After a full review of the existing control system for an RO plant it was identified that the majority of automation items were at the end of their life cycle and were no longer supported.
A package was put together to replace the existing PLC with a new PLC in a standalone panel along with its associated IO. The existing instrumentation would be wired back to the new panel, allowing for expansion in the future.
The new software program and SCADA mimicked the existing operation, all existing setpoints, process and CIP were replicated in the new package. This allowed for a smooth change over from an operators point of view, as there was no change in the operation of the plant.
Due to very short shutdown windows, meticulous planning was required and the change over was accomplished in three different phases. Each phase bought part of the new system online until following the final phase, all of the original equipment was removed.
