Ring Mill Controls Modernization

A client in the metals industry operates a large ring mill used to manufacture its product. Being in service for for approximately 30 years, it was running on a legacy PLC5 based control system with DC drives. The client engaged our team to modernize the entire electrical and controls platform to a current-generation Allen‑Bradley ControlLogix system with new drives. In addition, the project included replacing all control enclosures with new hardware to reduce risk associated with obsolescence and improve long-term reliability. 

A challenge encountered early on was the lack of complete documentation for the existing system. In response, our team, working alongside local electricians, reverse engineered the system to document the controls and electrical infrastructure fully, methodically identifying and capturing all critical system details. This ensured a smooth transition to the new platform.

With a clear understanding of the legacy system, our Automation Team developed a comprehensive modernization design. The solution included:

• New PLC and control enclosures
• Multiple drive cabinets
• Remote operator interface
• Custom-designed operator control station.

These were developed in collaboration with our Mechanical team using 3D modeling tools. Throughout the design process, we worked closely with the client to align on preferred hardware, operating philosophies, and system expectations until a complete drawing package was delivered, including panel layouts, bill of materials, and wiring schematics. 

Following design approval, we procured all major components for the project, including the Allen‑Bradley ControlLogix PLC platform, HMI systems, DC drives, and interface hardware for linear position sensors. In coordination with Rexel USA, we also sourced a fabricator to replicate the existing operator station design, maintaining familiarity for operations personnel while incorporating modernized components. At the same time, our team developed and tested the new PLC program to replicate and enhance the functionality of the legacy system.

To minimize downtime, installation and commissioning of the new system was executed during a planned production outage where our team managed on-site construction activities in coordination with a local electrical contractor to complete the installation efficiently and safely. Startup presented complex challenges, requiring a deep understanding of both the control system and the machine’s mechanical operation. Through strong collaboration and systematic troubleshooting, our team successfully brought the newly modernized system into operation, despite the challenges.

This project required close coordination across our Automation, Mechanical, and Project Management teams with the end result being a fully modernized electrical and controls system, including new drives, control hardware, field devices, and updated wiring infrastructure. 

The upgraded platform positions the client for improved reliability, reduced maintenance risk, and enhanced production performance for years to come.