Project Description

Project

Allen-Bradley PLC5 to ControlLogix Conversion

Location

Utah

Background

The client had an existing control system that utilized discontinued Allen-Bradley PLC5 Series controllers. The system conversion project included replacement of the outdated control system hardware and software, as well as the design and installation of a fiber network to replace the existing ControlNet communications with EtherNet/IP.

Challenges

The downtime allowed to execute the conversion was limited, and any schedule delays would result in substantial costs to the client.

Solutions

EN Engineering was responsible for all aspects of the project. The fiber network design included all necessary cabling, patching, and media conversion systems to accommodate new and existing control hardware at the station. The existing PLC5 programs were converted to the ControlLogix platform, and were modified to take advantage of modern programming standards available in the ControlLogix system. A complete proof-of-concept test was performed to validate the design prior to installation.

EN Engineering contracted and managed the installation of the new communication and control system equipment at the station. Due to the limited outage time, some of the installation was completed prior to the actual station outage. EN Engineering verified the new PLC systems and fiber network before the official station shutdown.

During the outage, a full commissioning of all field instrumentation was required to validate the new hardware and software systems, and a complete functional test of all control and shutdown systems validated the new programming. EN Engineering’s commissioning team worked 24-hour shifts until the commissioning was complete. In addition, EN Engineering created an outage schedule detailing the required tasks completed during each shift. This schedule was used as the primary metric for tracking progress during the installation and commissioning.