R - Retrofit
E - Engineering
D - Digitalization

• Mechanical & electrical integration
• PLC upgrade & system communication
• SCADA integration

About the project

TSA Port expanded its existing washing facility (tank cleaning) with a fourth washing line. This addition required both mechanical and electrical integrations, including the installation of a high-pressure pump and a thorough update of the existing PLC architecture.

In addition, the existing Schneider data collector PLC had to be modified to communicate with a new heating system, controlled by a separate Siemens PLC, and to supply additional data to the central cross-country SCADA platform.

Challenge

The project involved several technical challenges:

• Integration of a high-pressure pump into the new 4th washing line
• Significant electrical modifications to safely power the expansion
• Upgrade of the Schneider data collector PLC
• Communication with the new heating system running on a Siemens PLC
• Implementation of Modbus TCP/IP communication between both systems
• Expansion of the system to send additional process data to the central SCADA-MES (monitoring system)

Our contribution:

Mechanical & Electrical Integration:

• Installation of a new high-pressure pump for the fourth wash line
• Execution of all necessary electrical work for stable and safe operation
• Modifications to existing cabling, distribution boxes and safety circuits

PLC Upgrade & System Communication:

• Upgrade of the Schneider data collector PLC
• Configuration of Modbus TCP/IP communication between Schneider and the Siemens PLC of the heating system
• Expansion and optimisation of the PLC programme for new functions and data flows

SCADA integration:

• Additional process data made available for the cross-country SCADA-MES system, including:
• Pump statuses
• Heating parameters
• Error messages
• Real-time process values
• Order data processing for cleaning and/or heating (container) tanks
• Improved data transparency and monitoring for operators

Results for the customer:

• Fully integrated high-pressure pump in the new wash line
• Seamless communication between Schneider and Siemens PLCs via Modbus TCP/IP
• Reliable data flow to the central SCADA/MES platform
• Real-time monitoring increases operational efficiency
• All electrical modifications correctly carried out in accordance with standards
• Smooth operation of the washing lines thanks to a robust system architecture

REDI pillars in this project:

R – Retrofit
Upgrading of existing PLC infrastructure and integration of new hardware
E – Engineering
Electrical work, system integration and communication technology
D – Digitalisation
Processing of order data for cleaning and/or heating (container) tanks