Control System Upgrade


Mining & Metals

Business Issue

The current fermentation process was controlled by an obsolete Moore control system approaching the end of its useful life.  Obtaining parts and support for the equipment was difficult and resources were being consumed by the increasing challenges of the aging systems.

Project Summary

The process controlled by the Moore control system is a batch operation including tank control, pH control, and an extraction process.

The existing system consisted of 5 separate systems and included some independent PLC controlled equipment (Rockwell and Modicon) and independent single loop Moore controllers.  A new DeltaV system replaced the 5 existing systems and interfaced to other PLCs within the facility.  The system also interfaced through OPC to an existing plant data historian.

A demanding production schedule required that the switchover occur with minimum downtime.  Due to limited space in the control room, the hardware design also required using existing panels to house the new equipment and staggered installation to allow old panels to be removed as they were replaced to make room for the new panels.

Scope Responsibility

Cornerstone Controls was responsible for the following areas:

  • Project management activities including:
    • Scope Management
    • Budget Management
    • Project Scheduling
    • Installation management
  • Hardware design of the new DeltaV system including:
    • System Architecture Drawing
    • Panel layout and wiring design
    • Interfacing to existing PLCs
  • Fabrication of new control panels and control room furniture.
  • Software design, development and integration.
  • Computer system validation.
  • Installation/Integration of new DeltaV control panels.
  • Onsite commissioning.


The new DeltaV control system successfully replaced the obsolete Moore system with minimal impact to the production schedule.