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Control Cabinet

CSL Biotherapies extends the life of their process control equipment.

The installed control system was over 20 years old. The German manufacturer started phasing out the support for some of the modules which exposed the company to the risk of experiencing lengthy production downtime, should these modules fail. Due to the complexity and the specific functionality, an upgrade of the entire system was not a feasible solution.

Rom-Control assessed the installed base as well as the spare and faulty modules for frequency of use in the entire system, availability of spare modules in-house, manufacturer or elsewhere. The information recorded was firmware revisions, electronic components used, card model number, position in the cabinet, manufacturer. Rom-Control took detailed photos of each module and attached Rom-Control’s barcoded label with unique item number.

A gap analysis as well as a risk assessment has been conducted to identify the most vulnerable parts of the system should a module fail.

At the completion of the audit, CSL was presented with a plan that would specifically target the vulnerable areas as well as a comprehensive maintenance plan that would provide CSL with a “renewed” and reliable control system as support for the next 10 years.

The maintenance plan comprised of a combination of pro-active refurbishment, whereby the spare modules as well as the installed modules were refurbished, reverse engineering and manufacture or the modules no longer supported by the OEM and where CSL had no spares nor could they be sourced by Rom-Control.

A maintenance agreement was also setup where Rom-Control holds CSL specific electronic components in stock, 4 hour response and many other features meant to keep CSL’s equipment online with minimum production downtime due to electronic and process control equipment failures.

CSL saved in excess of 80% of the alternative cost of replacing the entire system.

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Control Cabinet

Rio-Tinto’s Boyne Smelters saves on Allen Bradley Panelview upgrades!

Although the LCD market has superseded the CRTs, there are still a large number of processes and application that utilise CRTs as the main mean of display and communication between the operator of the machinery and the process.

Nevertheless, CRTs are extremely heavy, occupy large volumes and consume relatively large amounts of electricity. There are also a number of defects that occur over time. Some of these defects can hinder the user’s ability to correctly identify patterns or writing on the screen or in some cases completely inhibit the user’s view altogether. These defects can vary, for example:

  • Colour spots that appear in different sectors of the display area,
  • Raster Burn – ageing effect when the image has been present for a long period of time and the brightness is reduced considerably,
  • Pattern Burn – the image gets imprinted on the tube,
  • Scan Burn-a line with reduced visibility

In the majority of the industrial, medical, and military applications, these monitors are embedded in the equipment they supervise and/or control which makes upgrade difficult and sometime impossible. The shape and size of the new monitor or panel can be different and fitting it (if at all possible) requires substantial modifications in the hosting equipment which can be costly and inefficient. The other disadvantage in the upgrade process is that the new monitor/panel most likely requires learning new software which can be difficult for the constantly ageing workforce.

Companies utilising CRT-based operator stations – be that from the industrial, resources, medical, utilities or military sectors (Numeric Control Machines, Medical equipment, PLC or DCS based operator stations/panels) – now have access to a better, cheaper and more effective alternative.

Within the industrial electronic equipment repair services arena, a total refurbishment of the old monitor/panel and retrofitting the old CRT to a new LCD based display is now readily available from Rom-Control Pty Ltd

The main advantage of this option are:

  • at least a 50% saving compared to the upgrade option;
  • a plug and play installation without the need of any additional modifications or training;
  • a “renewed” item where the components have been replaced with components of higher reliability and performance using today’s technology and replacing obsolete components originally used when manufactured – making the item maintainable, with a 1 year warranty, and have superior visibility.

Virtually, there are now retrofit solutions for any type of monitor or panel within the industrial automation services field. Companies do not have to spend their capital funds on an upgrade that does not add any value to the bottom line and does not improve the characteristics or performance of their process or the finished goods/service.

They can now take advantage of the Industrial Electronic RepairServices offered by Rom-Control.

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Control Cabinet

An audit of your electronic assets can reduce your maintenance costs.

Rom-Control Pty Ltd now offers a comprehensive electronic and process control equipment auditing for business entities in the industrial, utilities, resources and medical sectors. The audit will collect data related to your installed and spare parts base, such as:

  • Equipment manufacturer, model, part and serial number, function and the application performed
  • Firmware revisions and hardware supporting information
  • Level of support offered by the OEM and availability of spare parts (board level)Complete list of electronic components used on the asset

The deliverable are:

  • A database containing all the audited assets organised in a functional hierarchy
  • Backup of all firmware
  • Gap analysis related to business vulnerability to failure on assets not available as spare and the time-to-repair for these assets.

The results of the audit will also be used by Rom-Control to provide a comprehensive maintenance program, consisting of:

  • Proactive refurbishment of available spare assets
  • Proactive refurbishment of the production assets on a rotation basis.
  • Periodic Preventive Maintenance of both installed and spare equipment
  • Stocking the specific electronic components required to repair and refurbish the customer’s specific equipment
  • Priority on repairs

This is a proven approach that help our customers extend the useful life of their assets whilst reducing the production interruption due to failure of electronic and process control equipment.

Call Rom-Control on 0395434544 for additional information.

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About the Company

BMA Caval Ridge mine is the BHP Billiton Mitsubishi Alliance eighth operation in Queensland and employs around 500 people. The mine produces up to 5.5 million tonnes of premium quality metallurgical coal per annum and has a significant investment in their fleet of Caterpillar 793 Trucks.

Contact for Enquiries

1300 766 287

Summary

The Cat 793 truck is one of the largest trucks that Caterpillar produce powered by an 85 litre engine and weighs over 122 tonnes. Like on many of these large size trucks, the driver controls most of the trucks’ancillary systems through a large touch screen computer monitor.Having to operate in harsh environments, the screenshave become insensitive to touch which can result in unreliable operation. As these monitors are no longer manufactured or available, the alternative would be to upgrade to a new screen at a higher cost and requiringmodification to the trucks wiring system.ROM-Control was approached by BMA Caval Ridge to provide a more economical repair and refurbishment of the existing screens.

Issue to be resolved

The touch screens are an integral part of the operation for the large trucks providing information regarding operation and are the operators’ interface to controlling many of the truck functions. The tactile components of the monitors are integrated into the monitor’s architecture including the physical placement of wires and other connections. To refurbish these screens and ensure total reliability, ROM-Control referred to their database and contacted many of their suppliers internationally to locate specific components that would be compatible for the touch screen monitors. As a result they set about re-designing a new system that will allow the new parts to be fully consolidated and physically secure within the monitor’s housing.

The result was Rom-Control were the only provider that could offer a tangible bespoke solution that was fully guaranteed. Compared to the upgrade costs with original parts, the ROM-Control solution was by far the more economical alternative.

Action

ROM-Controls’ highly trained staff examined the touch screens and by contacting our large network of suppliers and providers, identified a suitable alternative to refurbish the screens at a fraction of the cost of a replacementand with minimal risk. Due to BMA Caval Ridge remote location, it was essential that the screen repairs be reliable after the modification which was assured as ROM Control’s procedures and testing regime conformed to AS9001. For all repairs and refurbishment, Rom-Control also provided a full one year unconditional warranty.

Result

In the field trials that were performed by BMA Caval Ridge proved the reliability of each touch screen and found a success rate of 100%. BMA Caval Ridgehas listed ROM-Control as the primary source for repairing these screens. Enquiries regarding this Case Study Adrian Ciorogaru

Ph. 1300 766 287

We will offer you an obligation-free consultation to talk about how Rom-Control can help your business. Leave your details and we will be in touch.







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