From Honeywell to PCS7 - Directly at 100% after 10 days
WEPA Hygieneprodukte GmbH
The traditional WEPA site in Mainz produces high-quality and sustainable tissue paper. In 2020, the plant management had set itself the ambitious goal of replacing the Honeywell process control system for stock preparation, the paper machine and the ancillary systems with a completely new system in a major rebuild.
KRIKO was identified as the right partner for the modernization due to its extensive experience in the modernization of process control systems and its in-depth industry expertise in the paper industry.
Requirements for KRIKO
Replacement of the Honeywell process control system with Siemens PCS7
Conversion during a shutdown period of 10 days
The multi-motor drive and the steam and condensate system should be available without interruption during the entire conversion
Hardware planning, programming and pre-tests for the entire conversion
The KRIKO solution
In order to carry out a comprehensive modernization in such a short downtime, meticulous preparatory work was absolutely essential. The first step was to precisely analyze and replicate the existing Honeywell system. The central architecture of the existing system had to be adapted to the optimal use of the new SIMATIC PCS 7 process peripherals ET 200SP HA. The process screens were recreated during the project planning phase in close cooperation with the operating team to ensure optimum process control.
The fact that the multi-motor drive and the steam and condensate system were to be available without interruption during the entire conversion was only possible because the virtual PCS 7 system had already been fully set up in advance and all links between PCS 7 and the external control systems had been tested.
The entire WEPA and KRIKO project team worked together closely and cooperatively. Various parts of the engineering could be carried out directly on site at WEPA. This made it possible to complete the hardware planning, programming and preliminary tests for the entire conversion in a preparation time of just under four months. Commissioning was successfully completed within the desired conversion time frame. After the machine was started up, production output was immediately ramped up to 100% without interruption.
This problem-free system change from Honeywell to PCS 7 enabled KRIKO to prove once again that we are not only specialists for migrations within the Siemens world, but also the right partner for migrations of all types of control and instrumentation systems.
Why with KRIKO
Benefits for the Customer
Know-how: We have experience with migrations of control and instrumentation systems from various manufacturers.
Short downtimes: Thanks to intensive preparatory work, commissioning could be implemented during the short downtime.
Cooperation based on trust: The close and collegial cooperation with the WEPA and KRIKO project team led to the successful implementation of the project.
Technologies Used
SIMATIC PCS7 Process Periphery ET 200SP HA
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