realizacje

At brewing plants, an outdated PCS7 v6.0 system was in use, which was no longer technically supported (the product had been discontinued). Older operating system versions and the lack of spare parts posed a risk of downtime and IT security threats. Upgrading the system while minimizing downtime and meeting the latest standards was a top priority.

Implementation

1. Project Preparation

A detailed analysis of the existing system was conducted to identify all components requiring an upgrade. A comprehensive migration plan was developed, focusing on minimizing downtime.

2. System Modernization

The system was upgraded from v6.0 to v9.1 SP2, merging projects and migrating operator panels to modern SIMATIC HMI Comfort Panels.

3. Virtual Environment Deployment

The system was deployed in a virtualized environment, providing greater flexibility, easier maintenance, and rapid expansion capabilities.

4. Testing and Commissioning

Comprehensive tests (FAT) were conducted using the PLCSIM simulator to verify system performance. Following successful test results, the system was commissioned at the plant while maintaining full functionality.

Implementation Results

• Increased system reliability.
• Introduction of new communication standards.
• Centralized control with scalability potential.
• Unified user interface for simplified operation.
• Enhanced IT/OT security.
• Easier integration with modern production management systems.

Hardware Configuration

• 3 x AS – Controllers
  • 1 x CPU 410-5H (replacement for CPU 417-4).
  • 2 x CPU 416-2.
• 1 x ES – Engineering Station (Virtual Environment).
• 1 x OS SERVER – Visualization Server (Virtual Environment).
• 3 x OS CLIENT – Dual-Monitor Operator Station (Virtual Environment).

Summary

The modernization of the SIMATIC PCS7 system at the Carlsberg plant was a crucial step in upgrading production processes and ensuring operational continuity. By implementing PCS7 v9.1 SP2, the company gained not only reliability and security but also enhanced integration with the latest automation and IT systems.

The upgrade eliminated risks associated with outdated hardware and software while paving the way for further system expansion. The use of a virtualized environment significantly increased flexibility and scalability, providing a competitive advantage in an evolving market. A well-planned migration strategy allowed for minimal downtime, which was critical for the client’s operations.

The project was successfully completed, delivering measurable benefits in terms of efficiency and future growth potential. Carlsberg can now fully leverage modern automation solutions, gaining industry leadership and long-term operational stability.