S7-300 to S7-1500 F-CPU Migration and SCADA Rebuild for a Waste Incineration Facility
Sector:
Waste & Recycling
Type:
Obsolecence Upgrade, Software
Platform:
Siemens
Certification:
CE / UKCA
Summary
DelaControl delivered a full control system obsolescence upgrade for an industrial waste incineration facility, replacing an end-of-life Siemens S7-300 platform with a current S7-1500 F-CPU, migrating the existing Step 7 5.5 PLC software to TIA Portal, and rebuilding the supervisory SCADA system from Wonderware InTouch to Siemens WinCC. The scope covered hardware build, full documentation, factory acceptance testing, site installation, commissioning, and operator training.
Challenge
The facility's incinerator control system was built around an obsolete Siemens S7-300 PLC platform, including ET200 remote I/O devices, presenting a long-term supportability risk.
The supervisory SCADA system was running on Wonderware InTouch, and the customer required both the control platform and the SCADA to be brought up to a modern, maintainable standard while preserving the existing control philosophy documented in the functional description.
Solution
DelaControl designed and built new control system backplates housing the replacement Siemens S7-1500 F-CPU and associated I/O modules. The Siemens PLC hardware, IPCs, and operator screens were free-issued by Siemens and housed in enclosures supplied by DelaControl. All consumables, panel metalwork, terminals (Weidmueller), low-voltage control gear, circuit protection, and 24V power supplies were Siemens-branded components selected to DelaControl's standard specification.
Site installation involved two industrial electricians working over ten days to disconnect, remove the old backplate, install the new backplate, and re-terminate all field cables. Field cable liaison with existing sub-contractors was also included.
The existing Step 7 5.5 PLC software was fully migrated to a TIA Portal S7-1500 project. Any control logic changes arising from the platform migration were captured in a dedicated PLC code migration report. The SCADA system was rewritten from scratch on Siemens WinCC, covering thirteen operator screens including plant overview, process area pages, trends, reports, logs, and alarms.
The delivery package included a full drawing pack (general arrangements and schematics in AutoCAD Inventor and AutoCAD Electrical/Eplan), thermal calculations using Rittal Therm software, a Declaration of Conformity to LVD and EMC directives, a functional test schedule agreed with the client, factory acceptance testing, site commissioning (two control systems engineers over fifteen calendar days), and two full-day operator training sessions at DelaControl's Bristol facility.
Key Facts
• Platform migration from obsolete Siemens S7-300 (Step 7 5.5) to S7-1500 F-CPU on TIA Portal
• SCADA rebuilt from Wonderware InTouch to Siemens WinCC — 13 operator screens in scope
• Site installation: 2 industrial electricians on site for 10 days (24 man days total)
• Site commissioning: 2 control systems engineers, 15 calendar days, 37 man days total
• Factory acceptance test conducted with end client and system integrator present
• 2 full-day operator training sessions included, hosted at DelaControl's Bristol facility
• Documentation package included thermal calculations, Declaration of Conformity, FAT schedule and certificate, detail design specification, software design specification, and operator manual
• Security requirement: only British passport holders assigned to the project; all project data held in director-level password-protected encrypted storage