An important part of maintaining an optimally performing facility is ensuring that the technology is up-to-date. Out-of-date systems need frequent repairs and maintenance that increase downtimes and negatively impact the bottom line. Vendors discontinue legacy product lines, making it more difficult to obtain equipment and adequate systems support for older systems.
Many industrial plants realize the need to upgrade their automation systems to achieve long-term sustainability, reduce risk, and improve profitability. A control systems migration is a solution that can protect your investment in your existing facility’s systems while at the same time ensure your facility can reach higher quality benchmarks and operate more efficiently.
A major Midwestern cement manufacturer needed an upgrade to their facility control systems. Although they had modified their terminal over the years, their control system had not been updated in line with the changes. As a result, the manufacturer relied on the institutional knowledge of a limited staff and work arounds to keep the terminal in operation. With our client’s PLC-5® control system, GE iFix® HMI, and spare parts quickly becoming obsolete, the situation had reached the point where a single additional system failure would force the terminal to cease all production.
Facing these risks to their business and high production demands, the cement manufacturer sought out the controls expertise at EAD to engineer a long-lasting systems migration solution. As a certified and experienced Allen-Bradley Rockwell provider, EAD was able to successfully implement the PLC-5® migration. We quickly upgraded the client’s existing controls system to ControlLogix® and their HMI application to FactoryTalk View SE® within the time constraints of their limited production downtime window.
EAD devised a method to save time by utilizing Allen-Bradley’s PLC-5® to ControlLogix® migration chassis, enabling the installation electrician to demo the old PLC-5® hardware and install the new ControlLogix® hardware for three racks of I/O in less than two hours. The method kept all the field wiring intact during the conversion installation, saving the client time and lowering costs during the time critical check-out and start-up processes. The PLC-5® to ControlLogix® conversion was therefore seamless, quick, and cost-efficient.
Robust System Network
In line with our commitment to creating a solution that supports our client’s long-term growth, we also designed a robust system network that replaced their out-of-date remote I/O and Ethernet network. The new system is flexible enough to support any future business changes such as a system expansion.
EAD was able to successfully migrate and modernize our client’s entire system, including all the changes they had made over the years to their terminal. As a final added benefit to our client, EAD implemented Allen-Bradley’s PlantPAx® system. PlantPAx® standardized the structure of our client’s controls systems, provided plant operators with the ability to monitor and track operational data in real-time and even added an extra layer of security to the terminal.
EAD not only completed the PLC-5® migration and other improvements successfully but also met the client’s strict down-time limitations, cutting the system over and completing the check-out and commissioning in less than two days.
All in all, a controls systems migration is an investment in your facility that will translate into a higher ROI. EAD does not just upgrade your systems – we go one step further, providing additional improvements tailored to meet your organization’s unique demands.
No matter how unique your challenges or how complex your requirements, we’ve got you covered. Backed by our team of experts – EAD’s most valued assets – we implement automation solutions that help you to improve the operational efficiency of your facility, reduce downtimes, and leverage the business intelligence that drives your business.
- Reduced installation downtime from 2 days to 2 hours
- Reduced check-out downtime from 1 day to 4 hours
- Allen-Bradley PLC-5® to ControlLogix® Systems Migration
- GE iFix® to Allen-Bradley FatoryTalk View SE® HMI Systems Migration
- Allen-Bradley PlantPAx® Implementation