Electrical, Control, Instrumentation Engineering and Consulting services

Project: Dust Handling Plants

Client: Eskom

Project Requirements

The control system of Eskom’s Dust Handling Plants had reached it’s end of life. The S5 PLCs were no longer supported by the OEM, with no spares readily available on the market. It was also difficult to maintain them because of limited know-how availability. ControlNET Consulting was tasked with replacing them with S7 PLC hardware and software.

New panels were made to replace the existing S5 PLCs. The old panels were removed, while leaving the field wiring intact. In order to give the client the benefit of the new hardware and software platform, it was necessary to reverse-engineer the old software and derive the control philosophy. The software was then implemented with new function blocks and faceplates, making it more informative for the operator and easier to fault-find and maintain.