Project Overview
A major system upgrade was completed efficiently, including the transition of 1,300 I/O points to a new PLC system in under four hours and full software integration within two days. To optimize operations across 1,500 flow paths between 70 storage tanks and production equipment, a smart pathway optimization algorithm was implemented, automating flow verification and selection. Additionally, five aging Square D PLC systems were successfully replaced over a single weekend, ensuring minimal disruption and improved system performance.
- Pathway optimization algorithm
- Existing wiring field verification before start up
- Custom interface card that reused the old Square D wiring harness – switched over 1300 IO to the new PLC upgrade in less than 4 hours with three CPS field technicians
- Preinstalled new PLC panel and prewired to existing IO panels for fast conversion
- Redundancy – GE Redundant PLC, Cimplicity Redundant HMI Servers and Redundant Profinet IO Networks
- Front Office Integration – Production Scheduling, Reporting
- Scalable to other tank farms and process equipment
