2011 automation summit orlando, fl · 2011 automation summit orlando, fl ... upgrade pcs7 from v4...

Navigating the world of automation

2011 Automation Summit Orlando, FL

Navigating the world of automation

Navigating the world of automationCopyright © Siemens Industry, Inc. 2011. All rights reserved.

2011 Automation Summit

Title: Connecting PCS7 to a 3rd Party Management System

Track: Novel Approaches to Problem Resolutions, Including Tips and Tricks

Topic: Interfacing to a 3rd Party Plant Management System

Presenter: Karen Pigler

Company: Pigler Automation, LLC


� Pigler Automation, LLC was founded in 2005 by Karen and Harald S. Piglerafter 17/20 years of employment with various Siemens Organizations in both Germany and the United States

� System Integrator for PCS7 and S7 Process Control Applications� Located in Firestone, Colorado, 30 miles north of Denver� 5 Employees and Growing� Industries Served: Oil and Gas, Power, Pharmaceutical and Mining

For more information please visit: www.piglerautomation.com

Or call : (866) 871-1456

Providing Excellence in Process Automation

Pigler Automation, LLC


Karen Pigler

Education and Employment� Born and Raised in Germany� Electrical Engineering Degree from Fachhochschule Kiel, Germany� 17+ years employment with Siemens in Germany and the US� Managing Member of Pigler Automation, LLC since 2005

PCS7 Experience• First Contact with PCS7 as Project Manager for Siemens Energy developing

add-ons for PCS7 to be Applied in the Power Industry in 1996.• Lead Project Engineer in the TVA Hydro Automation Project:

Retrofitted 29 Hydro Plants with PCS7 to be Operated from one Central Headquarter.

• As Managing Member of Pigler Automation, the Main Focus is to Support our Customers with PCS7 Installations, Improvements and Additions


The Project

Ethanol Management Company (EMC) is a company that blends gasoline products for a wide variety of customers.

Task:� Upgrade PCS7 from V4 to V7 as well as re-design the Management System

Interface for Secure Data Exchange

Key elements of the new design :� CP443-1 Advanced with FTP capabilities � VB Scripting capabilities of WinCC for directing data into a local MySQL

Database.

The outcome of this project has been in successful operation for over two yearsand presents yet another example of the great flexibility PCS7 offers. Lessonslearned during project design and implementation and tips for similar projectstructures will be discussed during this presentation.


Project Scope

� Gas Blending facility 24/7, 363 days a year

� 4 Loading Racks� 5 Offload Bays� 9 Holding Tanks

� Products are blended in a Sequential, Non-Continuous Blending Process� Colorado Dept. of Transportation requires Validation of i.e. Customer, Driver

and Trailer Information� Product is Received from different sources; therefore, frequent recipe changes

are Required


Original Software Installation

� PCS7 V4.0� Slot PLC in PCS7 ES/OS Station� Windows NT Operating System

� Sybase Database� Remote I/O Cabinet

� OP17 to handle Driver Interface� 3rd Party Reporting Tool for Load Order Reporting

� Terminal Management System (TMS)� Windows NT Operating System

� In-house Development utilizing Visual Basic 6 Platform� Data Storage in Dbase IV

� Communication from TMS VB6 directly into PCS7 Sybase Database


Original Software Installation


Problems

• NT Computers Failing

• No Computer Spare Partsor Replacements Available

The “Biggest” Problem:

When the PCS7 OS/ES failed, all Terminal Operation was Interrupted -> Loss of Revenue


Our Solution

Apply Newer, Better Hardware :• PCs with XP Professional Operating System• Spare Computers setup for Quick Exchange

Software Upgrades:• Update of PCS7 Software to Version 7• Use of an Open Source Database to be able to Report/Export Data as needed

Redefinition of the Project Structure:• Separation of the CPU from the PC to be able to Download/Engineer the

ES/OS without interrupting Terminal Operation• Redesign Communication to communicate directly between the CPU and the

TMS• Goal is 100% availability


Project Scope


New Design

• PCS7 V7.0 Service Pack 1 ES/OS• New External CPU 414

• CP443-1 Advanced providing FTP Client Application• MySQL Database on PC

• Navicat for Database Archiving and Load Order Reporting

• TMS Program on new PC with Windows XP Professional • Xampp Installation with MySQL as Database

• Filezilla as FTP Server• Apache as Web Server to present Database entries in webpage form

for Operator and Headquarters• Mercury to send Inventory Emails to Headquarters


Hardware Config – A Look at What’s Installed

CP443-1 Advanced Installed


Net Pro Settings – How We’re Communicating


TMS - PCS7 communication

• FTP, ASCII File Driven – Independent from Platforms!TMS PC creates text files from Database Information and Stores these files in the FTP Server

i.e.: Admin Telegramfrom TMS

Telegram is stored inFTP Server Folder


TMS – PCS7 Communication

• Customized Blocks handle the FTP Communication “handshake” and Data Handling into and out of Data Blocks


A Detailed Look at the Admin File


TMS –> PCS7 Communication

• PCS7 reads these text files and converts them into Data Blocks (i.e.: load orders, recipes ..)


TMS – PCS7 Communication


PCS7 -> TMS Communication

• PCS7 creates text files out of Data Blocks to Send Back to the FTP Server

• The TMS reads these files and insert them into the Data Base for future processing

Filename = ftp_directory + ftp_subdirectory_fromPLC + "PROD" + CStr(ordernumber) + ".txt"

SQL = ("load data infile '" + FileNameFTP + "' into table in_prodlog fields terminated by ',' lines terminated by " + end_char)

Cn_prod.Open "DSN=mySQL“

rs_prod.Open SQL, Cn_prod

Cn_prod.Close


PCS7 Stores Data in Additional Database

Customized Functions Prepare to Map Data to WinCC



Global Script VBS is utilized in WinCC to store data in MySQL DataBase



• Reporting Tool uses MySQL Database to create Load Order Reports


Design Challenges

• The Challenge:• Some Text Files include Large Strings

• S7-Functions for String Handling require large Amounts of Local Memory • Our Solution:

• Program Structure had to be Redesigned to Keep the Current PLC

• The Challenge:• Recovery from FTP Communication Errors due to PC Reboot or similar Actions

• Our Solution:• Interface Blocks recover from “Standard” Errors Automatically

• FTP Manual Installed on the ES for Ease of Access when Troubleshooting

Don’t forget to download Netpro!


How EMC Benefited From This Project

� Downtime Less than 10 Hours� The Switch over to the New System was completed after three pretests, each

two hours long� Final Commissioning only TWO Hours!

� FTP Communication is Reliable� FTP Communication is Rock Solid – No drop-outs in over 2 ½ years

� MySQL Databases are Reliable� Only One small “hick-up” experienced in the Same Timeframe

� Customer Enjoys the Web Interface� Allows Management to see Actual Production Values with Ease

� Upgrade to PCS7V8 should be painless!


What’s Next

Add-Ons to PCS7 Installation • Replace Accuload

• Integrate Tank Gauges• Update OP - Panels

• TMS Upgrades• Visual Basic to VB.net

• Enhance Data Extraction & Manipulation


More Information

For more information please visit: www.PiglerAutomation.com

Or call : (866) 871-1456Email: [email protected]

Thank You!

2011 automation summit orlando, fl · 2011 automation summit orlando, fl ... upgrade pcs7 from v4...

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