PLC

PLC Programming, Integration & Lifecycle Support

At Conen Solutions, we engineer robust, maintainable, and standards‑compliant PLC solutions that scale across process and packaging operations. Our teams apply IEC 61131, ISA‑88/PackML, and vendor best practices to deliver predictable performance, faster commissioning, and safer operations.

What We Deliver

  • Standards‑Driven PLC Development
    Modular architectures, rigorous naming conventions (tags, I/O, phases), and controller programming aligned to PlantPAx, ISA‑88 (batch phases/states), and PackML where applicable—ensuring consistency across lines and sites.
  • Platform Expertise (Rockwell & Siemens)
    Deep experience with Allen‑Bradley ControlLogix and communications modules, plus integration with HMI and third‑party systems.
  • SCADA & HMI Integration
    Creation and updates of home, overview, interface, parameter, phase, object screens; alarm strategy; global objects; local tags—built to site standards for consistent operator experience.
  • Batch & Recipe Control
    Configuration and updates of batch recipes with clear phase state models (Start/Run/Complete/Hold/Resume/Abort), parameter types (recipe, local, communication, calculated), and exception handling—aligned to ISA‑88.
  • Historian & Data Models
    Systematic mapping of new PLC tags to Aveva Historian for traceability, analytics, and reporting—kept in step with existing historized tags.
  • Testing & Commissioning
    Simulation‑based verification (internal FAT, quality FAT, customer‑witnessed FAT) against formal test specifications, followed by site implementation (downloads/changes, device I/O support) and structured commissioning procedures.
  • Documentation & Governance
    Delivery of FDS, test specifications, method statements, risk assessments, change requests, and cause‑and‑effect matrices to ensure auditability and smooth handover.
  • Safety & Interlocks
    Integration of permissives, trips, and dual‑channel safety devices in control logic; alignment with functional safety practices and Ex‑rated equipment standards where required.

Typical PLC Scope

  • Controller programming to site standards and firmware policies (e.g., v35 where specified) with change control and versioning.
  • I/O assignment and schedules; interface to existing terminations and panels during upgrades/retrofits.
  • Ethernet/serial connectivity for HMIs, historians, and condition monitoring systems via managed switches and secure segmentation.

Industries & Use Cases

  • Food & Beverage: Batch/recipe automation, CIP phases, route permissives, alarm rationalization, historian reporting.
  • Power & Gas Turbines: Start‑up/shutdown sequencing, trip protection, vibration/valve interfaces, monitored fuel control.
  • Specialty Manufacturing: PackML for packaging, integration to coding/printing systems (e.g., Linx/Markem), and lifecycle documentation.

Why Conen Solutions?

  • A design manual that codifies best practices across process and packaging, interfaces to third‑party systems, and repeatable workflows—accelerating delivery and reducing long‑term maintenance cost.
  • A proven project framework from scope and FDS through FAT/commissioning and handover—minimizing risk and improving startup outcomes.