KAR-QARACHOG Adding Additional 200TPH Vertical Cement Mill to the DCS Project (PCS7 V9.1)

Project Overview

Cement Mill C at KAR-QARACHOG Cement Plant was operating as a single station independent of the plant's PCS7 system. The purpose of the project was to fully integrate its Program into the PCS7 V9.1 SP2 system which has 6 AS stations making it the 7th station connected to the Redundant Servers.
The CPU412 was replaced with CPU410-5H in order to be compatible with PCS7 system. The original Step 7 code was completely re-engineered to PCS 7 environment using Continuous Function Chart (CFC) programming, using specialized CEMAT blocks tailored for cement plant operations. Also legacy WinCC V7 SCADA application was reprogrammed to map directly to these newly generated CFC instances. A new Industrial PC was deployed as an OS Client for the Cement Mill connecting to the Servers.