With time, the control system hardware and software become obsolete. That's why it is important to keep the systems running up to date with modern technologies, or, at least, not too far away from it.
A few things are required to migrate a Siemens project:
Controls:
- must have a copy of the original STEP 7 project (.S7P), preferably with comments and tag names. Otherwise it will be required additional time to add new comments and tag descriptions. Having proper comments and IO names is mandatory for starting up, commissioning and troubleshooting.
- Install in the same VM (attention to the Windows versions requirements) SIMATIC Manager (OS older than Windows 8) and TIA v13 SP1/SP2 Professional.
- Use the function "Migrate" after opening TIA Portal, rather than "Open Project". It may be necessary to untick the option "Exclude Hardware" in case the hardware is too old and does not exist in TIA Portal.
- Compile and correct the issues (e.g., pointer issues).
- Change the CPU model to the new model.
- Having a project in that version (TIA v13 SP1/SP2 Professional) is very useful because it then can be opened directly by newer TIA Portal versions, such as V17 and V18.
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- Check all the OBs, FCs, FBs are the same. Attention to some of the functions that may have been migrated automatically to another version. For example the PID CONT_C in the migrated software may be migrated to a Technology Object rather than a FC. The DB numbers, tags, HMI connections may be changed.
- Remove from the code obsolete IO.
- Improve the industrial network in the new project if possible, e.g., by adding a redundant PROFINET network.
- Check the analogue signals NORM_X and SCALE_X are appropriate normalized and scaled in the new hardware.
- Test as much as possible in the workshop and FAT, everything from IO, networking (PROFINET and PROFIBUS, DP-DP Couplers, PN-PN Couplers), simulation, HMI trends, alarms.
- Check the PID settings, scan time, parameters. Monitor the process and be flexible to adjust the PID settings accordingly.
- Retain important values in the PLC.
- Edit the Starting values of the Set-points or parameters.
- Check for filters in the software, e.g., moving averages used to analog input values.
- Do a Watch Table with all the IO. Attention to the reverted IO like control valves that are reverted.
Electrical:
- Review existing power supplies and improve or do a new one if necessary. If there are more than one power supply, ensure there is no difference in their voltages.
- Ensure compatibility between existing and new IO termination.
- Ensure existing drawings are available.
- Ensure output cards meet the current requirements, e.g., relay output cards.
- Ensure power supplies and racks are earthed.
- Ensure shield bar on analog cables, e.g., analog input, telefast, RTD, analog output.
- If system is connected to more than one SCADA, ensure the communication to all SCADA systems are healthy.
- Evaluate if hardwired (multi-core cable, relays) communication between PLCs is simpler than networked.
- Check polarity of analog output signals.
- Use resistor to convert between 4-20mA and 0-10V during tests with a current source meter.
- Ensure there is no additional power supply incorrectly introduced to existing instrumentation.
Process:
- Talk to operators and process engineers that work on site with this equipment to better understand how it works.
- Take the opportunity to improve some simple existing issues, e.g. too small alarm page, trend issues.
- Take a photo of all the HMI screens before migration for reference.
- Attention to run-away processes, e.g., exothermic chemical process, oxidisation, pH, etc.
Project:
- Take a phased approach to reduce risks.
- Identify the risks and create alternative plans.
References:
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