Transicon upgrades redundant GEM80 PLC and SCADA system on Aluminium Plant - without downtime

Home > Case Studies > Transicon successfully upgrades redundant GEM80 PLC and SCADA system on Aluminium Plant – with ZERO downtime

Customer Requirement

  • Our customer needed to upgrade their GEM80 PLC Master / Standby System to the latest Emerson RX3i PLC range
  • Replacing the GEM80’s needed careful planning as the plant needed to be running 24/7 during the upgrade phase
  • The systems comprised of over 2,800 rungs of code with over 1,400 Digital I/O points and 64 Analogues
  • The two systems needed to be synchronised for a bumpless change over
  • SCADA Server had to be fully operational during the upgrade phase

Our Solution

  • With our expert knowledge of the GEM80 range and Emerson (ex GE) PLCs the code was migrated with success
  • Due to the need for no interruption of the process during installation the conversion was fully tested with plant simulation code within our factory.
  • Our customer was able to witness and control our Factory Acceptance testing remotely using our digital twin.
  • Our in-depth knowledge of PCVue/P1200 SCADA enabled us to migrate the graphics to the new platform.
  • With our unique phased approach Transicon installed and commissioned the new system in under 4 days, whilst maintaining production, much to the satisfaction of our customer.
  • Transicon have also successfully carried out conversions to Siemens / Rockwell PLC’s