Migration - Reconstruction during ongoing operation

Migration of automation technology

Many currently installed control systems are outdated and are no longer supported by the manufacturer. This means that spare parts are hardly availabe and there are only a few possibilities to connect current systems. Also, it is increasingly difficult to find service engineers who master the older automation systems perfectly. The replacement of automation technology often causes a plant standstill which in itself poses great risks. Therefore, a comparison to an "open heart surgery" describes the complexity of the topic quite well. This comparison also indicates that the operator benefits from his experience and KIMA has been successfully working on a lot of respective projects. For many years now, KIMA has migrated various control systems in different industrial sectors. The exact scheduling of processes and schedules, as well as the prior simulation of the new software ensure a virtually risk-free migration.

Current migration projects:

Reconstruction waterworks
Scope:200 drives, 250 measurements, 30 controllers/sequences
Prior system:ABB / OHP(ProWin)
New system:Siemens (WinCC/Step7)
Reconstruction period:Reconnection of about 20 external stations during ongoing operation. Renewal of the plant bus/control system during operation. Step-by-step replacement of about 22 controllers and IO peripheries during ongoing operation and at night.
Speciality:redundant PLC system (Siemens), redundant Server-Client System, Acron, Sinaut ST7, Page Control

Reconstruction cement plant
Scope:250 drives, 200 measurements, 50 controllers/routes
Prior system:Siemens PCS7 CEMAT (Client-Server) with S5 controllers and S5 periphery
New system:Siemens PCS7 CEMAT (Client-Server) with S7 controllers and S7 periphery
Reconstruction period:Replacement of the mill control as well as raw material transport within two weeks. Exchange of hardware for the continuous blending silo approx. one week: Exchange of software for the continuous blending silo approx. one week.
Speciality:The plant will be reconstructed in several steps to avoid prolonged downtime. The unpreventable downtime takes place on holidays and can be compensated by stockpiling.

Reconstruction mineral mixing plant
Scope:130 drives, 100 measurements, Integration of an old S5 PLC
Prior system:hardwired process control via group switches and partial integration of PLC
New system:Siemens WinCC/Step7 KIMA Software for linked material transport
Reconstruction period:The plant was reconstructed within 10 days during the annual winter repair.
Speciality:Renewal of the entire electrical installation in parallel during ongoing operation. The overall project incl. engineering-CAD, switchgear cabinet construction, software development, installation and commissioning took less than 3 months.

When does a company have to start thinking about a reconstruction:

Availability of spare parts:Modules have been discontinued, new computers require current operating systems that usually are not compatible with old systems and may therefore hide undetected risks
Service:Only a few employees/operators are able to handle old systems safely.

operational safety:
Touch protection in switchgear cabinets is not sufficient.
Safety:Necessary requirements of the professional association, such as new performance levels, are not achieved!
Product optimization:Increasing performance and ensuring the required quality using modern automation, measuring and control technology.

More news

KIMA WaterCon - Hydroelectricity – Nature and Technology in Harmony
At the Bavarian Hydroelectric Power Station at Leipheim, modular power supply systems are being installed to provide an uninterrupted power supply for all power station ...

KIMAWaterCon at the fair in Salzburg/Austria RENEXPO INTERHYDRO
A lot of interested customers visited the "KIMAWaterCon" exhibiton stand J18 at the RENEXPO INTERHYDRO in Salzburg/Austria from November 29 to November 30, 2017. Our visitors ...

Process engineering on a sound footing - The base for end-to-end automation
As a Siemens Solution Partner, we have successfully demonstrated our expertise in the field of electrical and Automation Technology for years. In addition to the certifications ...

Using energy more efficiently - Jens Spahn finds out about the project for the reduction of emissions at KIMA
Jens Spahn, member of the Bundestag for the CDU (Christ democrats) and Parliamentary State Secretary of the Federal Ministry of Finance, has visited KIMA. KIMA was founded in ...

KIMA Smart Power Supply
- individual customer solutions– introduced at the engineering fair Four future engineers executed a relaunch of KIMA's own UPS lab unit and presented the results at the ...

Article World Cement - Industry-specific Energy Management Software
In World Cement's Februray issue KIMA has addressed the topic Energy Management. You may find the article ...

Article ZEK Hydro - KW Gundelfingen
In the ZEK Hydro's February issue KIMA addresses the topic Migration. You may find the German article ...

Article World Cement - Migration - addressing the key questions
KIMA talks through some of the main issues surrounding the Topic of Migration in the November issue of the World Cement Magazine. You may find the article as a PDF here: ...

High demand for UL compliant switchgear cabinets!
As a certified "UL-Panel Builder" (UL508a) KIMA has engineered and manufactured switchgear cabinets for machines and plants for the North American market for years. Switchgear ...

Article DVGW - Investing in latest technology
After a successful trial run KIMA and a regional gas and water supplier look back positively upon the successful reconstruction of the entire automation system in a ...

Cycling to work 2014 - we won!
KIMA was awarded with the title "most bicycle-active Company" with the initiative "Cycling to work" during a ceremony. The award was assigned for the long-term participation ...

Cemtech 2014 Dubai
Proximity to our customers Over the years KIMA has developed a satisfied customer base in the Arab world. At the Cemtech exhibition in Dubai from February 02 to February ...

Prospective lifesavers
- Third blood typing drive at KIMA/32 employees participated - As the old proverb goes: All good things come in threes. The employees of KIMA Automatisierung GmbH took it ...

ÖkoProfit 2013
Workshop No. 6 at KIMA Managing Director and ÖkoProfit-participant Alfred Klein welcomed around 30 guests and guest speakers to the 6th workshop at the premises in ...

Cycling to work 2013
Since 2010 KIMA participates in the campaign "Cycling to work"! This year again, teams were internally formed for the summer months of June, July and August. KIMA donates an ...

Welcome to our new homepage!
We hope you enjoy browsing our website. For further information our secure customer area is available as well. Please contact us for the login information. We look forward ...