The Project: Design a Flexible Control System that Allows the Client to Scale

A cheese production facility had three PLC5s critical to daily operations at full capacity, creating a bottleneck for an expansion of ongoing reporting projects. Acknowledging there was an immediate need to remove the existing PLC5s for a ControlLogix replacement, they contacted E Tech Group to facilitate the control system upgrade. Having worked with the customer on a CIP automation project, and their intimate familiarity with the three PLC5s, our team was already up to speed and could act quickly. 

The Challenge: Upgrade, Integrate & Implement on a Tight Timeline

The project team had to determine physical and communication connections. The challenge was the existence of multiple DeviceNet networks to existing MCCs with legacy VFDs. Additionally, IO was dispersed over many areas, in multiple panels requiring process knowledge of the core of the facility. 

Working with the exact opposite of a fully-integrated automation system inside of a 12-hour timeline to completion would require a creative approach to converting and integrating the new controls.

The Solution: Work With & Around Existing Automation Infrastructure

To minimize the downtime necessary to implement the new control system, all PLC5 IO racks were retained in place and a custom control system panel was designed and installed to house the new Controllogix PLC and associated communications modules.  

During onsite support, the project team was able to convert a PanelView Plus that had previously been overlooked to the updated application communications. Our automation team had 12 hours to complete the conversion, which involved taking over existing IO, doing point-to-point checks and validating the HMI. This timeline would allow the client to begin their CIP process before production the next day, with the new ControlLogix installed.

IO Lists were developed to help with commissions, and detailed DeviceNet networks were documented. The team also solved challenges from non-default DeviceNet Node configurations and transitioning RIO communications to remote racks. 

The Results: Scalability, More Data, Enhanced Visualization

The existing Wonderware Applications used for SCADA were updated by E Tech Group’s engineering team and communicated on the first attempt. The project team was able to meet and exceed the tight conversion schedule, with the customer beginning CIP sequences within 10 hours. Following these updates, the project team provided 48-hour continuous onsite support, available to assist with any immediate issues. With this project completed, the customer was able to benefit from the improved reporting, visualization and connectivity with the upgraded PLC system.