FNsteel is an organization with a lot of knowledge and experience in the field of steel. Not surprising: FNsteel specializes in the production of wire rod for automotive and machine building applications. Steel wire solutions are also produced for the production of bearings, universal joints, bolts, nuts and spring steel.
FNsteel has a rolling mill and wire processing center in Alblasserdam (South Holland).
FNsteel's question
A so-called Factory link (SCADA system) was used in the rolling mill. This system enabled the visualization of factory automation. This gives a clear overview of the operation of the factory, which is controlled by Siemens PLCs. Unfortunately, this system was outdated: the software was no longer supported and knowledge of this system was becoming increasingly limited. DWG helped FNsteel to replace the SCADA system one-to-one. The goal? A future-proof system that can last for years to come!
In this case we tell more about our approach, to give existing and new customers insight into how we work in the field of software migrations.
The solution
DWG proposed to FNsteel to migrate the Factory link application, which in the old situation consisted of the SCADA system and a UCS system, to a modern WinCC Runtime professional system from Siemens, which is part of the TIA portal product group. Why was this chosen? Two systems can be merged into one SCADA system.
Very efficient!
Our software engineers have drawn up the technical part of the design based on the functional design.
The purpose behind this is to record the technical implementation with which the functionality is achieved.
It is therefore the basic document for the implementation. This important documentation also serves as support in case of malfunctions and/or future changes.
The benefits
With the latest Siemens solution, a server-client principle has been deployed, whereby the SCADA project runs on the virtual server and the clients are connected to the server. The server is connected to the PLCs which collect and process the data so that the correct display of the images is made available. In addition to this delivery, DWG delivered an Engineering Station (ESS) with which the SCADA application can be modified and maintained.
The process of completion
The solution offered has been brought to a success by following the steps below in order:
- Design phase
- Realization phase
- Test phase
- Pre-FAT
- FAT
- Commissioning
At DWG we like to make work practical. For various projects we use a quality methodology that is based on validation and verification of various project steps (the V-model). The validation of the delivered system was performed at various levels of detail based on wishes as expressed.
The success of this project is largely determined by the acceptance of the system by the end user. With the described way of working, the focus throughout the project remained on the contribution of the system in supporting the end user.
To learn more about our Industrial Automation expertise, view this page on our website. You can also contact us to make an appointment. We are happy to tell you more about our services, in short:
the pleasure of DWG.
The pleasure of our Software Engineer
The size and the eventual migration to WinCC professional SCADA package made this a challenging project to work on. Together we have thought-through all the phases described in this case. After the completion of the project, FNsteel was satisfied with the result and the progress of the project. This is what we do it for after all! A happy customer.
For me this is an example of: The pleasure of DWG!
Jelle Mank – Software Engineer DWG
The pleasure of our customer
FNsteel has been working with DWG since 2014. SCADA replacement project was the largest to date. The complete SCADA system of ‘rolling mill and utilities’ has been replaced.
Their V-model approach really appealed to us. As a result, all project steps were clear and in control, resulting in a project that was delivered within scope, time and budget. After the project, the SLA with DWG was adjusted and extended.
Ayhan Osmanoglou – Senior Project Engineer Electrical
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