Upgrades & migrations in process automation

Migrations focus on increasing the efficiency, the availability of an installation, and prolonging its service life. Agidens Food & Beverage brings installations up to date, with obsolete parts being either updated or replaced.

Obsolete automated systems can cause a host of problems: system expansions are no longer possible, the installation no longer complies with legislation, support is no longer guaranteed, or the maintenance costs keep rising. In many of these cases, a migration or update is advisable or even necessary.

Migrations focus on increasing the efficiency, the availability of an installation, and prolonging its service life. Agidens Bulk Liquid Storage brings installations up to date, with obsolete parts being either updated or replaced where necessary. Agidens takes care of migrations and upgrades of entire automation systems or one or more parts in the case of PLC/SCADA, electrical installations and panels, communication cards & drivers and MES.

Migration in three steps

Inventory

The first step is to make an inventory of the existing systems and functionalities. Firstly, an inventory is made of all the hardware and software. The focus then switches to all functionalities (recipe management, communication, Grafcet management, etc.) and back-ups. Is there any internal or external process knowledge available? What is the status of the documentation? We look at the maximum migration time: is there scope for a longer downtime or will a phased re-tooling be necessary? A detailed inventory is the basis for a successful migration.

Formulating a migration plan

During this phase, the data collected is checked and compared. This will result in one or more potential solutions. Together with the client, we select a new automation system and determine the standards it must meet. Some of the focus points are:

  • Risk analysis: what are the consequences and risks of an upgrade? Will it have an impact on the other the infrastructure? Will the downtime have an effect on operations?
  • Concept: choice of the new systems, software, or components. For example, we can migrate the whole system or only the CPU (and not I/Os) and select the communication technology.
  • Planning: we avoid a ‘big bang’ approach and define manageable subprojects. We also formulate an action plan and identify concrete milestones.
Implementation

With a smart and clearly communicated plan, we can start with the actual migration. In this phase, we carry out the detailed engineering and implement the new automation system (hardware and software). Extensive testing, both off-site (FAT) and on-site (SAT), guarantees a smooth transition to the new system. Wherever possible, a fallback plan will allow a return to the previous (or a workable) situation at any time.

We will provide the necessary as-built documentation and manuals with descriptions of the changes, such as a different programming language, new communication protocol, electrical diagrams, operator manuals, etc.  A professional maintenance team provides 24/7 support.

Agidens Food & Beverage for upgrades and migrations

  • Agidens has a large engineering capacity. We carry out small and large-scale migrations and provide the necessary continuity for this (a large team guarantees a smooth progress of the migration process).
  • We are a recognised integrator of various automation systems: Siemens, Rockwell Automation, Wonderware, GE, Schneider, etc.
  • A special maintenance team is trained to provide 24/7 service support to our customers.
  • Agidens searches together with the customer the best solution and with a top quality delivery aims for a long-term relationship.
  • Our project approach guarantees a timely delivery. We are used to carrying out migrations and upgrades during brief shutdowns.
  • We ensure there is an increased availability of the system. In this way your installation can be brought to order in accordance with the applicable safety conditions.

How can we help?

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