Indicators for Upgrading Your Control System

Upgrading control systems is usually recommended when:

• The system has reached its operational end or fails to function properly.
•  Significant energy savings can be achieved through an upgrade.
• Other substantial plant renovations or upgrades are already underway.

Several warning signs suggest the need for an upgrade. When software versions become obsolete or incompatible with current Windows operating systems, it poses high risks for cybersecurity threats and viruses. Another clear signal is when hardware production ceases, and sourcing spare parts becomes challenging or impossible. Relying on second-hand parts from platforms like eBay indicates it’s time to plan for an upgrade to avoid potential facility-wide shutdowns due to minor failures.

Choosing Between Partial and Full System Upgrades

While replacing a control system can be costly, phased upgrades can help manage expenses.

Partial System Upgrades

Partial upgrades involve replacing specific components while retaining the rest of the system. However, compatibility between old and new technologies is crucial for this approach. When feasible, partial upgrades allow facilities to leverage modern software and hardware benefits without the need for a complete overhaul.

 

Examples of partial upgrades include:

• HMI Computer and Software Replacement:

Maintain existing control hardware while updating the HMI computer and software. This enables the control system to utilize modern Windows networks for tasks like printing reports, storing historical data, and remote alarming. However, the existing PLC program remains unchanged, missing out on enhanced functionality and energy efficiency.

- PLC Controller and Program Replacement:

Update the PLC controller and its programming while keeping the I/O modules, field instruments, and wiring intact. This strategy harnesses the latest energy-efficient algorithms and advanced control functions.

Full System Upgrades

A full upgrade becomes necessary for outdated control systems, particularly those over 20 years old. These legacy systems were often proprietary and stand-alone, making phased upgrades impractical. When control hardware cannot interface with modern HMI systems, a complete replacement is inevitable.

Advantages of Modern Control Systems

Unlike consumer electronics, control systems are not replaced merely because a new model is available. However, upgrading at the right time can offer significant advantages for both business operations and staff welfare.

Enhanced Energy Efficiency

Modern systems incorporate advanced controls for optimizing processes such as compressor sequencing and head pressure regulation, which are crucial for energy efficiency. Systems older than a decade likely miss out on these benefits.

Improved Communication and Integration

Integrating all equipment and sensors across a facility streamlines operations. Operators can monitor the entire plant from a single screen, allowing for better time management and energy usage optimization. Managers benefit from enhanced data for energy consumption analysis.

Remote and Mobile Access

Contemporary cloud-based software provides remote monitoring and alerting capabilities. For example, in a refrigeration plant with minimal staffing, remote access allows operators to address alarms from offsite, improving response times and operational efficiency.

Conclusion

Modern expectations are for fully integrated control systems managed from a central hub. A contemporary control system should unify various controls — from process equipment to tank levels and pump controls — on a common network. This unified approach allows operators to access consistent information from any control screen within the plant. Older systems lack these integrative capabilities.

Assessing your control system’s age and efficiency is crucial. Although the upfront cost of upgrading can be substantial, the long-term benefits in energy efficiency, operational communication, and overall facility efficiency provide a compelling case for modernization. Upgrading your control system is not just about keeping up with technology; it's a strategic investment in your facility's future performance and reliability.

Need help assessing and upgrading your control system? Contact Neohance for expert advice and customized solutions. Our team is ready to assist you at every step of the process, from evaluation to implementation.