Experience example

Legacy PLC Migration

"You wanted to be in this business, so you better harden up!" - Jennifer Lopez

Industry
Manufacturing

Sector
Food

Segment
Production Systems

Project

  • The client is global dairy nutrition company, employing over 1,500 people in Australia.
  • The client identified that a Soft PLC installed at their Tasmanian facility presented an operational risk.
  • The Soft PLC was operating on a system with an aging processor, there was limited local support and a failure could take production down for a significant period.
  • To address the risk and to facilitate an upcoming process upgrade the client desired to upgrade the Soft PLC.
  • The plant could only be shut down for one day to allow the upgrade to be completed.
  • Based on a long history of working together the client trusted Cromarty to deliver the project.

Solution

To deliver the required outcome Cromarty:

  • Extensively planned the design, equipment, materials and installation work required to successfully implement the upgrade.
  • Converted the code and identified all consequential changes required in dependent PLCs and SCADA screens that interface directly or indirectly with Soft PLC.
  • Carried out comprehensive simulation testing in advance of the deployment to prove all functionality before cutover.
  • Worked closely with the client to develop a deployment strategy.
  • Performed the upgrade works in accordance with the agreed strategy.
  • Ensured the functionality such as control sequences, alarms, and measurements post deployment were the same as before deployment, such that no operator re-training was required,
  • provided engineering support post 7 days after changeover.

Outcome

A famous golfer once said, "the more I practice, the luckier I get", this is evident in how smoothly the upgrade was implemented. The window for the upgrade was opened and closed in one day and production didn't miss a beat. Cromarty not only met but exceeded the clients brief.

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