EAD modernized an outdated Siemens controls system over three process subsystems and designed the new ControlLogix® control system to meet our client’s standards. We also incorporated our clients existing standalone auxiliary control systems into the new control system design and software.
Control System Modernization Services for Mining and Extraction
EAD has years of experience in providing control system modernization services among a host of other services in various engineering disciplines. Some of our best work is in facilities and environments with continuous operations. When a leading global extraction and mining conglomerate called upon our controls engineering experts to update their control systems within a short downtime, we were ready to put our years of experience performing systems migrations to the test. Our client needed a control system upgrade solution that both modernized and standardized their current system. Their objective was to make their systems more efficient to maintain and reduce the frequency of unplanned system downtimes.
Outdated benchmarks and old control systems may prove to be problematic for several reasons, and system failure resulting in downtime at the most unexpected times is just one of them. For instance, in many cases old control systems do not provide the required efficiency, reliability, work cycle cost efficiency, or even safety.
To stay sustainable in the global digital economy and at par with competition, companies count on technological systems to provide these essential benefits. While it was easy to dismiss modernization as being too complicated or expensive previously, it’s not an option anymore but an essential requisite in these modern times. Moreover, given the rapid technological developments over the last few years, control system modernization is not an impossible aim today.
EAD overcame several challenges over the course of the project to successfully upgrade our client’s outdated Siemens control systems to Allen-Bradley ControlLogix® systems. Although our client’s field instrumentation had become obsolete, EAD was able to overcome the problem by identifying instrumentation and designing protocol conversions and software to accommodate for differences among the protocols and data structures.
As part of our system migration, we were also able to identify and address issues related to our client’s existing network infrastructure, Wonderware® SCADA configuration, and field devices that did not work as they should. By the end of the project, our client had a robust system with an expected lifetime of over 20 years.
The success of the system migration hinged on our understanding of our client’s needs and our ability to work within their standards. EAD was able to meet all client requirements on-time and within their budget, reducing the frequency of facility downtimes, and lowering our client’s maintenance costs. We understand our clients’ need to minimize downtime as much as possible as it impacts profitability. All our solutions are robust and geared towards increasing reliability, efficiency, and safety. EAD received praise for how well we communicated throughout the execution of the project, working hand-in-hand with the operations team to ensure the seamless adoption of the new system.
Among a range of other services, EAD provides control system modernization services and control system design services for the mining industry. As an industry leader, EAD has years of experience in designing customized solutions that address challenges and cater to unique client requirements.
We also have expertise in custom control panels, control systems integration, technical services, and support. Our staff consists of highly trained automation professionals with years of hands-on experience in instrumentation and industrial engineering.
Our people are what distinguish us from the rest – the best and brightest minds in the industry. They are equipped with not only the expert knowledge but also the tools and techniques to provide the best solution that helps you succeed.
- Reduced the risk of a hardware failure and months of downtime
- Seamless execution that met all project and budget requirements
- Siemens® to Allen-Bradley ControlLogix® system migration
- Solutions for HMI & SCADA Applications
- Network Infrastructure Design Improvements
Looking for control system expertise and support? Learn more about what we do on our services page or get a hold of us by visiting our contact page or give us a call at 402.884.8650.