Upgrade Of A Validated RO Water Control System

A global pediatric nutrition company recently required an upgrade to an aging RO Water Control System. The validated control system was capable of meeting production requirements; however, the HMI software platform had reached the end of its lifecycle. Much of the SCADA hardware and software was becoming unsupportable and was in critical need of an upgrade. The objective of the upgrade was to bring the system to a current and fully supportable state using the latest technology and methodologies in process control and networking. ECS was contracted to deliver the upgrade. The delivery involved engineering the migration to company standards.

The upgrade consisted of:
• replacement of the iFIX® SCADA system to Inductive Automation’s Ignition SCADA
• replacement of the operator terminals and SCADA host server
• migration of the distributed I/O network from ControlNet to Ethernet I/P
• upgrading the controller to the latest Rockwell controller

As part of the upgrade, the ControlNet fieldbus was replaced with a 1756-EN2TR based Ethernet fieldbus, with DLR (Device Level Ring) redundancy. Existing 1756-ENET ethernet modules were replaced with improved 1756-EN2T modules, and the controller was upgraded to a 1756-L83E.

In addition to the hardware upgrades, the existing iFIX® HMI / SCADA system was replaced with Ignition, an HMI / SCADA platform by Inductive Automation. The Ignition application was made to closely resemble the look/feel of the iFIX® application, with improvements for modernization, usability, and functionality. The Ignition application implemented new features such as ECS’ own historical “DVR” module to provide engineering and maintenance the ability to “rewind” the process on the HMI to a desired date and time and replay what previously happened. The solution also included an improved alarming system complete with Alarm Navigation.

ECS provided all of the engineering, software development, startup and commissioning. As part of the engineering, ECS provided the IQ (Installation Qualification) and OQ (Operation Qualification) documentation to support the validation requirements.

With the completion of the project, the control system was up to date with current plant and industry standards.

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