Utilities and auxiliary systems visualization
For a client in the automotive industry, we delivered a two-stage project covering the visualization of utilities and auxiliary system operations. The implementation spanned two production plants and enabled centralized monitoring of process parameters, faster response to failures, and coordination of system operations from a single location.
Goals
- Providing real-time data on equipment status and failures
- Enabling monitoring of multiple plants from a single location
- Improved control over utility systems and energy consumption
Challenges
- Lack of documentation and source code
- System commissioning without production downtime
- Adaptation to specific requirements of the automotive industry
- Consolidation of multiple standalone operator stations running different software versions into one unified system
- Standardization of communication protocols
Solutions
- Siemens WinCC 7.5
- Siemens S7 controllers
- Ethernet communication
- Standard WinCC driver for SIMATIC PLCs
- Native WinCC Modbus TCP/IP driver for third-party systems
Benefits
- Reduced response time to failures
- Fast and accurate fault localization
- Access to device logs and operational reports
- Optimization of control systems based on collected data
- Reduced risk of production downtime
- Centralized control of two production plants
Preparation
Before the modernization, the automotive plants operated with local control systems for individual devices, without the ability to remotely monitor parameters or control processes. The goal of the project was to integrate PLC controllers into the plant-wide Ethernet network, implement system visualization, and enable centralized operation of the installations from the control room.
In the existing PLC systems, we replaced the CPU modules with units enabling Ethernet communication. We also modified the controller programs to enable remote operation of equipment. Additionally, data from the gas monitoring system and the 110 kV substation monitoring system were integrated into the visualization platform.
Realization
The first stage of the project covered one production plant, while the second stage concerned a factory located several kilometers away. Each plant operates independent servers and client stations.
The visualization system was implemented using Siemens WinCC 7.5. It consists of two redundant servers, three client stations, and four independent WinCC stations. The project was completed with the establishment of communication between the two plants and the creation of a video wall client consisting of nine 55” 4K monitors. The solution enables real-time visualization of operations across both facilities.
Visualization scope
The visualization system covers the following installations:
- Boiler house — S7 315-2PN/DP + S7-1200
- Compressor station — 2 × S7 315-2DP
- Hydrophore station — S7 315-2PN/DP
- Fuel station — S7 315-2PN/DP
- 110 kV substation — Siemens PAS
- Gas consumption monitoring system by Atrem
- Ventilation systems
- Lighting systems
To standardize the software communication layer, we adopted the principle of using the standard WinCC driver for communication with SIMATIC controllers, while using the native WinCC Modbus TCP/IP driver for third-party systems.
Summary
The implemented visualization system for utilities and auxiliary installations enabled full control over technical infrastructure operations and utility consumption across two production plants. With centralized monitoring from a single control room, we reduced response time to failures, improved fault detection, and increased access to process data.
The solution improved coordination between both facilities, reduced the risk of production downtime, and enabled optimization of control systems based on collected operational data. The project was executed without disrupting ongoing production, ensuring continuous plant operation throughout the implementation.
