Client Challenge
A specialty chemicals manufacturer needed to integrate their standalone calcium delivery system with the Main ControlLogix PLC and FactoryTalk SE Operator Interface. The legacy system, powered by MicroLogix PLCs, lacked centralized control and efficient setpoint management, leading to operational inefficiencies. The client wanted to replace the outdated PLCs with modern remote I/O modules while retaining the system’s existing functionality.
Additional requirements included:
- Modifying the existing drawing package to incorporate the new calcium I/O.
- Providing localized control and feedback in the lab room with a new PanelView touchscreen.
- Ensuring minimal disruption to ongoing operations during the system upgrade.
Our Solution
DSI Innovations delivered a seamless integration of the calcium delivery system into the Main PLC, enhancing functionality, reliability, and ease of use. Key elements of the project included:
- Control System Upgrades:
- Replaced the existing MicroLogix PLCs with CompactLogix remote I/O modules connected to the Main PLC via Ethernet/IP.
- Added calcium delivery control logic to the Main PLC, allowing centralized management of weight setpoints and improved system performance.
- Operator Interface Enhancements:
- Integrated calcium controls into the FactoryTalk SE Operator Interface for centralized monitoring and control.
- Installed a PanelView touchscreen in the lab room to provide operators with localized control and feedback for calcium system operations.
- Documentation Updates:
- Modified existing electrical drawings to include the new calcium I/O configuration, ensuring accurate records for future maintenance and troubleshooting.
- Installation and Commissioning:
- Completed wiring terminations within the existing enclosure to accommodate the new remote I/O modules.
- Provided on-site field technician support for one week and engineering support for commissioning over two weeks, ensuring a smooth transition to the upgraded system.
The Results
The integration of the calcium delivery system with the Main ControlLogix PLC delivered significant benefits to the client:
- Centralized Control: Weight setpoints are now managed directly through the Main PLC and Operator Interface, improving system efficiency and reducing manual input errors.
- Enhanced Operator Access: The new PanelView touchscreen in the lab room provided operators with localized control and real-time feedback, increasing operational flexibility.
- Improved System Reliability: Replacing the legacy MicroLogix PLCs with CompactLogix remote I/O reduced the risk of equipment failure and enhanced communication with the Main PLC.
- Streamlined Maintenance: Updated documentation ensured that future system maintenance and upgrades could be performed efficiently.
- Minimized Disruption: On-site support during installation and commissioning minimized downtime and ensured a successful transition.
By modernizing the calcium delivery system, DSI Innovations provided the client with a robust, efficient, and future-ready solution that integrated seamlessly with their existing control infrastructure.
