project
Hardwired-to-PLC CCM Automation Modernisation — Maharashtra, India
Brownfield conversion of a two-strand CCM from hardwired contactor logic to separate PLC-based strand control, modern drives, SCADA and secondary automation.
Project profile
Engineering scope at a glance
- Industry
- Steel & Metals
- Geography
- India, Maharashtra, India
- Capability
- PLC/SCADA, Retrofit, Drives, Secondary Cooling Automation
- Publication
- Anonymous project record
Verified technologies
Control architecture and technology tags
- Allen-Bradley MicroLogix 1400
- PowerFlex 40
- PowerFlex 525
- SCADA
- Secondary Cooling Automation
Project Overview
A two-strand CCM operating with contactor and hardwired control required a modern strand-control architecture.
Existing Challenge / Requirement
The installed system had hardwired contactor logic and no modern PLC architecture for individual strand control.
Elexorn Scope
- Separate Allen-Bradley MicroLogix 1400 PLC system per strand
- PowerFlex 40-to-PowerFlex 525 migration
- SCADA
- Secondary automation
Control Architecture / Technology
- Before — Hardwired Contactor Logic
- Migration
- After — PLC-Based Strand Control
- Modern Drives
- SCADA + Secondary Automation
Engineering Approach
The brownfield conversion introduced independent strand PLCs and coordinated the drive, supervisory and secondary-automation layers.
Commissioning / Execution
The modernised controls were integrated into the existing two-strand application.
Verified Result
The control platform was converted from hardwired contactor logic to PLC-based strand control with modern drives, SCADA and secondary automation.
Reference architecture
Hardwired-to-PLC Modernisation
A before-and-after view of the verified brownfield control conversion.
Before
Hardwired Contactor LogicMigration
Separate Strand PLC SystemsDrives
PowerFlex 525After
SCADA + Secondary Automation
Project media boundary
No customer logo, customer-identifying photograph or customer document is displayed. The diagrams on this page are Elexorn technical architecture graphics based only on the verified public scope.