Widnes-based control technology specialist Denca Controls has completed a significant legacy PLC (programmable logic controllers) upgrade programme at the R&D facilities of a leading pharmaceutical company.
The upgrade of the five black side/white-side sterile production facilities has been underway since Denca began the replacement of PLC equipment on the site in 2003.
Main contractor ABB tasked Denca with the staged replacement of the equipment in the production and fumigation suite, which involved the scheduled replacement of Siemens S5 PLCs with Siemens S7 PLCs and associated legacy support..
Denca led the engineering design for new, compatible circuits, re-writing existing PLC software in the correct format and rewriting HMI driver software, providing full bench testing and simulations, and carrying out installation and commissioning. All testing was carried out to IQ/OQ protocols. Standing for installation qualification/operational qualification, these demonstrate that equipment is as it was when it left the factory and ready to operate.
Denca was also charged with replacing the legacy PLCs in the automated wash-water systems in various production suites.