PCS7 System Upgrade to the Latest Version at Carlsberg Poland
SIMATIC PCS 7 is an advanced process control system from Siemens, forming part of the Totally Integrated Automation (TIA) platform. Its modular architecture enables seamless integration of control processes with both industrial and IT systems, ensuring high reliability, scalability, and adaptability to specific plant requirements.
The introduction of the new system version enhances process control capabilities, accelerates response to operational changes, and facilitates integration of IT/OT environments with modern industrial automation solutions.
Goals
- Upgrade from PCS 7 v6.0 to v9.1 SP2, including controller replacement
- Upgrade from PCS 7 v8.2 to v9.1 SP2
- Integration of both systems into a single project
- Deployment of PCS 7 in a virtualized environment
- Migration of existing operator panels to SIMATIC HMI Comfort Panels
- Upgrade of SIMATIC PDM
- Execution of FAT tests using PLCSIM simulation
Challenges
- Minimized downtime during implementation
- Migration of the project to the latest APL version while maintaining full control system functionality
- Elimination of existing errors and system inconsistencies
- Preservation of existing field-level hardware configuration
Solutions
- SIMATIC PCS 7 v9.1 SP2
- SIMATIC HMI Comfort Panels
- FAT testing using PLCSIM
Benefits
- Centralized control and system scalability
- Unified operation and standardized user interface
- Increased system reliability
- Implementation of new communication standards
- Improved integration with modern automation products
- Better IT/OT integration capabilities
- Enhanced system security
In brewing plants, an outdated version of PCS 7 v6.0 was in use, which was no longer supported by the manufacturer. Older operating system versions and limited spare parts availability increased the risk of downtime and IT security threats. Therefore, it was critical to modernize the system with minimal downtime while aligning it with the latest technical standards.
Realization
Project preparation
We carried out a detailed analysis of the existing system and identified components requiring upgrades. We then developed a migration plan focused on minimizing downtime while maintaining full control system functionality.
System modernization
We upgraded the system from PCS 7 v6.0 to PCS 7 v9.1 SP2, merged the projects, and migrated operator panels to modern SIMATIC HMI Comfort Panels.
Virtual environment deployment
We deployed the system in a virtualized environment, increasing solution flexibility, simplifying maintenance, and enabling easier future system expansion.
Testing and commissioning
We performed FAT tests using the PLCSIM simulator to verify system performance before plant commissioning. After successful testing, the system was fully deployed while maintaining complete functionality.
Implementation results
- Increased system reliability
- Implementation of new communication standards
- Centralized control with scalability for future expansion
- Unified user interface improving system operation
- Enhanced IT/OT security level
- Easier integration with modern production management systems
Hardware configuration
- 3 × AS — automation stations:
- 1 × CPU 410-5H — upgrade from CPU 417-4
- 2 × CPU 416-2
- 1 × ES — engineering station in a virtualized environment
- 1 × OS Server — visualization server in a virtualized environment
- 3 × OS Client — dual-monitor operator stations in a virtualized environment
Summary
The modernization of the SIMATIC PCS 7 system at the Carlsberg Polska plant was an important step in upgrading production processes and improving operational continuity. By implementing PCS 7 v9.1 SP2, we increased system reliability, safety, and integration capabilities with modern automation solutions and IT/OT environments.
The upgrade reduced risks associated with operating outdated hardware and software and established a solid foundation for future system expansion. The use of a virtualized environment improved flexibility and scalability, while a well-planned migration strategy minimized downtime, which was critical for production continuity.
The project was successfully completed, delivering measurable benefits in efficiency, safety, and the potential for further development of the process control system.
