ADM Milling UK - Smooth upgrade of production-critical 1980s control panel
ADM Milling is a market leader for flour and bakery ingredients with a strong reputation for product quality, technical support and customer service. At their Corby mill, OAL has seamlessly upgraded and modernised production-critical control panels, achieving zero unplanned plant downtime - a notable achievement given the complexities involved.
Upgrading ageing control panels presents significant challenges, particularly for businesses like ADM that depend heavily on continuous production and cannot risk sales losses due to downtime. In this critical situation, ADM trusted OAL based on several key strengths: OAL's industry reputation for being “easy to work with, their proven ability to meet stringent deadlines, and their commitment to prioritising customer needs in all proposed solutions.
The purpose of this project was to replace the existing obsolete MCP12 control panel.
The panels control three flour packing lines.
The new control panel offers less downtime and easier maintenance moving forward due to up-to-date components and accurate documentation. Furthrermore the new panel meets the latest electrical standards and incoprates extra functions
“OAL showed excellent health and safety whilst on-site. They were a respectful team and a diligent workforce with high standards. Nothing was too much trouble for the team and there was no noise on the project!”
OAL engineers complete the installation of the new control panel.
Challenge
The control panel dated from the 1980’s, so although there was a nearly complete set of original drawings, all the modifications over the years were not necessarily fully documented.
Additionally, the fact that the existing field devices and cabling were to be reused, meant that a lot of survey work was required to ensure there were no unknowns when the old panel was disconnected and the new one installed.
The panel needed to be swapped out during a 14-day shutdown, during which no packing could take place, so it was essential to the business that it was completed on time.
The “old” control panel.
Solution
OAL executed the project using our proven methodology, “The OAL Way”. The key activities completed are highlighted below:
Extensive survey work to ensure there were no unexpected issues when disconnecting the existing old panel. As the old saying goes, “An hour in planning (specification) saves 10 hours of doing!”
Designed and build of the new control panel at our factory in Peterborough.
Software modifications the new PLC and I/O sensors.
Factory acceptance test (FAT) of all equipment at OAL.
Disassembly of the new control panel into sections. Reassembly in situ on site due to access restrictions; it needed to be on the 3rd floor.
The following tasks were completed in the 14-day planned downtime window whilst the clocks were ticking:
Identify and disconnect cables from the old panel.
Disassemble and remove the old panel.
Position the new control panel and reconnect cables
Perform I/O testing of all field devices and recomission each packing line.
The plant was ready for start-up on Monday as planned. OAL provided 24/7 cover for support issues following go-live which has subsequently rolled into an annual support contract.
The new upgraded control panels in situ.
Results
Since the successful completion of the project, ADM has had no electrical component failures. The project has secured future reliability and adherence to DSEAR regulations.
The integration of new, current-specification equipment is expected to significantly reduce downtime and simplify maintenance due to the availability of updated and precise documentation.
Upgrading the control panel construction to meet current standards has facilitated the easy modification of control sequences and enabled the incorporation of several additional functions, as requested.
OAL can upgrade your systems too - speak to our team today for advice and guidance.
At a glance
Customer since: 2004
Challenge
Packing lines reliant on a critical control panel from the 1980s
No original electrical drawings
Lots of survey work required
Strict lead time to begin and complete work
Solution
Extensive survey work carried out enabling an accurate work timeframe
The new current spec allows less downtime and easier maintenance
Up-to-date system documentation
Addition of several extra functions
Results
Zero electrical component failures
Up-To-Date system for reliability and longevity
Documentation now up to date for easier future maintenance
