Project C

Project Report: Bio Plant Retrofit and Control System Upgrade

1. Project Overview  

This project involved the retrofit and automation upgrade of an existing biogas feeding station. The works marked the first implementation of this specific configuration within our operations.

The main objective was to integrate a Vogelsang Premix 4-in-1 fluid feeding system into the existing process infrastructure, improving feedstock preparation and overall plant performance.

2. Project Objectives 

• Integrate a Vogelsang Premix 4-in-1 unit into the biogas feeding process.  
• Replace the legacy German WINCC-based SCADA system with a modern, maintainable solution.  
• Develop and install a new Siemens PLC and SCADA system using TIA Portal.  
• Implement a fully automated valve network for seamless process control. 
• Create a new database-to-SCADA and SCADA-to-database interface for all process tags.
• Commission and validate all control systems, ensuring full plant operability and reliability.   

3. Background

The existing Bioplant system had become unreliable due to frequent breakdowns and limited support availability. The legacy setup operated on a German-engineered WINCC SCADA system hosted remotely on a server in Germany, creating difficulties in obtaining timely maintenance and updates. 

The original installation consisted of 21 German-language SCADA screens. The plant owner required a complete migration and expansion of these screens to a new 14-screen configuration, running on upgraded local hardware and a new control platform. 

4. System Design and Integration

4.1 Vogelsang Premix 4-in-1 System

The Vogelsang Premix 4-in-1 unit provides inline separation and homogenization of input substrates before transfer to the pumping system. This ensures uniform feedstock consistency, reduces mechanical wear on downstream equipment (particularly mixers), and improves process efficiency. 

The system supports remote diagnostics, maintenance, and firmware/software updates through a secure network connection, allowing for rapid troubleshooting and continuous improvement. 

4.2 PLC and SCADA Implementation

A new Siemens PLC was installed and programmed using TIA Portal, providing a modern, flexible, and maintainable control solution.

A new SCADA system was developed within the same environment to ensure seamless communication, real-time monitoring, and data logging capabilities.

Key features include: 

• Centralized control and monitoring via HMI (Human-Machine Interface). 
• Real-time process visualization and historical data trending.  
• Automated alarm handling and system diagnostics. 
• Integration with database systems for tag management and data storage.  

4.3 Hardware and Control Network

A fully automated valve network was implemented to facilitate dynamic process control and enable full system operation from the central HMI station.

All Variable Speed Drives (VSDs) and Forward/Reverse starters were integrated into the PLC and SCADA systems for improved control and fault management.

5. Software Development 

• Development of new SCADA screens (14 total), expanding upon the original German system design. 
• Creation of new PLC software for all new hardware components, including the Huning feeding system and hammer mill.  
• Establishment of a new database interface for tag management and data synchronization between PLC and SCADA.
• Careful removal of the legacy German feeding program, which was complex and fully written in German. 
• Creation and commissioning of a new base feeding module compatible with the Huning and Vogelsang systems. 

6. Commissioning and Testing 

Comprehensive commissioning was carried out on-site, including: 

• Full I/O verification and system integrity testing. 
• Validation of all SCADA screens, tag communications, and database operations. 
• Functional testing of the Vogelsang Premix 4-in-1 unit, Huning feeder, and hammer mill. 
• Verification of automated valve control, VSD operation, and alarm handling. 
• Optimization of process sequences to ensure stable and efficient operation. 

7. Outcomes and Benefits

The retrofit and control system upgrade successfully delivered a robust, maintainable, and efficient biogas feeding process. Key benefits include: 

• Increased reliability through modernized Siemens-based automation.
• Improved feedstock consistency and reduced wear on mechanical components. 
• Enhanced maintainability via remote diagnostic capability. 
• Simplified operation through centralized SCADA control and visualization. 
• Elimination of dependence on the original remote German WINCC system. 

8. Conclusion

The successful completion of the Bio Plant Retrofit and Control System Upgrade demonstrates our capability to design, integrate, and commission complex automation solutions within existing plant infrastructures.

The upgraded system now provides improved reliability, flexibility, and scalability, ensuring long-term operational stability and ease of maintenance.