Project Overview
In a strategic move to modernize aging infrastructure, an ESCO customer initiated a two-phase upgrade of one of their critical control systems that feeds raw product into the plant, transitioning from a legacy PLC-5 system communicating on Data Highway Plus (DH+) to a ControlLogix platform using Ethernet/IP. The project was led by ESCO Automation and executed in collaboration with ESCO Electric and a local electrical contractor.
Phased Execution
The project was carefully split into two shutdown windows to minimize disruption:
Phase 1: Completed during the 2024 shutdown, with ESCO Automation partnering with ESCO Electric for installation and commissioning.
Phase 2: Executed during the 2025 shutdown, with support from a local electrical contractor.
Both phases were completed on time and within the shutdown windows, ensuring uninterrupted operations post-upgrade.
Technical Scope
– Replacement of the legacy PLC-5 system with ControlLogix GuardLogix 5580 controllers.
– Deployment of 9 new 17 Slot ControlLogix I/O racks across multiple different control panels, with standardized customer components.
– Implementation of a modern ethernet network using Stratix network switches for robust device communication.
– Updates to Wonderware SCADA screens to align with the new control architecture and latest plant standards.
Design and Documentation
Detailed engineering drawings and BOMs were developed by the electrical design team and reviewed collaboratively with the software development team, and the customers engineering staff. Feedback from all parties helped refine the documentation to match field conditions and program logic and control sequencing. The final design files captured the full scope of the control system layout and network configuration.
Collaboration and Coordination
The project’s success was driven by strong cross-functional collaboration:
– ESCO Automation led the design, programming, and commissioning efforts leveraging multiple teams internally.
– ESCO Electric and a local contractor handled field installation and commissioning support.
– Our customers engineering staff provided critical input on standards, preferences, and field conditions.
Regular meetings and status updates ensured alignment across all stakeholders, with timely resolution of design questions and material selection challenges.
Outcome
– A modern, Ethernet-based control system with improved reliability and maintainability.
– Enhanced SCADA visualization and operator interface.
– Compliance with the customers’ current design, programming, and safety standards.
Written By: Cole Banes, ESCO Automation, Electric Design Manager