Process plant
Legacy PLC migration and SCADA modernization
- Scope
- Controller migration, SCADA rebuild, alarm rationalisation, FAT and SAT
- Timeframe
- Pending confirmation
- Customer
- Not named — approval pending
The challenge
Controllers were past support with no spares available, and the engineers who wrote the original logic had left. Years of undocumented changes meant the program was the only remaining record of how the process actually ran, and the migration risk had been deferred repeatedly.
What we did
- Existing logic captured and documented before any replacement was designed
- Process behaviour reviewed with the operators who run the plant daily
- New controllers engineered in TIA Portal with structured, commented code
- SCADA screens rebuilt around operator decisions, with alarms rationalised
- Factory acceptance testing before shipment, then site acceptance testing during an agreed shutdown window
- Source code, documentation and rights handed over on completion
Results
Measured results for this project are not published yet. Customer name and measured results awaiting written approval. Rather than print a number we cannot attribute, this section stays empty until the customer signs off on the figures and how they were measured.
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