Control Panel Upgrade
Project Overview
ALMEC Services completed a comprehensive control panel upgrade for Rotherham Steel Works, replacing outdated relay-based control systems with modern PLC technology. This project involved designing and installing new control panels with advanced automation capabilities, touchscreen HMI interfaces, and integrated safety systems to meet current industrial standards.
Project Specifications
- Client: Rotherham Steel Works
- Duration: 4 weeks
- Services: Control Panel Design, PLC Programming, Installation
- Equipment: Siemens S7-1500 PLC, 15" HMI Panel, Safety Relays
The Challenge
The existing control system was over 20 years old and experiencing frequent failures, causing production delays. The client needed a modern solution that would integrate with their existing equipment while providing enhanced monitoring capabilities and improved safety features. The upgrade had to be completed during a tight maintenance window.
Our Solution
We designed a custom PLC-based control system with redundant safety features and real-time monitoring capabilities. The new system includes a user-friendly HMI with customizable dashboards, remote access for diagnostics, and comprehensive alarm management. All installations were pre-tested off-site to minimize on-site commissioning time.
Results & Benefits
- 60% reduction in system failures
- Remote monitoring capabilities implemented
- Improved operator safety with dual-channel safety circuits
- 25% increase in production efficiency
- Predictive maintenance alerts reducing downtime
Need Control System Upgrades?
Contact us to discuss how we can modernize your industrial control systems