Georgia Pacific Paper Converting SCADA System Upgrade

Overview

OS Engineering completed a large-scale SCADA migration from the initial feasibility study and preliminary design, to the development of the new system, all the way through final startup and commissioning. A powerful but outdated system that was originally developed by in-house staff was replaced using a heavily customized implementation of Ignition software.

The new system was built on a large architecture consisting of more than
ten new virtualized servers, and relied heavily on “High Performance HMI” graphical standards that were developed in partnership with mill engineering staff.

Scope

Developed a communication architecture supporting more than 150 PLCs and other control system devices from many manufacturers and spanning several generations.
Migrated more than 100,000 tags, many of which were packaged into custom data formats
Identified and replaced interfaces with business systems, reporting applications, and product labeling and scanning systems
Established interfaces with several SQL-based databases and a PI historian
Worked closely with mill staff to create detailed graphical standards, documented in a style guide
Developed nearly 200 graphical screens, created from a library of dozens of custom template objects, allowing for consistent graphics throughout the facility
Created custom graphical tools allowing for rapid classification and categorization of system alarms
Worked closely with mill and corporate IT staff to ensure compliance with company IT policies and industry best practices for cyber security
Provided nearly three weeks of hands-on and classroom training to operations, maintenance, and engineering staff