Project and industry:
Moore Process Controls undertook a modernisation initiative spanning the mining, petrochemical, and oil & gas sectors. This project involved upgrading legacy Siemens ET200M I/O systems to the advanced ET200SP HA platform.
The primary aim was to bring ageing infrastructure in line with contemporary, supportable technology, ensuring operational continuity while minimising both cost and disruption.
Project Outcome:
The modernisation of legacy installations was achieved while retaining much of the existing infrastructure.
Key outcomes include:
• Extended asset life: ET200M systems were upgraded without the need for full panel rebuilds.
• Future-proofed operations: The new platform is compatible with Siemens S7-1500 and PCS 7 systems.
• Reduced risk and cost: Reusing existing wiring and cabinets lowered risks and expenses.
• Improved scalability: The modular ET200SP HA architecture supports flexible expansion.
• Maintained operational continuity: Implementation caused minimal disruption to production.
This resulted in a flexible, future-ready automation solution that supports ongoing plant growth and digital transformation.
Biggest challenge and solution:
The project overcame several significant industry hurdles:
• Legacy hardware: ET200M and S7-300 systems are discontinued, limiting the availability of spare parts.
• Obsolescence risks: Integrating modern automation technology was difficult with outdated platforms.
• Space constraints: Existing cabinets were not designed to accommodate new-generation hardware.
• Operational risk: Ageing systems increased the likelihood of failure and downtime.
Moore Process Controls implemented a practical, low-risk migration strategy as a solution, including:
• Plug-and-play migration: Adapter housings with D-SUB connectors enabled direct connection between existing ET200M cabling and ET200SP HA modules.
• Mechanical adaptation: Custom mounting brackets (8HR35 series) allowed for piggyback installation on existing S7-300 rails, preserving cabinet layouts.
• Flexible installation: Adjustable bracket spacing facilitated installation within legacy cabinets, avoiding major rewiring.
• Minimal downtime: Using existing wiring harnesses significantly reduced commissioning time and plant disruption.
• Engineering support: EPLAN macros and detailed wiring diagrams ensured consistent, efficient, and error-free implementation.
This approach enabled a seamless transition to modern automation, maintaining production stability throughout the process.
Key technologies:
• Siemens ET200SP HA distributed I/O
• Siemens S7-1500 and PCS 7 compatibility
• Adapter housings with D-SUB connectivity
• Custom mounting brackets (8HR35 series)
• EPLAN macros and wiring documentation
One thing we would do differently:
A greater focus on early-stage assessment of cabinet layouts and legacy constraints would further streamline installation and reduce on-site adjustments.
Unique selling point:
Moore Process Controls provides smart, low-disruption modernisation, enabling plants to move from obsolete systems to future-ready platforms without costly rebuilds or extended downtime.
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