Managing control system upgrades.
Technology continues to evolve rapidly, so industry is continually seeking to keep pace with new trends in control systems. This need is well understood by manufacturers worldwide, but the challenge remains to implement upgrades without costly downtime or production loss. “It is an issue that needs to be addressed continuously,” says Steve Gerber, automation product manager, Schneider Electric South Africa. “Internationally and in South Africa, we are partnering with industrial companies to help them plan and perform plant modernisation easily, efficiently and at their own pace.”
Industrial systems around the world are ageing and Gerber says a significant number of control systems currently in operation are nearing the end of their useful lives. “Plant managers are becoming increasingly aware of the fact that in order to remain competitive they need to align their infrastructures with the latest technology standards. To accomplish this they face the demanding task of planning a system upgrade, which amounts to much more than a process change. A total system modernisation means undertaking a thorough audit, risk identification, a well-defined road map and a lifecycle support plan. Such a strategic undertaking deserves competent and professional support.”
Gerber says that with an impressive history in the automation, control and distribution business, Schneider Electric is qualified to address these concerns. Over the past 40 years the company’s automation products – including PLC, HMI, IO, drives and scada – have been installed across multiple applications in South Africa and around the world. “Even the most reliable products eventually age, so we devised a complete support solution for our users, offering consulting and upgrade services that help to retain previous investment in knowledge and equipment, while assuring a state-of-the-art level of efficiency and productivity throughout the lifecycle of a plant.”
Schneider Electric’s modernisation make upgrade implementations as quick and easy as possible at all levels of the plant architecture, including hardware, software and the plant network.
Gerber explains that Modicon customers can now upgrade to the latest Modicon Quantum PLC while retaining 100% of an existing 984 application. “We have also developed a sixth programming language in Unity Pro software that allows users to retain prior applications within the same programming environment.”
Users can also modernise their software by simply porting developed algorithms to the new platform. Based on a similar, user-friendly interface, Gerber says this programming suite tests, develops and manages applications, while offering improved throughput, reduced downtime and better process visibility.
Users of the Modicon Compact 984 PLC can upgrade to the cutting-edge Modicon M340 PLC while retaining their existing field wiring. With the quick-wiring adapters replacing the controller is simple and time-efficient, giving users quick access to the high-end capabilities of the new M340, including improved networking, data processing, and response times. Towards the end of 2012, users will also be able to import their 984 applications to Unity Pro while upgrading to M340. Modernisation solutions for the plant network include a full upgrade to the latest networking standard of Ethernet and Factory Cast HMI, or adding a proxy to the existing Modbus+ in order to ensure connectivity to other PLC and HMI/Scada devices without reprogramming.
“Our path to modernisation is based on PlantStruxure, an integrated solution that allows industrial and infrastructure companies to meet their automation needs and, at the same time, deliver on growing energy management requirements,” says Gerber.
“Working closely with customers we can ease the transition to innovative industrial process management. By retaining the previous investment as well as the accumulated know-how of the operating personnel, system users can now access the latest electronic components, reduce maintenance and ownership costs, as well as increase reliability and productivity.
“Schneider Electric supervises and manages this change hand-in-hand with the customer and the system integrators, adjusting the pace to suit the individual budget and maintenance schedules.”
For more information contact Jacqui Gradwell, Schneider Electric SA, +27 (0)11 254 6400, [email protected], www.schneider-electric.co.za
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