A comprehensive PLC HMI upgrade was the cornerstone of TBL Dar es Salaam’s journey to enhance the efficiency and reliability of its production systems. Faced with aging infrastructure and outdated technology, TBL needed a modern solution. Therefore, they partnered with IAES for a complete automation upgrade. This transformation included PLC systems, HMI interfaces, and condenser integration for optimal performance.
The Automation Challenge at TBL
The existing control systems used old technology that caused multiple problems. Specifically, the outdated S7-200 controllers and WinCC Flexible 2008 platform limited growth and caused reliability issues. Consequently, a comprehensive upgrade became essential for improved performance and future expansion.
Strategic Technical Solution
Comprehensive System Assessment
First, we began with a detailed evaluation of all existing systems. Our team analyzed every component to identify upgrade requirements and potential integration challenges.
PLC and HMI Modernization
Then, we replaced the outdated S7-200 controllers with advanced S7-1500 series units. These modern controllers provide superior processing power and much better reliability for continuous operations.
Software Platform Upgrade
Next, we converted the programming environment from Step 7 v5.5 to TIA Portal v13. This new platform creates a unified engineering framework that ensures smooth integration and better system efficiency.
Condenser Integration Strategy
Furthermore, integrating the 12 condensers required special automation programming. Our team developed custom programs and reconfigured inputs and outputs for perfect operation based on discharge pressure.
Professional Implementation Process
Careful Installation Planning
To minimize production downtime, we meticulously planned the installation schedule. We coordinated each step to ensure smooth transitions between old and new systems.
Hardware Replacement
First, we removed the old hardware components. Then, we installed new Siemens PLCs and HMIs with precision and attention to detail.
Rigorous System Testing
After installation, we conducted thorough on-site testing. This ensured all components worked together perfectly and met performance standards.
Comprehensive Staff Training
Finally, we trained TBL’s technical team on operating and maintaining the new systems. This knowledge transfer ensures long-term success and self-sufficiency.
Significant Upgrade Benefits
Enhanced System Performance
The new S7-1500 controllers greatly improved processing speed and reliability. Additionally, system stability increased significantly, reducing operational interruptions.
Future-Ready Engineering Platform
The TIA Portal environment provides a centralized and efficient engineering platform. Therefore, future modifications and maintenance become much simpler and faster.
Optimized Energy Efficiency
Integrating the 12 condensers optimized energy consumption. The system now automatically adjusts based on real-time discharge pressure, leading to better efficiency and cost savings.
Improved Operational Flexibility
Moreover, the new system offers greater flexibility for process changes. This adaptability supports TBL’s evolving production requirements.
Conclusion: Positioned for Sustainable Growth
In conclusion, this automation upgrade demonstrates TBL’s commitment to modern technology. As a result, they maintain a competitive position in the brewing industry. The project also highlights IAES’s expertise in delivering tailored automation solutions. With this upgrade, TBL Dar es Salaam is well-prepared for sustainable growth and continued operational excellence.
