Paper Pulp Recycling Plant
We upgraded an outdated S5 PLC-controlled paper pulp recycling plant, integrating a modern control system with advanced product analysis. Our approach minimized disruption, ensured seamless integration, and enhanced operational reliability.
The Challenge
Our client required the replacement of an outdated S5 PLC-controlled paper/pulp recycling plant. The goal was to implement a modern control system with an integrated communication network for advanced product analysis. However, over the years, the outdated system had been extensively modified without proper updates to the documentation, leading to significant design challenges. Additionally, the new control system needed to integrate seamlessly with the existing plant infrastructure.
Our Approach
To address these challenges, we began by thoroughly understanding the current plant design. Given the incomplete and outdated documentation, our team conducted a detailed site investigation while keeping the plant operational. This involved capturing up-to-date information on the existing control system, field equipment, and site cabling, all while adhering to strict safety protocols and risk assessments.
We analysed the compatibility between the new control system and the existing plant components, such as sensors and cabling. Since it was not feasible to check every connection in advance, some issues were identified during the commissioning phase and resolved swiftly within a tightly constrained shutdown window.
The Outcome
With the plant design clarified, we developed a control solution that leveraged the existing field equipment, site cabling, and control cabinets. This minimised disruption to the plant layout while modernising its operational capabilities. The new control system was successfully integrated, providing advanced product analysis features and ensuring the plant’s longevity.
Despite the challenges posed by the lack of documentation and the need to maintain production, the upgrade was completed efficiently. The result was improved reliability, enhanced control and diagnostic capabilities, and the provision of new electrical schematic and layout drawings, ensuring future modifications can be captured quickly.
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