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The project focused on replacing ageing low-voltage direct-on-line (DOL) switchgear with modern Siemens SIMOCODE motor management systems integrated via PROFINET communications. Verbrec developed a constructible, shutdown-ready design that enabled a smooth transition from legacy systems while minimising downtime and maintaining operational continuity.
SIMOCODE
Advanced motor management system integration
PROFINET
Modern communication protocol replacing DeviceNet
Shutdown-ready
Design optimised for minimal downtime execution
Verbrec developed a comprehensive electrical and control system design for the motor control centre, including MCC layout modifications, PLC configuration and network topology. The approach ensured the upgraded system could be implemented efficiently during planned shutdown periods while improving overall system reliability and performance.
Verbrec engineered a practical design strategy that enabled a significant portion of installation work to be completed ahead of shutdown periods. By pre-installing selected components outside the MCC tiers, the team reduced the volume of work required during critical shutdown windows. The design also streamlined the transition from DeviceNet to PROFINET, ensuring systems could be brought back online quickly and efficiently with minimal disruption.
The detailed design enabled the client to significantly reduce shutdown time by completing much of the installation work in advance. Controlled commissioning processes allowed both legacy and new systems to be managed effectively during cutover, reducing risk and minimising the impact of issues. The project not only improved operational reliability but also established a scalable, repeatable approach for modernising legacy electrical and control systems across industrial sites.
This approach demonstrates a repeatable model for modernising legacy electrical and control systems where uptime, safety and execution certainty are critical.