ENCI is a Dutch manufacturer of Cement with branches in Maastricht, Rotterdam, IJmuiden and Den Bosch and is part of the Heidelberg Group. They produce Cement for construction by grinding of vowel and blast furnace and a number of additives.
By 2015, Verwater automated the ball mill 8 in IJmuiden, now Rotterdam's bullet mill 2 has been modernized in 2017. The old automation system (ECS SCADA and Siemens S5 PLC) of mill 2 are replaced by a new automation system, Siemens PCS7 with CEMAT Library. Also, the power supply and cabling for the installation has been completely replaced. This new installation has a lot of new opportunities for ENCI, easy maintenance, quick failure analyses and a stable system. The PCS7 system is the new standard for the ENCI plants. ENCI IJmuiden and Maastricht, already use this new standard. New technologies like virtualization and APL library are used.
The project has been carried out multi-disciplinary: Hardware engineering and drawing AutoCAD/EPLAN, Software engineering, Panel Building, E&I montage for cabling the field devices. Also some mechanical and civils works are executed by Verwater.
The software engineering consisted of building the PCS7 software application with the CMAT library. Verwater has chosen for a Virtual VMware solution with 1 Engineering station, 2 redundant OS servers, 2 Operating clients. The challenge for this project was preparations in a working factory and conversion in ENCI's holiday stop. Thanks to the preparation, good development and testing and good cooperation with the customer, this goal has been achieved..
Some numbers: 1 MCC, 10 km cabling, 1 PLC, 13 remote IO stations, 1000 IO, 100 motors, 60 transmitters, 6 ABB drives on Profibus.