Siemens Control System Upgrade - Huntsman
Commissioned by Huntsman, Koster Industrial B.V. carried out the complete hardware and software upgrade of the existing Siemens S7 control environment.
To ensure the continuity of the continuous chemical processes, the system was migrated to a modern Siemens S7/TIA Portal architecture, including redundant CPUs and decentralized ET 200SP I/O stations via Profinet. This shortened cycle times and significantly improved diagnostic reliability.
For this project, we carried out the following technical activities:
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Engineering & Design: Revision of the electrical schematics (Eplan P8) and preparation of the FDS (Functional Design Specification).
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Hardware & Panel Building: Replacement of the Rittal control cabinets, including 24VDC power supplies, safety relays, and ET 200SP racks.
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Software engineering: Migration and rewriting of the PLC software in TIA Portal, implementation of fail-safe (F) logic, and integration of the WinCC SCADA visualization.
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Safety: Validation of the safety circuits in accordance with the applicable EN ISO 13849-1 standards.
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FAT, SAT & Commissioning: Extensive I/O simulation (FAT), followed by a tightly managed cut-over during a planned shutdown with minimal downtime.
