In 2016, Birla Carbon and Siemens initiated a modernization of their Siemens APACS+ DCS, which had been in operation for more than 20 years, to SIMATIC PCS 7. Goals included improving process efficiencies, better managing yields, increasing the number of measurement points and integrating digital technologies on all new devices.
This required transitioning their APACS+ IO modules to the newer SIMATIC ET 200SP HA IO, which introduced the potential for extended commissioning times and significant hardware replacement costs – both of which Birla Carbon wished to avoid.
To support Birla Carbon in achieving a simplified, lower-cost IO cutover requiring minimal downtime, Siemens integrated a new and innovative solution allowing for the ET200SP HA IO to be installed into their existing APACS+ cabinet, with the APACS+ backplane and Marshalled Terminal Assembly (MTA) cable remaining in place. Known as the Front Adapter (FAD) Solution, this strategy would preserve their current cable connection to the APACS+ MTA.
By incorporating the FAD Solution as part of their plant-wide modernization to SIMATIC PCS 7, Birla Carbon drastically reduced the amount of production downtime necessary to migrate their DCS. The FAD Solution also lowered the total cost of ownership by maximizing use of Birla Carbon’s existing APACS+ hardware.
Front Adapter (FAD) Solution for APACS+ to PCS 7 IO Migration
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