Project Spotlight: Drive System Upgrade – A Controls Engineer’s First Major Milestone

In this edition of our Project Spotlight series, we speak with one of the engineers on the team, John Kelly, about a significant drive upgrade project.  

This project not only delivered measurable improvements for the Pulp & Paper client but also marked a major milestone early in his engineering career at iconsys. The project involved the decommissioning of obsolete automation infrastructure and its replacement with a modern, harmonics-compliant drive and control system. It was executed seamlessly within an existing plant architecture.  This was not a straightforward replacement; it was a technically rigorous undertaking that demanded integration with legacy systems, precise software engineering, and meticulous installation within tight operational windows. 

Whilst this is John’s perspective on the project, it’s worth bearing in mind that the large iconsys team jointly made this project come to life and be so successful, lead by Technical Director, Tim Rhodes.

For John, this project held a deeper meaning. 

A Project with Personal Significance

My father was the main engineer in a paper mill. Working on this project triggered some old and pleasant memories.

His father led engineering operations at a paper mill in Dublin, where John himself worked after university. Now, as a Senior Controls Engineer, returning to a familiar industrial setting allowed him to reflect on the foundations of his career while making a meaningful contribution to another mill in the sector. 

The Objective: Modernisation with Compliance and Continuity

The primary objective was to replace a legacy fleet of ABB ACS600 drives with a new suite of low harmonic ACS880 drives. In total, 23 chassis-mounted drives were designed and commissioned across two custom-engineered drive suites.  This formed part of a wider control modernisation effort which also included decommissioning four legacy ABB AC80 PLCs and implementing a Rockwell ControlLogix 5000 platform. The Rockwell PLC was chosen to align with the client’s existing infrastructure and engineering competencies.  

The upgraded system needed to comply with modern low harmonic regulations while occupying the same footprint as the legacy installation—a non-negotiable constraint driven by physical space limitations and shutdown timelines. 

First Assignment, Immediate Impact

This was John’s first project after joining iconsys, and it quickly became a professional highlight. It represented a high-impact, cross-discipline programme requiring coordination across control software, electrical design, and mechanical installation. 

From factory acceptance testing through to on-site commissioning, the team delivered under pressure. It was a privilege to be part of such a technically capable and cohesive group.

A Broad Scope of Responsibility

John’s principal role was software engineering. He authored the drive control software in Rockwell’s ControlLogix platform, based on a detailed Functional Specification prepared by our Technical Director, Tim Rhodes.  His responsibilities included machine section control, safety function implementation, and development of a reusable drive control block tailored to the specific requirements of the paper-making process. He also oversaw the integration of ABB’s latest Drive Safety module into the PLC environment.

As ABB drive technology was relatively new to him, John undertook rapid upskilling to ensure full commissioning competency, including parameter configuration and diagnostic routines. Beyond software, John contributed to elements of electrical design, such as defining network topologies and I/O wiring conventions. This holistic involvement broadened his engineering perspective and added significant value to the delivery team. 

Legacy Complexity: Locked Code and Proprietary Blocks

One of the most formidable challenges was that the original ABB AC80 PLCs contained proprietary code blocks that were inaccessible and too generic to be site-relevant. These limitations created substantial uncertainty during the design phase. Fortunately, the team benefited from the deep ABB expertise of Tim Rhodes, who was able to develop a clear, site-specific functional model that informed both PLC and drive configuration. This specification became the foundation for all software development, risk assessments, and interface testing. 

Integrating New Technology with Legacy Systems

Although the SCADA and ABB Quality Control systems were not upgraded as part of the project, full integration with the new control platform was mandatory. This necessitated multiple on-site visits to review existing architecture, assess signal routing, and define data exchanges. To mitigate commissioning risk, a purpose-built test rig was assembled at our facility to emulate SCADA functionality.

This enabled comprehensive pre-deployment validation of all interfaces. However, due to system dependencies, real-world integration with the Quality PLC could only occur during final commissioning, which demanded a high degree of foresight and precision. 

Installation Excellence under Tight Deadlines

While not directly involved in the physical installation, John praised the outstanding execution of the fieldwork by Mathew Muscutt’s team. The shutdown window was minimal, and yet every milestone was met with precision. 

The installation team executed flawlessly. Their planning and attention to detail ensured the system went live without incident.

Key Outcomes

Delivering a critical infrastructure upgrade under these conditions is never routine. For John, the project was both a technical and personal triumph. 

Seeing the machine return to production without issues was incredibly satisfying. It validated the planning, testing, and collaboration that went into every stage. It also helped me build strong relationships and confidence early in my career.

Enabling Technologies

The project was made possible through a combination of ABB and Rockwell technologies. ABB supplied the ACS880 low harmonic drive technology and associated safety components. Rockwell Automation was selected as the control platform, reflecting the client’s internal engineering standards. The success of the project also highlights the value of iconsys’ platform-agnostic approach, allowing clients to benefit from the best available technologies while maintaining control system consistency and scalability. 

Final Reflections

This project exemplifies the capability we have to deliver high-complexity upgrades in live production environments. From reverse engineering inaccessible legacy logic to deploying harmonics-compliant infrastructure, the programme required deep expertise, rigorous coordination, and unwavering quality assurance. 

Projects like this are not simply upgrades. They are strategic investments in safety, efficiency, and operational resilience. They also illustrate the human side of engineering—the relationships, the memories, and the passion that drive us forward. 

Read the full case study for this project here.