Complex paper machine upgrade, overcoming obsolescence challenges

Our multi-faceted solution

Leveraging our extensive experience in obsolescence upgrades and industrial automation capabilities across various vendor platforms, iconsys was selected to execute the upgrade project.

To address the range of challenges faced by our customer, iconsys delivered a comprehensive full paper machine retrofit and upgrade solution that focused on both modernisation and operational continuity, including:

Drive system upgrade: The obsolete drives were replaced with advanced ABB ACS880 drives. This retrofit method allowed for the reuse of existing infrastructure such as power cabling, control wiring, and ventilation systems, reducing both costs and installation time. The low harmonic regenerative front-end modules in the new drives also ensured compliance with the latest energy efficiency regulations.

Complete drive suite overhaul: New drive suites were installed for both the paper machine and fan pump systems. For the paper machine, a new enclosure system featuring the latest ACS880 drive modules was installed, incorporating regenerative low harmonic technology whilst also significantly reducing the emitted harmonics compared to the current installation. The fan pump system was also upgraded with a tailored VX25 Rittal-built enclosure that integrated the new drives and controls.

Controller modernisation: The obsolete ABB AC80 Controllers were upgraded to a new Rockwell ControlLogix Safety Controller. This provided a faster, more reliable control over machine operations, and enhanced flexibility to adapt to future upgrades or process changes. This controller modernisation also included the design and installation of a new drive network, allowing all drives to be linked and monitored through Drive Composer Pro software.

Network integration & monitoring: A new Ethernet IP drive network was implemented, connecting all drives to the ControlLogic PLC and Drive Composer Pro software for real-time monitoring and optimisation. This included the installation of an EWON remote monitoring gateway, which allowed for seamless updates and troubleshooting without interrupting production.

Safety & compliance integration: As part of the upgrade, the ControlLogic Safety PLC utilised CIP Safety™ to provide safety over EtherNet communications between the ABB and Rockwell platforms. This is the first implementation of CIP Safety™ on ABB Drives in EMEA and UK. The PLC also had Remote safety IO, ensuring the upgraded system integrated with the current Mill EM Stops and IO to meet and improve safety standards. Additionally, iconsys ensured the project was fully UKCA and CE compliant, with no changes to the machine’s functionality that would introduce new hazard potentials.

Installation & commissioning: To minimise downtime and maintain production efficiency during the upgrade, we have developed a detailed installation plan working in partnership with the client. This plan allows the mill to continue operating while upgrades are completed incrementally, avoiding a full shutdown.