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PLC/HMI System Upgrade

About

Client: CONFIDENTIAL
Location: Salisbury, MD
Completed: <$1MM
Value Class: 2014

This Client is a leading provider of grains, oilseeds, soybean meals, hulls, vegetables, refined oils, palm oils and other related agricultural products.

Project Details

The Client upgraded a 25-year-old PLC control system in the Edible Oil Refinery of their Soybean Processing Plant. The project involved the replacement of three Allen Bradley PLC5 controllers and all associated I/O with a complete Allen Bradley ControlLogix system.  In addition, the HMI system which consisted of six operator workstations running out of date software on old computers were upgraded to state-of-the-art computers running Rockwell FactoryTalk View Site Edition software.

TAI designed a custom PLC-5 to ControlLogix Conversion system which allowed a phased in panel-by-panel approach. Existing panels where reused. Field wiring was left untouched to minimize possibility of wiring errors. The conversion was accomplished over multiple weekends during the plant’s downtime, which minimized production outages.

TAI developed the drawings and construction documents needed for a panel shop to build the replacement I/O subpanels as well as for the electrical installation work. TAI wrote all the PLC code to convert the code from PLC-5 to ControlLogix and to communicate with the new Ethernet-based I/O. TAI converted all the HMI graphics from the old RSView format to FactoryTalk View and brought the graphics to state-of-the-art quality. TAI also provided and configured report generation software to provide automated shift reports.

Key Technologies
  • Rockwell FT View SE, Standalone
  • XLReporter by Sytech
  • Allen Bradley ControlLogix
Relevant Project Details
  • TAI provided 1 new PLC Panel (to replace 3 existing PLCs)
  • TAI provided 4 new HMI workstations.
  • TAI provided 17 new Remote I/O Subpanels
  • TAI provided all engineering and integration of new PLC panels, subpanels, and HMI workstations while the plant was in operation, with limited downtime availability for plant tie-ins.
  • TAI worked with the client to establish a remote link to the system over the internet to provide remote PLC programming and diagnostic services.
  • TAI provided all start up services which included supervising the installation and configuration of all new PLC hardware and operator workstations, I&C checkout, commissioning and operator training.
Key Deliverables
  • Complete As-Built Electrical Drawing Package
  • On-site commissioning Support
  • Close coordination with the plant maintenance staff and electrical contractor.
  • Modern Control System.
Results

The upgrades made the control system current which also allowed for immediate and future growth. The plant was able to double its capacity under the upgraded control system. Additionally, the new equipment was integrated and commissioned into the existing new system without needing to stop plant production.

Services Provided:

  • Commissioning Services
  • PLC/HMI Programming
  • Project Management
  • Start-Up Services

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