacement of the VSDs in the existing panels without replacing any field wiring. The use of modelling and extensive PLC software simulation reduced commissioning time and resulted in a quick plant start up.
A feasibility study was done for the upgrade of the control system of a platinum concentrator.
Several different options and strategies were proposed to allow a section-by-section upgrade of the plant with minimal interruption to production and alignment with the existing plant maintenance schedule.