Manufacturing control upgrade to improve safety, compliance, and operational reliability
A major European steel producer partnered with Contec to modernize the automation software controlling its desulfurization processes. The objective was to upgrade the existing control system to a modern automation platform while improving operator safety, environmental compliance, and long-term maintainability.
By implementing a new control architecture based on Rockwell automation technologies and aligning the system with modern development standards, Contec helped transform the installation into a more reliable and future-ready production environment. The upgraded platform provides improved monitoring capabilities, enhanced safety logic, and structured data reporting aligned with environmental regulations.
Operational Improvements:
-
Upgraded desulfurization control software to modern automation standards
-
Improved operator and process safety through implementation of safety PLC logic
-
Enhanced environmental compliance through structured data reporting
-
Advanced diagnostics and monitoring capabilities for maintenance teams
-
Automation platform prepared for future regulatory requirements
The challenge
Meeting safety and environmental requirements while modernizing automation systems
The existing desulfurization control system required modernization to support higher standards of operational safety and environmental compliance. As regulations around industrial emissions continue to evolve, the installation needed a more robust platform capable of meeting both current and future legislative requirements.
At the same time, operators required improved visibility of process conditions, while maintenance teams needed better diagnostic tools to identify potential equipment issues early. The challenge was to upgrade the software architecture and safety logic without compromising the stability of the ongoing production processes.
Our approach
Implementing modern control and safety architecture
Contec delivered a comprehensive modernization of the desulfurization automation system based on the Rockwell ControlLogix platform combined with FactoryTalk View and the PlantPAx V5 process control architecture.
Working closely with the client’s engineering team, Contec first analyzed the existing system and operational requirements. Based on this assessment, new safety PLC logic was developed and implemented to improve both operator and process safety.
The desulfurization control software was then revamped and migrated to the Rockwell PlantPAx standard, bringing the installation into a modern development environment aligned with current industrial automation practices. This upgrade significantly improved maintainability and system transparency.
To support regulatory reporting obligations, a historical data management solution was implemented. Process data is now collected, structured, and converted into formats suitable for official environmental reporting, ensuring compliance with legal monitoring requirements.
Finally, additional maintenance diagnostic tools were introduced. Smart monitoring terminals were deployed for pumps operating without drives, enabling more advanced condition monitoring. These technologies provide maintenance teams with earlier insight into potential malfunctions, helping prevent unplanned downtime.
