Cement Plant PLC/DCS Modernization Project

Hong Kong Saul Electric Co., Ltd.

Cement Plant PLC/DCS Modernization Project

Hong Kong Saul Electric Co., Ltd.

Project Background

The client, a leading cement manufacturer, was operating with legacy PLC and DCS systems on its main production line. These outdated systems led to frequent breakdowns, limited process visibility, and high maintenance costs, impacting overall productivity and plant safety.

Challenges

Obsolete PLC/DCS hardware with limited spare parts availability
No centralized monitoring or remote diagnostics
Need to minimize production downtime during system migration
Integration with existing field devices and instrumentation

Our Solution

Hong Kong Saul Electric Co., Ltd. provided a turnkey modernization solution:

Replaced legacy PLCs with Siemens S7-1500 series controllers
Upgraded the DCS to a modern, scalable platform covering kiln, mill, and packing areas
Deployed a centralized SCADA system for real-time monitoring, control, and data analytics
Phased migration strategy to ensure continuous production with minimal downtime
Comprehensive training for plant operators and maintenance staff

Results & Benefits

Production efficiency increased by 18%
Unplanned downtime reduced by 60%
Enhanced process visibility and predictive maintenance capabilities
Improved plant safety and operational reliability
Operators benefit from intuitive dashboards and remote access

Contact Us

For more information about our cement plant automation and modernization solutions:
Email: zoe0159@163.com
Phone: +86 18030274856

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