CASE STUDY
Legacy PLC-5 Migration Improves Reliability of Blending Operations
Industrial Minerals Producer
Industrial Processing / Minerals
Project Management; Control System Design & Programming; PLC-5 to ControlLogix Conversion; HMI Replication & Integration; Commissioning & Startup Support; Service Contract
Overview
TMPC supported a critical controls modernization effort at a U.S. Silica blending facility in Ottawa, IL by upgrading the legacy PLC-5 system to a modern ControlLogix platform. The migration covered the main blending PLC and all associated remote I/O racks, with full replication of Wonderware HMI screens and a phased implementation plan to minimize downtime.
Problem
An aging PLC-5 control system posed operational and support risks, while tight production schedules required that the upgrade occur with minimal disruption and without loss of existing functionality.
Solution
TMPC engineered a phased migration strategy, developing an updated PLC-5 program for transition, a new ControlLogix application with Ethernet-based I/O, and Wonderware HMI replication. TMPC provided on-site commissioning, I/O checkout, and operator training during a scheduled outage.
Results
- Modernized blending system controls without extended downtime
- Reduced risk from obsolete hardware and improved maintainability
- Seamless transition for operators using replicated HMI screens
- Successfully commissioned and returned to production on schedule
