Regenerative Drive Replacement Control Panel for a UK Chemical Processing Facility
Sector:
Chemical Processing
Type:
New Build - Control System, Software
Platform:
Siemens
Certification:
CE / UKCA
Summary
DelaControl designed, built, programmed, and commissioned a new wall-mounted control panel housing a regenerative variable speed drive system to replace legacy drive equipment at a UK chemical processing facility. The panel integrates with an existing control system via hardwired I/O and is network-ready for future connection to a site-wide DCS.
Challenge
An existing legacy drive system — a Barmag-controlled arrangement — needed replacing with a modern regenerative drive solution capable of controlling two motors already purchased by the customer with regeneration capability.
The new control system was required to integrate with the existing Barmag controller via hardwired signals and be capable of future communication with a higher-level Honeywell DCS. The customer had initially wished to house the new drive components within the existing Barmag control panel, but the available internal space — approximately 300 mm wide by 450 mm tall — was insufficient given component sizes and the manufacturer-required air gaps needed to prevent overheating. A new, separate enclosure was therefore required.
The solution also needed to conform to the customer's internal electrical design and installation specifications, which were provided after the initial scope had been established.
Solution
DelaControl designed and built a new wall-mounted Rittal enclosure (1000 mm H × 800 mm W × 400 mm D, RAL 7035) housing a complete regenerative drive control system. Two Siemens SINAMICS G120 power modules (5.5 kW, 3-phase AC, 380–480 V) were selected, each paired with a CU240E-2 PN-F control unit featuring integrated Safety Integrated functions and PROFINET communications. A Siemens S7-1200 PLC was installed to provide overall system control and network communications, supporting MODBUS/TCP, Ethernet/TCP, and PROFINET to enable future DCS integration.
The panel front was fitted with a mimic plate carrying operator controls — including pushbuttons, selector switches, pilot lights, and a speed reference potentiometer — in place of an HMI at this stage, with provision made for an HMI to be added in a future phase. Panel cooling was addressed through a Rittal Blue e+ fan-and-filter unit with thermal calculations carried out using Rittal Therm software.
DelaControl produced a full documentation package including electrical schematics (AutoCAD Electrical or Eplan), general arrangement drawings (AutoCAD Inventor), thermal calculations, a Factory Acceptance Test schedule and certificate, and a Declaration of Conformity to LVD and EMC directives in accordance with BS EN 60204, BS EN 61439-1, and BS EN 61439-2. All software was loaded and commissioned prior to delivery, with all native software files provided to the customer.
Site installation and commissioning were included in scope, with a control systems engineer and an industrial electrician each allocated up to three days on site. The panel was connected to the existing Barmag control panel, with power supply and I/O fed from the existing installation.
Key Facts
• Two Siemens SINAMICS G120 power modules, each 5.5 kW, 3-phase AC input
• Two Siemens G120 CU240E-2 PN-F control units with Safety Integrated (STO, SS1, SLS, SSM, SDI) and PROFINET
• Siemens S7-1200 PLC with digital I/O expansion modules
• Rittal 1000 mm H × 800 mm W × 400 mm D wall-mounted enclosure, RAL 7035
• Rittal Blue e+ active fan-and-filter cooling with Rittal Therm thermal calculations
• PROFINET, MODBUS/TCP, and Ethernet/TCP communications — DCS-ready
• Full documentation package: schematics, GAs, FAT schedule and certificate, Declaration of Conformity, thermal calculations
• Site installation and commissioning included (up to 3 days each discipline)