Eliminate Risk Associated with Obsolete Rockwell PLC Systems
Managing the lifecycle of your control system can be a daunting risk. Migrating your existing control systems mitigates expensive and extensive downtime. A poorly executed upgrade presents the same risk. Discover how our PLC-5/SLC-500 Migration Team can solve these lifecycle challenges with the experience to execute on schedule.
PLC Migration Self-Assessment
Top Reasons to Perform a Migration
- Obsolete hardware can cause downtime due to:
- Lack of spare parts
- Time-consuming troubleshooting
- Unstable connections
- Software that is difficult to navigate
- Improved throughput by decreased cycle times associated with equipment that is slower in performance
- Improved quality metrics and reduced scrap reduction rates/costs
- Reduced lifecycle costs—old equipment gets more expensive to
maintain over time - Migrate legacy PLCs and replace hard-wired relay systems with contemporary Safety PLC (like GuardLogix)—this allows safety-related programs to reside in a single controller chassis, providing flexibility in programming and troubleshooting using Studio 5000 Logix Designer Software
- Upgrade and modernize your OT Network including legacy field devices that are not ethernet capable—doing so will provide additional bandwidth for your entire control network, improve diagnostics for troubleshooting, and reduce downtime
Solutions Migration Methodology
FZ’s Migration Team developed a proven strategy that will allow you to quickly and easily migrate from PLC-5/SLC-500 controllers and 1771/1746/1747-Series I/O to an Integrated Modern Control System while maintaining the existing field wiring and physical footprint in your control cabinet. This approach will provide you with:
- A high level of confidence of on time execution backed by experience, planning and risk mitigation
- Lower conversion time
- Minimized production downtime
- Reduced construction costs
- Reduced risk by preserving existing field wiring connections
- Lower engineering costs
Benefits of Migration
- Improve reliability
- Reduced maintenance costs
- Complete system verification and
as-built documentation - Innovative process control
- Proactive implementation
- Remote support capabilities
- Easier procurement of replacement
parts
The FZ Difference
- Extensive migration experience and a formalized migration strategy
- Coordination of system install with plant turnaround schedule
- Phased migration at a rate suitable to your applications and budget
- Independent of brand affiliation
- Comprehensive project coordination engagement
- Multi-departmental support (SCADA, Electrical Engineering, Communication, Cyber Security, Measurement)
- Onsite coordination of system replacement
- Post-project support and training
Proven PLC Migration Process
Step 1: Self-Assessment Score Card (2 hours with FZ engineer)
- Review of existing control system architecture
- Identification of obsolete/near obsolete hardware/software
- Identification of current control system risks
- Migration cost estimates for AFE generation purposes
Step 2: Onsite Assessment (1-3 days based on plant size/potential scope)
- Control narrative review/update
- Shutdown key verification
- Migration of new PLC programming
- Internal integrated system testing
- Site acceptance testing (SAT)
Step 3 & 4: Compile Results & Develop Proposal (1-3 days)
- Construction coordination
- Site acceptance testing (SAT)
- Verification and commissioning
- Scheduled turnover coordination
- Operating training
- Post-installation service and support
Step 5: Present Onsite Findings and Proposal (2 hours)
- We will come back to your site and have an in-person meeting with key stakeholders
- We will review and discuss our findings and the proposal
- Outcome of meeting—define next steps and path forward
Step 6: Formal Design State
- If we agree to move forward, FZ will proceed to a design stage to build the formal design
- Once design stage is reviewed and
agreed upon, FZ will host a formal
kick-off meeting and begin project
execution.
Full Suite of Industrial Solutions
- Networking infrastructure: wired, wireless
- Vision inspection systems
- Robotics
- Digital solutions
- IIoT & Industry 4.0 solutions
- Panel build
- HMI and SCADA development
- Andon messaging
- Arc flash studies
- Data rack installation
- Plant floor maintenance
- Electrical power and automation
- Material and equipment procurement
- Fiber optic cabling
- Infrared thermography testing
- Low and medium voltage distribution
- Machine troubleshooting and repair
- Medium-voltage cable and outdoor equipment terminations
- Onsite machine wiring
- Switchgear cleaning and inspecting
- Power quality metering
- Structured cabling
- Preventative maintenance
- Lighting controls, programming, and layout
- Transformer oil testing
- Transformer setting and heavy equipment rigging
- Outdoor equipment installation
- Underground conduit and cable installation
- Trenching, excavation and vibratory plowing
- Utility locating
- Virtual Design and Construction (VDC)