A ‘turnkey’ upgrade of a Legacy Drive, PLC and Safety control system

Tata Steel (Shotton Works) faced safety, gating, guarding, and obsolescence issues with drives, PLCs, and SCADA systems on their No.2 Colorcoat Line. These risks included operator safety, downtime, and limited spares. A modern multi-screen SCADA solution was implemented, improving machine setup, advanced diagnostics, and operator experience.

 

Our Solution

iconsys delivered a comprehensive turnkey solution at Shotton Works, including new DC drives, PLCs with remote I/O, SCADA, networking, modern safety systems, and two core-handling robots. The project encompassed electrical design, software, installation, commissioning, and standby support. 

Tata Steel’s risk assessment drove the implementation of fixed guarding, safety systems, and controlled access, achieving PUWER compliance. Upgrades included Siemens S7-1500F Safety Processors, ET200MP/SP remote I/O, WinCC SCADA, Siemens Safe Architecture Drives, and ProfiNet/ProfiSafe networking. 

Existing control panels were modified, retaining enclosures and replacing backplates to save installation time. Safety gate access was integrated with a Fortress AmGard Profisafe solution. 

Two unreliable Bronx core loaders were replaced with ABB IRB 6700 robots. The robots checked core quality and met payload, reach, and cycle time demands. Virtual simulations ensured design accuracy, while custom end-of-arm tooling (EOAT) and a Cognex vision system optimised performance and alignment. 

iconsys managed the complete electrical and mechanical installation. The solution significantly improved safety, productivity, efficiency, and product quality, exceeding customer expectations. 

 

Results

• Replacement of obsolete and non-supported equipment 
• Improved operator safety  
• Improved production efficiency and output quality