The Background.

Two machines critical for the foundry’s operation relied on obsolete GE control systems comprising 2 x 90/30 PLCs and 2 x PanelMate 1000 HMIs. Given the scarce availability of spares, the client wanted to mitigate against any potential costly failures.

Operator training was also a concern as the order books were at capacity and there was no time allotted to train operators on a new control system. Therefor, the HMI screens were copied like-for-like to allow operators to start work right away following the commissioning.

Installation and commissioning had to be carried out during the two week plant shutdown, however, all work carried out and plant fully commissioned and handed back within 3 days.

The Client

A leading UK Bronze Foundry who specialise in complex finish-machined, pressure-tight castings, produced in Gunmetal, Aluminium Bronze and a full range of non-ferrous alloys. Customers include the NHS and the Fire Service.

The Solution.

iTech replaced the obsolete GE 90/30 PLC, IO cards and HMI with an up-to-date RX3i PLC system and QuickPanel+ from Emerson.

The footprint of the new PLC is identical to the original, meaning no costly panel modifications were required. We also supplied, engineered and installed a modern touchscreen Emerson HMI replacing an elderly, monochrome LCD display.

The Benefits.

Combined 30+ years experience with GE / Emerson control system products and engineering software providing second-to-none expertise.

Quick turnaround time from engineering to commissioning. Both machines were commissioned in 3 days with all commissioning activities carried out during a scheduled plant shutdown in order to minimise business impact.

All activities carried out during the COVID-19 lockdown due to the clients customer base including NHS and Fire Service. iTech doing it’s part in keeping key infrastructure running when it is needed most.