FEATURE COMMUNICATIONS & NETWORKS
EFFICIENT AND EFFECTIVE UPGRADE MEANS SIMPLER, FASTER MIGRATION
A Connected Enterprise approach brings many benefits, and because Ethernet/IP is based on standard, unmodified Ethernet, it means that very little needs to be done for these connections to be established. Full security solutions are also available for user control and to prevent unwarranted access
Datastor Systems has helped a livestock compound feed manufacturer migrate its legacy system to an up-to-date automation solution from Rockwell Automation
A
BN is a leading British manufacturer of monogastric compound feed,
providing both products and complementary solutions to the pig and poultry livestock industries. The company operates 10 mills across the UK and is owned by Associated British Foods. Automation is an integral part of ABN’s
plan to operate its facilities as efficiently as possible. Blending, grinding, pressing and bagging processes require precise control to help enforce the stringent ingredients, processing and quality levels demanded by both ABN and its customers. The company recently reviewed its
network capabilities and automation products at its Bury St Edmunds plant. The review highlighted that equipment was beginning to show its age – both in terms of performance and obsolescence – and was in need of upgrade and replacement. It called upon Rockwell Automation Recognised System Integrator Datastor Systems who appraised the existing infrastructure and recommended a system migration over to a new Integrated Architecture control and network solution based on Rockwell’s Allen-Bradley products and running on a modern EtherNet/IP network. The primary challenge faced by Datastor Systems was the development of an efficient and effective migration strategy, which encompassed the phasing of the old system over to the new infrastructure – without too much disruption to production operations. This meant that the old and new system had to overlap and operate in tandem before the final switchover. With obsolescence and migration becoming more commonplace as
40 NOVEMBER 2016 | PROCESS & CONTROL
automation solutions undergo constant evolution, Rockwell Automation already had in place a migration solution that has been successfully deployed throughout the world. This meant that a lot of the hard work could be removed from the project, with just the application-specific demands creating the challenges. Bill Wright, managing director at
Datastor Systems, explained the approach at ABN: “We compiled a document based on a traffic light system that detailed the current state of spares in terms of ‘available’, ‘not available’ and ‘readily available, but heading into obsolescence’. The completion of this analysis highlighted the need for a new solution and it was at this stage that we spoke with Rockwell Automation and discussed its Logix system and its PLC-5 migration tools.” The large migration at ABN, phased over four weekend shutdowns, comprised the replacement of the core network, multiple controller changes, and the incorporation of a SCADA solution that runs on PCs above the new programmable automation controllers (PAC). “We decided to utilise the Allen-Bradley 1771-to-1756 IO Swing-arm Conversion System,” Wright explained. “This enabled the current PLC-5 I/O to be used, while using the latest Allen-Bradley PACs, thus minimising the need for new electrical wiring. As a result, it provided a cost saving to the client. You can use the existing swing arm with terminal wiring and use push plugs into new backplane. The changeover time is a lot less as you don’t have to rewire, thanks to the reuse of existing terminals and backplanes.
“Along with the replacement of the PLC- 5 controllers,” Wright continued, “there were existing SLC-5/04 controllers that had to be brought into the new ControlLogix PAC environment in both the grinding and blending areas. This was achieved using the existing SLC I/O in the plant with 1747-AENTR EtherNet/IP adapter modules. These modules provide an Ethernet link back to the main ControlLogix PAC so the SLC I/O could be used as remote I/O.” By using EtherNet/IP as the primary
communication protocol, Datastor can offer its customers remote monitoring and maintenance, with the option to connect the machine into its customers’ Connected Enterprise. This helps manufacturers create a more competitive enterprise that can improve productivity, sustainability and economic performance. Other benefits of access to real-time, contextualised information, include minimised downtime, improved technology and process optimisation, greater workforce efficiency and smarter expenditure. The Rockwell Automation migration solution saves time and is inherently less prone to the risk associated with a full rewire, such as wrong connections. “We have migrated other I/O platforms over the years,” Wright explained, “and the Rockwell Automation system is a huge improvement. This project went live January/February 2015 and so far there have been no issues; it has all worked really well and there is the added comfort factor that the network is now more secure and more robust.” He continued: “We can also now connect
remotely thanks to the use of EtherNet/IP, and the new network is far faster and slicker than the old system’s DH+ network. ABN has asked us to provide remote support at all ABN sites thanks to these new networks and we have given them the ability to have their own remote access.” According to Lindsay Sharp, Group
engineering manager at ABN: “The new network and controllers are giving us really clear levels of visibility into our processes and infrastructure. The future upgrade path is also less complicated and more straightforward due to the use of open
protocols...The whole integrated approach will help us to maintain our quality and control levels so we can keep our customers happy.” Wright concluded: “The Rockwell
Automation solution was not the cheapest option available, but in the long term there is a definite cost advantage in terms of OEE, asset utilisation and overall life costs.”
Rockwell Automation
www.rockwellautomation/com/en_uk/
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