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Case Studies

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.

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Although the LCD market has superseded the CRTs, there are still a large number of processes and application that utilise CRTs as the main mean of display and communication between the operator of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

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.

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.