Why the Key to a Safe Process Control Migration Might be Found in Cyberspace...

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Siemens AG

To be able to guarantee trouble-free system functionality when the sub-units are recommissioned, Siemens uses its Simit simulation software which allows all the control systems to be monitored and tested prior to conversion of the physical plant. The first migration step started in 2011.

To date, 12 conversion stages have been successfully completed, four using a mixed control system and eight completely using PCS 7. At the same time, one process unit (from Solvay) was completely converted to PCS 7. The Siemens teams are currently working on two further conversion stages.

A “Virtual Twin” Safeguards the Changeover Process

The purpose of using the dynamic simulation software tool from Siemens is to ensure the best possible preparation for changeover of the Solvay/Butachimie chemical factories to the PCS 7 process control system.

The concept suggested by Siemens is based on the connection of software featuring integrated solutions which enables the plants to be digitalized, guaranteeing the trouble-free exchange of data on every level. To allow the subunits to test this reliably prior to migration and recommissioning, Solvay/Butachimie uses a “virtual twin”. This virtual digital copy of the plant is able to simulate its dynamic behavior.

Achieving Problem–Free Commissioning

During the critical commissioning phase, the functionality of the system is paramount: Changeover to the new control system takes place within extremely short transition periods which are precisely stipulated and have to be adhered to without fail.

The use of Simit and digital simulation allows the control system to be tested, and a check performed of the various sequences and interacting processes in advance, making for a problem-free physical commissioning process. Following completion of the tests, the plant can be safely changed over without running any risk.

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