siemens process automation conference (space) 2014 ... · pcs7 417-4 controller op-1 process hall...

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Liquid Milk Plant Automation – Panchmahal Dairy, Godhra, India,Keyur Vyas, Hi-Mak Pvt. Ltd., Vadodara, Gujarat

Siemens Process Automation Conference (SPACe) 2014, Gurgaon, India


DCS Control System for Dairy IndustryAutomation System for Panchmahal Dairy, Godhra - Liquid Milk Plant – 8 Lac Liters Per Day

Restricted / © Siemens AG 2014. All Rights Reserved.

Hi-Mak Pvt Ltd

Hi-Mak Established in 1993.Siemens System House Since 1994.56 Team Members.Office Area Approximately 12,000 Sq. Feet.Manufacturing Facilities in Industrial Area(GIDC).Siemens Solution Partner for PCS 7 Since 2009.Experienced Team for Various Industry Sectors: Dairy, Chemicals & Fertilizers, Pharma, Oil & Gas, Textile, Paper & Plastic, Metal, Power, Renewable Energy, Glass & Ceramics.


Project Requirement - Complete Dairy Automation Control System

Project Requirement:-1. Integrated Dairy Automation from Reception

to Crate Conveyor System.2. Engineering Documentation - CSFD3. H/W & S/W Engineering & FAT4. Co-ordination with Various Machine

Suppliers for Data Exchange & Connectivity to DCS.

5. MIS Server Client System6. Energy and Utility Monitoring System7. Ring Redundancy on I/O Link8. Commissioning Support9. System Training.


System Feature & Benefits

System Benefit to Customer System Features

1 Reliable System Which Can Work for Reception to Final Packing Line Automation

PCS 7 AS417-4 can Handle Complete Dairy Automation. Proven Hardware & Software

2 Easy to Configure Complex Process Thanks to PCS-7 Engineering Tools – Standard Block for Pump, Valve, Agitator, etc.

3 Route Selection for Product and CIP PCS-7 Priority and Route Selection Logic

4 MIS Connectivity PCS-7 OS Easy Data Achieve and Storage Feature

5 100 % Availability for CPU to I/O Connectivity Profinet Ring Redundancy of Latest Controller

6 High Speed High Accuracy Processing Profinet Based Communication, High Speed Latest Controller, High Resolution Analogue Cards.


Solution Offered – PCS 7 V8.0 with 2 OS, 1 OS/ES & MIS Server/Client

Profibus DP – 12 MBPs

PCS 7 OS/E.S

MIS Client-LAB

PCS7 417-4Controller

Op-1 ProcessHall

RIO-1

Ethernet S/w Apx. Distance 250 mtr.

PCS-7 OS-1 PCS-7 OS-2 at PACKING AREAMIS Server

MIS Client-1 CCR MIS Client-Weigh Bridge MIS Client-Second Floor

ETHERNET 100 MBPS

PROFINET 100 MBPS

RIO-22

Third party Equipment Separator , PCC Panel – COM15 & COM20 – 20 Nodes

SS Panel for 22 Nos. RIO Stations


Plant Overview with Status Indication


Plant Overview – Raw Milk Storage Tank


Plant Overview – Milk Pasteuriser


Plant Overview – Pasteurized Milk Storage Tank


Plant Overview – Milk Filling


Plant Overview – ClP Kitchen


Plant Overview – Utility for EMS System


Project Engineering & Execution


Engineering of Project – Control Matrix


Engineering Standardization – Tank

1. Real Time Information of Product in Tank

2. Historical Product Information in Tank

3. PA – Product Available4. EC, ED - Empty Clean& Dirty5. FAT & SNF Percentage – Real

Time6. Tank Ageing Time for Product, CIP

& Empty Dirty7. Interlock Status8. Pre-Selection of CIP Possible


Engineering Standardization – Pipe

Real Time Information of PipeReal Time Pipe Status with Following Code

1. W- Water in Line2. M – Milk in Line3. ED – Empty Dirty4. EC – Empty Clean5. PA – Product Available

Line Status with Colour Code1. – Production Running2. – Water Flushing Running3. – CIP Running

Pipe Ageing Time for Product, CIP & Empty DirtyInterlock Status


Engineering of Project – Block Icon Library for Various Elements

Icon - Standardization Name of Element

Valves

Pump

Agitator

Analog Open & Close loops


Engineering Standardization – Priority Selection

Priority of Tank Selection:1. Selection of Priority Based on

Operator Input2. Source Selection Priority3. Destination Selection Priority4. Auto-Change Over Based on Level

Bump Less Transfer From Current to Next Priority

5. Plausibility & Interlock Check6. Total Empty Selection for Tank

Unloading Sequence


Engineering standardization – CIP Recipe Selection

1. Recipe Step Preparation2. Route and Recipe Selection3. CIP Request with Interlock

Status4. Step Control of Route CIP


Engineering of Project – Real Time Route Status for Product & CIP

1.Interlock Status with Colour Code

2.Route Name3.CIP Elapsed Time of

Each Route4.Status for CIP Route –

Available / Not


Plant Status Bar – Complete Plant Product Status Overview

CIP CircuitStatus

Production Status

Material Status

Finish Product Status

Operator Login


Engineering of Project – MIS Reports


Engineering Documentation Standard


Training to Customer


Smt. Anadiben Patel (CM – Gujarat) Inaugurated Panchmahal Dairy Plant


Appreciation from Consultant & Customer


Winning Team

PanchmahalDairy

Customer

Siemens Principals

Hi-Mak Pvt. Ltd.Solution Partner

Perfect Solutions Consultant

Magnam NetlinkPvt. Ltd.

EPC


The Panchmahal Dist. Co-Op. Milk Producers Union Ltd., GodhraManaging Director - Shri Suresh Patel

Perfect Solutions, Ahmedabad

General Manager - Shri Sachin Chaudhari

Magnam Netlink Pvt. Ltd., Vadodara

Managing Director - Shri Mahesh Chandra

Siemens LtdOffice-in Charge (Vadodara) - Shri Rajal Trivedi

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Keyur Vyas – CEO

Hi-Mak Pvt. Ltd.201-209, Blue Diamond Complex,

Fatehgunj Cross Road,

Vadodara , Pin: 390 002

State: Gujarat , India.

Phone : +91-265-2795413 / 2795348

Mobile : +91-9824014224

Fax : +91-265-2795583

Mail : Keyur.vyas @himak.in

Web : www.Himak.in

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siemens process automation conference (space) 2014 ... · pcs7 417-4 controller op-1 process hall...

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