Update to the PCS7 Control System for Two Continuous Casting Lines
As part of a comprehensive modernization project, gefeba supported Hüttenwerke Krupp Mannesmann GmbH in ensuring the long-term viability of its production facilities. The existing Round Line 1 and 2 were to be migrated to the modern Siemens PCS7 automation platform—while production continued and with minimal downtime. A particular challenge was the extremely short conversion period of just one week per line. At the same time, existing STEP7 functions had to be fully migrated to PCS7, the entire IT and network infrastructure had to be modernized, and all controllers and operator stations had to be replaced.
gefeba completely redeveloped the software for the continuous casting lines and migrated all functions of the existing STEP7 application to a modern PCS7 architecture. In addition, the entire IT and network infrastructure, as well as all control systems and local operator stations, were modernized. All of the plant’s user interfaces were uniformly implemented as PCS7 clients and supplemented with user screens tailored to each specific workstation. The existing authorization concept was fully integrated into PCS7. The entire control system was implemented in a virtualization environment based on VMware ESXi. At the same time, gefeba consolidated two control rooms into a single central control room and modernized all computer workstations. To ensure that the very short conversion timeline was met, both plants were fully replicated in a simulation environment. This allowed all functions to be comprehensively tested in advance and enabled the operating personnel to work with the new user interface at an early stage.
The successful migration to Siemens PCS7 resulted in a modern and high-performance automation platform for the two continuous casting lines. The new system architecture improves usability, increases plant availability, and creates a stable foundation for future expansions. Thanks to upstream simulation and comprehensive testing, commissioning was successfully completed within the tight conversion schedule. At the same time, operating personnel benefit from a standardized and intuitive user interface as well as modernized control stations.
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