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Integration of QB Modules with Siemens PCS 7

Discover how we integrated QB modules with Siemens PCS 7 using MTP standards. A case study on bridging modular hardware with enterprise DCS for "plug-and-produce" efficiency.

Industry

Industrial Automation / Life Sciences / Pharmaceutical Manufacturing

Scope

Hardware and Software integration

Timeframe

1 month

Technology

  • MTP Standard (NAMUR / VDI/VDE/NAMUR 2658)
  • Siemens PCS 7 / WinCC / Open OS
  • OPC UA Connectivity
  • Simatic MTP Creator & MTP Validator
  • VMware Virtualization
  • Remote Diagnostic Suitcase (RDS)

1

IT/OT Engineer

2

Project phases

The client

Siemens – a global leader in technology, industrial automation, and digitalization. The company provides advanced solutions for the manufacturing and process industries, including its process control system, Siemens PCS 7. As a pioneer in implementing Industry 4.0 standards, Siemens develops ecosystems that support the flexibility and interoperability of OT systems based on standards such as MTP (Module Type Package).

Business needs

The primary objective was to validate and implement modular production standards within the client's innovation centers and "Living Lab" test facilities. The client required the integration of modular hardware units (QB modules) into the Siemens PCS 7 Distributed Control System (DCS) to verify the interoperability of the MTP standard. The solution was intended to enable a "plug-and-produce" workflow, reducing manual configuration efforts and simplifying the scaling of automated process systems.

The challenge

  • 01

    MTP Compatibility Generating and validating MTP/AML files that could be successfully imported into the client’s PCS 7 / Open OS environment.

  • 02

    Protocol Alignment Configuring OPC UA communication to match the specific requirements of WinCC/PCS 7.

  • 03

    Standard Evolution Overcoming limitations in native MTP support within existing systems, specifically regarding advanced services and process values.

  • 04

    Adaptive Integration Defining flexible integration scenarios ranging from simple manual control to complex, automated control loops.

Our solution

We acted as both a hardware provider and a technology partner, delivering a fully validated integration path for modular units within a DCS framework.

  1. MTP Implementation & Validation

    Developed and refined MTP files using internal generators and industry-standard tools (Simatic MTP Creator), ensuring successful recognition of units as MTP Process Equipment Assemblies (PEAs).

  2. Dual-Tier Integration Framework

    Established two distinct integration levels—a "Minimal" variant for rapid manual control and a "Full" variant for advanced process orchestration and extended logic.

  3. Simulation Environment

    Created a virtualized environment (VMware + PCS 7/WinCC) to demonstrate HMI interfaces and operator workflows before physical deployment.

Technology used

  • MTP Standard (NAMUR / VDI/VDE/NAMUR 2658)
  • Siemens PCS 7 / WinCC / Open OS
  • OPC UA Connectivity
  • Simatic MTP Creator & MTP Validator
  • VMware Virtualization
  • Remote Diagnostic Suitcase (RDS)

The outcome

The project successfully demonstrated that QB modules are "MTP-ready" for enterprise-level systems environments, providing a real-world playground for innovation in the client’s "Living Lab.

  • Successful devices Import
  • Reduced Engineering Effort
  • Accelerated Knowledge Transfer
  • Future-Proof Roadmap

What we implemented

  • Modular Units Readiness Configured Cube Pumps, Sensors, and Multiscales as independent PEAs with native OPC UA servers.
  • Custom MTP Engineering Conducted iterative manual corrections and tool-based validations to ensure the MTP files met the specific structural needs of the client's DCS version.
  • Living Lab Deployment Shipped physical units equipped with Power over Ethernet (PoE) and Remote Diagnostic Suitcases (RDS) to ensure 24/7 availability and remote support for the client's engineers.
  • Functional Scope Definition Detailed requirements for HMI visualization, process signals, and alarm handling, aligning the technical output with the client’s operational standards.
Karol Doroszewski
Working with Siemens to bring our QB modules into the PCS 7 environment really showed what the MTP standard can do in practice. We didn't just want to connect hardware; we wanted to prove that 'plug-and-produce' actually works in a complex DCS setup. By mapping out clear integration levels and testing everything in a virtual sandbox first, we’ve created a solid roadmap for any legacy system to adopt modularity without the usual technical headaches.
Karol Doroszewski — Delivery Executive

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