Oil & Gas

DCS system successfully installed in running plant by upgrading SIMATIC S5 to PCS 7(top end system 417H, Hot Stand-by) Oil and Gas logistics company in Mumbai with multiple ES OS stations. First ever application of PCS7 in Oil & Gas sector.

Up gradation from S5 to PCS7

Originally the system was commissioned with SIMATIC S5 -155U and GRAVO (visualization) way back in 1996-97. Though customer never faced any problem with S5 system, they decided to switch over to PCS7 on following grounds :
To overcome the problem of obsolesce of S5 and its spare parts.
To provide connectivity to their other areas like

• Communication from Gas Terminal to Liquid Terminal (200Mtrs)
• Communication from Gas Terminal to Sea Lord Terminal (Remotely located at 2 KMs and connected through Fiber Optic)

• PCS7 – 417 H was employed to handle the process I/O’s at Gas Terminal.
• SIMATIC S7-300 system used for Liquid Terminal & one more S7-300 used at SEALORD Containers (2KMs away) . All the networking was done on Fiber Optic.
• 4 number OS station (each with dual monitor) connected over PROFINET and 1 number ES+OS station was made available near to the main PCS system.
• Connectivity to office network was achieved through Ethernet Switches. SAP Server gets connected over the network to get the required data. Reporting package is based on Visual Basic.
  
  
How this was Achieved…
• All the programs and data was collected and proper planning and basic framework(programming) was carried out at our end which took almost 1 ½ months.
• The site activities went on for another 1 ½ months which included :
  - Simulation of each and every interlock at site for PCS7
  - Correction and modification of PCS7 screens
• Firstly GAS Terminal was switched over, using S5-S7 adaptors hence no new wiring was required. PCS7 was functional within just 2 hours. This means the switch over and shut down was only for 2 hours which may be a record in itself.
• After the success of GAS Terminal, the other two sections Liquid terminal & Sea Lord were also connected to PCS7 within given time frame.
• 45 mass flow meters already connected to PCS 7 over MODBUS and 55 more shall be added in near future. The communication is READ and WRITE type.