Empowering people. Exceptional services. Delivering on promises. PLC5 & SLC to ControlLogix/GuardLogix Conversions A Project Profile

Transcription

1 Empowering people. Exceptional services. Delivering on promises. PLC5 & SLC to ControlLogix/GuardLogix Conversions A Project Profile Prepared by ESCO Group, June 2016

2 Empower people. Exceptional services. Delivering on promises.

3 ESCO Group Part of your team We are ESCO Group, headquartered in Marion, Iowa, with satellite offices in Des Moines and Fort Dodge, IA, and in Louisville, CO, near Denver. Because of our locations and our size, we are capable to taking care of our clients needs, whenever, and wherever they may be. Our flexibility and versatility has sent us all over the world doing projects for our long-term clients. ESCO Group is a parent company with three business units: ESCO Automation, ESCO Electric, and ESCO Safety. With our three business units, ESCO is in the unique position to offer our clients a variety of services to meet their needs and their production goals. When you work with ESCO, you are working with a company that forms strong relationships with our clients which gives us in-depth knowledge of your plant, what its needs are, and how it runs. It s a partnership approach, meaning we partner with our clients in business and become an integral part of your team. Page 3

4 Project list ESCO Automation: Examples of conversion projects Cereal Cereal Delivery Cereal Bulkhouse Cereal Packaging Utilities (Chillers) HVAC Snack Packaging Snack Snack Delivery Douglas Casepackers (OEM) Frosting Mix es Media Milling Batching System PLC5/Foxboro to CLX via Ethernet PLC5 to CLX via Ethernet PLC5 to CLX via Ethernet PLC5 to GuardLogix via Ethernet PLC5 to CLX via Ethernet PLC5 to CompactLogix (EMS) via Devicenet to drives PLC5 to CLX via ControlNet and Remote I/O PLC5 to GuardLogix via Ethernet PLC5 to CLX via ControlNet PLC5 to CLX via Ethernet PLC5 to CLX and VFD Conversion Partial PLC5 to CLX while keeping PLC5 Chassis Remote I/O and safety circuit upgrades 2013: SLC 5/04 via DH+ to CLX via Ethernet. One SLC remote rack changed to CLX. 2014: SLC 5/04 via DH+ to CLX via Ethernet. One SLC remote rack changed to CLX. 2015: SLC 5/05 to CLX via Ethernet. Four (4) SLC remote racks change to CLX remote racks. PF755 Drives over RIO to Ethernet. Partial PLC5 to CLX while keeping PLC5 Chassis Remote I/O. Page 4 SOLUTION DRIVEN

5 conversion ESCO completed a Packaging Line Conversion Project in 2012 for a longterm client in the food and beverage industry. In this project 12 PLC5 ors were converted into one GuardLogix or, with Safety I/O and standard ControlLogix I/O via Ethernet. To keep some machinery in the Bulk Area operational during the upgrade, the project had to be done in intermediate phases. This required an in-depth evaluation of OEM equipment and engineering to determine both the electrical and mechanical splits required. There was very limited physical capacity to incorporate all the controls and equipment essential for the panel, so the ESCO engineers had to plan accordingly to overcome this challenge. With design and planning, all the required equipment was installed successfully. Another challenge that occurred in this project were nuisance hardware overcurrent faults on the newly installed PowerFlex 70 VFDs. After verifying there were no design issues, ESCO worked with Rockwell and performed field analysis of: conduit routes, conduit fills, motor grounds, panel grounds, and VFD grounding. In the end it was determined there was a failing motor on an unrelated adjacent system. The packaging line conversion was completed successfully, meeting our client s expectations by converting all the processors into one, making the line more efficient and reliable. This improved their productivity with a better utilization of their assets and made for easier trouble-shooting, which lead to less downtown. The Advantage Improve productivity with better system performance and asset utilization Promote globalization with accessible plant-wide information Support sustainability by extending the lifecycles of your products Cultivate innovation by increasing system flexibility and decreasing risk Page 5

6 conversion ESCO began this project with the task of doing an engineering and cost analysis of converting the processors from PLC5 to ControlLogix, or converting all racks to ControlLogix hardware. This analysis also incorporated an upgrade from PanelView to Wonderware. After consideration of the cost analysis, our client was able to use valuable information to decide on initially completing a partial conversion where the processors were converted to ControlLogix. ControlNet was used to talk to the remaining chassis. There were two SLC chassis on Remote I/O that couldn t be converted to Controlnet, so those were left on Remote I/O. They were eventually converted into ControlLogix in a follow-up project. The warehouse conversion was completed successfully, meeting our client s expectations. The cost analysis gave our client the information necessary to make important decisions for their plant, their productivity, the lifecycles of their products, and the decreased risk that migration offers. Once the decision was made, ESCO was able to perform all the tasks required to upgrade the system. Page 6 SOLUTION DRIVEN

7 palletizers... A long-term client asked ESCO to convert five palletizers, four stretchwrappers, and the associated conveyors to GuardLogix from PLC 5. This project was completed in phases to ensure the production line would continue to run efficiently, cutting out costly downtime for our client. Because unnecessary machinery stops were engineered out, the safety and operation of the equipment was more reliable and productive. This project required ESCO Automation to: Work with operators to design and size panels in a fashion that would not impair their flexibility and visibility in the working area. Maximize space in the panels that were re-used on equipment to fit all the new controls equipment. Redesign hard-wired safety circuits to GuardLogix Safety I/O via Ethernet. Complete panel design and verification of electrical schematics. Redesign the power distribution to simplify implementing safety contactors and reduce the number of transformers from three to one. Developed and executed a Safety Validation with the clients Safety Representative. Page 7

8 conversion ESCO was contracted to complete a process conversion project by a longterm client in the food and beverage industry. This project would require three phases in order to achieve the intended outcome. Phase 1 In this phase of the project, ESCO designed new servo panels with Ultra3000 controllers to work with ControlLogix processors. These processors worked in parallel with an existing PLC5 processor. Phase 2 This phase of the project required ESCO to replace PLC5 Remote I/O with ControlNet. Phase 3 In the final phase of the project, ESCO converted ControlNet PLC5 chassis to CLX chassis. There was also a modification and redesign of the field devices to swap sourcing inputs/sinking outputs to more conventional sinking inputs/sourcing outputs model. The process conversion was completed competently and timely, increasing the production value of the plant. Page 8 SOLUTION DRIVEN

9 conversion In 2012, ESCO worked with a client to create a phased approached migration plan for converting multiple press/ dryer lines. The following year, ESCO implemented the first press/dryer line converting a SLC 5/04 via DH+ to CLX via Ethernet. A second conversion then occurred in In 2016, ESCO was asked to perform the third press/dryer conversion. This request was to convert a SLC 5/05 to ControlLogix. The system had four SLC remote racks, that were replaced with ControlLogix racks. The project also called for two Powerflex 755 drives to be converted from RIO to Ethernet. Keeping our client s production time as a top priority, ESCO only required a week of downtime for all racks to be rewired from SLC to ControlLogix. Only one additional week was then used for all I/O checkout and sequence testing, making this project a successful, but timely one. Efficiency and expert project management was key to the success of this endeavor. ESCO was able to meet the client s expectations in a responsive and reliable manner. Page 9

10 batching system A project involving converting a media milling batching system was brought to ESCO from a long-term client. The client needed a PLC 5/60 converted to a ControlLogix. The system had six PLC5 remote racks and four PowerFlex drives. The upgrade to the ControLogix also needed to add batching functionality to the existing controls system, which ESCO was able to achieve. Lastly, the client required the upgrade to the PLC, and additionally requested an upgrade to the PLC I/O in the future. This allowed the client to add the batching functionality and upgrade the PLC with minimal installation risk and cost. Page 10 SOLUTION DRIVEN

11 The value added Keeping your plant on a consistent and dependable production schedule is key to keeping your costs down and your profits up. By taking steps to make improvements to your plant through PLC conversion, allows you to avoid slow production times or costly machine inefficiencies. ESCO has a lot to offer clients with our expertise and extensive training in these products. We are a Recognized System Integrator with Rockwell Automation which makes our understanding of projects such as these, exceptional. ESCO also has great relationships with our suppliers, meaning that our clients reap the benefits of our professional discount on products and parts needed to complete these projects. Our goal is to bring value to our clients through our services and our relationships, therefore positively affecting your company s bottom line. Recognized System Integrator ESCO Group 3450 Third Street Marion, IA (319) phone (319) fax Chad Burlingham Account Manager (319) Ryan Haskin Project Manager (319) Page 11

12 Corporate Headquarters 3450 Third Street P.O. Box 708 Marion, Iowa (319) phone (319) fax 2100 Dixon Street Suite C Des Moines, Iowa (515) phone (515) fax 357 S. McCaslin Blvd. Suite 200 Louisville, Colorado (303) phone (720) fax 9 South 1st Street Fort Dodge, Iowa (515) phone (515) fax us at sales@theescogroup.com