(P-03)

The process line's old control panels were replaced with a new PLC-based system; the line was recommissioned within the planned maintenance shutdown.

Sector
Food / process
City
Gebze / Kocaeli
Year
2025
Duration
72 hours
Scope
6 panels
Measurable Result

Problem

The legacy control system, with spare parts no longer available, was extending downtime; the revision had to fit the 72-hour shutdown in the production schedule.

Result

The line was commissioned without exceeding the shutdown window; fault-driven unplanned stops dropped to zero in the following quarter.

Scope of Work
  • PLC-based renewal of 6 control panels
  • Migration of field instruments and signal lines
  • Installation of SCADA monitoring screens
  • Recommissioning and operator training
Products Used
  • PLC and I/O modules
  • In-panel control equipment
  • Signal and communication cables
  • SCADA software licenses
Field Gallery
New PLC-based control panel
New control panels, with series-compatible PLC and I/O layout.
Commissioning in front of the panel with monitoring screens
During commissioning the line was tracked on the monitoring screens.
Ex-proof junction box in the process area
Field instruments were migrated through the existing ex-proof boxes.
Terminal migration was done with one-to-one address list mapping.
Cold test: all signals were verified at the bench before the shutdown.
Operator training was delivered together with the handover.
Panel Detail

New panels were assembled preserving brand-series compatibility; legacy terminal addresses were mapped one-to-one and cold-tested before commissioning.

Field Note

The full signal list was verified on site before migration; a fallback scenario and rollback plan were shared with the client before the shutdown began.

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