emPOWERUP Virtual: Leading Digital Transformation in the AI Era, March 25
January 10, 2025
ProjectX: GrayMatter Transforms Swimming Pool Management System for Florida County
January 30, 2025emPOWERUP Virtual: Leading Digital Transformation in the AI Era, March 25
January 10, 2025ProjectX: GrayMatter Transforms Swimming Pool Management System for Florida County
January 30, 2025GRAYMATTER PROJECTX
ProjectX: From Legacy to Leading Edge — A Successful PLC Upgrade Journey
Problem
A U.S.-based chemicals company faced significant challenges with its outdated plant control system.
Its legacy PLCs (Programmable Logic Controllers) were hindering operational efficiency. The antiquated system could not support the modern demands of the plant. Company leaders were considering an expensive DCS-based solution, but wanted a more economical solution that would achieve its goals.
Solution
GrayMatter assisted in the plant upgrade project, beginning with a comprehensive controls assessment. Leveraging lessons learned from a similar project, GrayMatter provided a detailed plan tailored to the chemicals company's needs. GrayMatter moved forward with upgrading to a modern PLC platform, allowing for an intermediate step that preserved the existing legacy I/O system while upgrading the system.
The partnership included collaboration on the physical upgrades of I/O panels and the PLC cabinet, with GrayMatter providing crucial consulting services, engineering support, and programming configuration.
This hands-on approach ensured that the company could effectively implement the upgrades while minimizing disruption to operations.
Results
The upgrade project successfully addressed the significant limitations of the outdated control system.
By modernizing the plant's PLCs, the company improved operational efficiency and gained access to advanced functionalities that enhance process monitoring and control. The decision to use the modern PLC platform, coupled with GrayMatter's ongoing support, ensured a seamless transition from the legacy system to a more sophisticated and capable control environment.
The upgrade project not only mitigated the risks associated with the old system but also positioned the chemicals company for future growth and technological advancements. With enhanced capabilities, the plant can now respond more effectively to operational challenges and leverage data analytics to optimize production processes.