A well known beverage manufacturer based in Glasgow, had ongoing obsolescence issues with their existing, site-wide, (20+i-Fix nodes) SCADA system. Due to the fragmented, ageing system on site a decision was made to upgrade the full SCADA system to make it more modern, resilient, and secure.
Elite’s engineers started working on the 9-month long project by merging and optimizing the existing databases into a single database. Elite removed numerous duplicate data tags and modernised some of the technologies that were previously used. Various differing versions of the site-wide SCADA node’s were upgraded to the latest revision.
In addition, a total of 9 servers were merged into a single (cloud based) unit whilst the existing servers were all virtualised.
As a result, our client can now merge & expand their plant system with ease and less potential downtime implications. Routine maintenance is easier with regular backups now performed automatically with less strain on the plant resources. The system is significantly more secure and much more flexible for remote access from an administering perspective.
Elite is once again proud to support local business, providing modern and effective engineering solutions to our customers!
Our customer, a main manufacturer of whisky and spirits, required to optimize and simplify the cereal intake process in their distillery. The project included the removal and replacement of obsolete equipment and the optimization of the control system.
The scope of the project included replacement of an old MCC and the design and installation of Siemens S7 based process control system. In addition, the new S7 system required integration with the existing ABB DCS. Following implementation and testing, site installation of MCC and commissioning took place. Solution developed by Elite has additionally incorporated a client/server SCADA based network and a HMI for Process Visualization, Management, Maintenance, Diagnostics and Standard features for alarming, trending and user configuration.
The new system employed has been optimized simplified compared to the previous iteration. The new process control equipment should be more efficient and reliable. Operation and maintenance personnel have improved monitoring and diagnostic capability available in runtime; this in turn should help reduce plant downtime.
Expanding on the knowledge and expertise gained by Elite, we are once again proud to offer a solution to one of our key clients and build upon our relationship with our partners.
Following the successful completion of a project last year for a major manufacturer based in Slovakia, Elite were asked to further enhance and expand the client’s control system. The original control system in the new state of the art plant, produces the syrup that is used for the manufacturing of kitchen sinks.
The original control panel design, PLC software programming and designing of the HMI Screens were carried out at Elite’s site in Livingston, with a site visit to Slovakia needed for the on-site commissioning.
The commissioning phase for the system expansion proved to be quite a challenge due to the critical nature of the existing process. Any code modifications or additions had to be performed in a 2-hour window, as this was the maximum permitted downtime.
The entire expansion project lasted around 3 months from initial development to commissioning.
The original hardware used for this work was based on Rockwell’s standard and safety Compactlogix PLC’s.
Linked via Ethernet, these PLC’s were expanded to accommodate the additional control requirements.
Due to the existing installation being an Elite-developed solution, the development for the expansion became much more streamlined and this definitely helped the control expansion to run smoothly.
The successful outcome of this work means that our customer has now doubled their manufacturing capabilities when compared to the previous layout of the plant.
Following many years of operation, the Siemens S5-based PLC used at out clients’ site was becoming ever more difficult to maintain. Replacement parts were also becoming more and more difficult to source, due to the length of time the PLC had been deemed as being obsolete. In addition, fault finding on the old system was very problematic. Upon an occurrence of a fault, it was very difficult to determine the root cause of the issue. Due to the critical nature of the system, there typically wasn’t time to request Elite to attend site and help to determine the cause. Elite was asked to provide a more modern, upgraded solution incorporating a new PLC and HMI.
The solution implemented has incorporated the use of a Siemens S7-1500 Series PLC. This was programmed using the latest Siemens TIA Portal software with integrated Advanced Safety features.
The existing PLC code was migrated in stages from STEP5, to STEP7 Classic, and then to TIA Portal. In addition, the HMI was further enhanced and programmed to receive system messages related to the exact cause of fault events. These were then presented for display on the alarms mimic.
Our client has achieved the goal of their project, and can now identify various faults with ease given the capabilities of the modernised system. In addition, due to the relevance of the upgraded system, all spares can be sourced with ease and cost effectiveness. It should also be noted that the reliability of the system has also been improved significantly.
Elite is once again proud to offer a ground-breaking solution to one of its key customers and look forward to new challenges in the future.