Case Studies

Distributed Safety System for Pilot Plant

emergency stop buttons
Posted in Aerospace and Defense, Allen Bradley PLC, HMI and SCADA, Manufacturing Automation and Intelligence, Motion Control, PLC Programming, User Interface Design

Summary

DMC designed and programmed a control system for an R&D facility that mixes, casts, and assembles propellants and explosives.

Solution

DMC designed a standalone air-gapped network to host all the automated equipment for the client's facility.

Using Integrated Architecture Builder, our engineers created a Rockwell controls architecture with a standard hardware set. We utilized the Rockwell library of process objects for PLC software and HMI controls. To allow operators to safely de-energize any piece of equipment from any of 11 remote control stations, DMC also designed a network of Rockwell Compact GuardLogix controllers and other SIL 3 components.

DMC designed 30+ control panels to meet the UL508A standard. To meet hazardous location requirements, we utilized a combination of explosion-proof and intrinsically safe components. We took full ownership of the software development lifecycle, including requirements gathering, detailed design, programming, and development and execution of test plans.

Finally, we coordinated with the construction team for power and telecommunication infrastructure.

Learn more about DMC's Rockwell Automation expertise and contact us for your next project.

Customer Benefits

  • Flexibility: operators can control or monitor any piece of equipment from any control station
  • Ease of training: standard user interface for all equipment
  • Maintainability: standardardized controls hardware and software for all equipment
  • Safe operations

Technologies

  • Rockwell Compact GuardLogix
  • Rockwell ControlLogix Redundancy
  • FactoryTalk Site Edition
  • Rockwell Library of Process Objects
  • ThinManager
  • FactoryTalk AssetCentre
  • Kepware KEPServerEX
  • Modbus/TCP
  • BACNet
  • Microsoft HyperV