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
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Testimonials

Andy and his team were a pleasure to work with. The project met all deadlines and targets. Good communication throughout. The installation and commissioning on site went extremely well with very little downtime. I would definitely recommend Transicon to anyone else looking to replace their GEM80 PLCs with a modern solution.

Controls & Automation Engineer - Aluminium Processor

Very happy with the upgrade and especially the time taken to complete the job. Would also like to give credit to the Apprentice that was brought to site with the team. I was very impressed with his skill level and must be receiving excellent training.

Section Engineer - Metals Sector

Atritor has worked with Transicon for over 20 years and that speaks volumes in itself. Transicon is far more than a supplier of electrical control equipment and software, we work with them in partnership, and they are important to the quality of the solutions we provide to our clients. They understand our processes and provide innovative and proactive electrical and installation resources. The fact that Transicon works across a broad range of sectors in automotive and manufacturing means that they not only have the depth of experience that we require, but our clients also know and trust them too. The key reason for the length of our relationship is their willingness to develop solutions with us and problem-solve on-site when required.

Background: Atritor Ltd has provided drying and milling solutions to the mineral, chemical, and mineral industries worldwide since 1980 and has over 90 years of experience in equipment manufacture to draw upon.

www.atritor.com

Simon Cheesmore – Technical Director Atritor Ltd

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