Control system retrofit in paper manufacturing

The challenge

A European paper manufacturer operates a plant whose automation is built on Simatic S5, ET200 remote I/O and Sinec L2. Spare parts for these systems are no longer reliably available. The plant itself is running and is meant to keep running. What was needed was a way to renew the control technology without stopping production for it.

Our contribution

It began with recording the actual state of the plant, including the changes that never made it back into the documentation over the years. Next came the replacement concept for the discontinued components and the check whether the existing enclosures can accommodate the new technology at all. The revised electrical documentation covers schematics, parts lists, terminal and layout drawings. Every conversion step is cut so that the customer’s maintenance team can carry it out themselves.

The result

The modernisation runs in stages that fit into operations – so far without interrupting production. Our designers accompany the work and adjust the planning wherever the conversion brings new findings to light.