MilliporeSigma produces chemicals used in the life sciences and semiconductor industries and tasked Trident Automation with finding a solution to upgrading its control systems. The company previously relied on APACS using Windows 95 running the MycroAdvantage HMI. To implement a more modern DCS, they wanted a solution that was scalable, flexible, intuitive, required minimal downtime for installation, and reduced total cost of ownership.
Before moving to the solution phase, Trident engineers first had to learn the MycroAdvantage system—an older platform that none of them had ever worked on before. “We do this all the time,” said Nathan Nutter, Controls Engineer II. “We learn a lot of legacy systems in a short timeline in order to reverse engineer a process for the newer systems.” To do so the team divided responsibilities among different people each focusing on instrumentation, code, and HMI.
The solution was to use ET200SP HA from Profinet, one of the newest IO platforms on the market. The system offered a longer lifecycle for the customer, fast cabling, easy station set up, provided high performance transmission of large volumes of data, and all in a compact size. It also was designed to use under extremely tough industrial conditions.
Since this was the first installation, teams had to learn new hardware, new IO configurations, and new networking. “It was important that we were proficient in this system because the ET200SP HA Profinet will be the next wave of IO for years to come,” said Yogesh Maheshwari, Engineering Manager.
Prior to install, the Trident team created a virtual environment so the customer could learn the product. Constant communication with the customer and help from Siemens allowed everyone to standardize the process and create optimum efficiency in design and installation. The install was executed with minimal delays and Trident teams are currently working on upgrading another plant for MilliporeSigma.