Rustronic MKII

We deliver a PLC‑based replacement for the Rustronic MKII controller that reuses existing wiring and panel footprint wherever practical. This keeps outage windows short, reduces risk, and preserves proven field devices. The new controller is supplied either as a plug‑compatible rack replacement or as a pre‑engineered cabinet with interface harnesses to your existing TCM/field terminations.

Controller platforms we offer

• Allen‑Bradley ControlLogix / CompactLogix (Studio 5000 / PlantPAx)
  EtherNet/IP architecture, rich AOI/UDT libraries, proven gas‑turbine sequencing and protection templates.
• Siemens S7‑1500 (TIA Portal)
  PROFINET/Profisafe, modular OB/FB/DB design, with published MKII upgrade precedents on S7 hardware.

Why these two? They’re globally supported, spare‑rich platforms with long roadmaps and strong lifecycle tools—ideal for replacing an obsolete MKII where OEM parts are scarce.

---

Architecture at a glance

• I/O & interfaces: New PLC I/O is mapped channel‑for‑channel to existing MKII signals using adapter boards or interface looms; special interfaces (e.g., vibration, overspeed, F&G, fuel valves) are brought into dedicated modules/subsystems.
• Networks: Industrial Ethernet backbones (EtherNet/IP or PROFINET). Legacy serial links and hardwired handshakes are retained where required.
• Safety: Separate hardwired safety—or a SIL‑rated safety layer—for trips/ESD; 1oo3 overspeed with independent hardware and certified vibration monitoring.
• Operator interface (HMI/SCADA): Modern PC‑based HMI (FactoryTalk View, WinCC, or AVEVA InTouch) with trending, alarm/event summaries, and auto‑navigation during start sequences to surface the right KPIs at the right time. Existing MKII alarm semantics and colour conventions can be preserved to reduce operator retraining.
• Historian/MES connectivity: Structured tag mapping to your historian and optional MES/ERP hooks for production and maintenance analytics.
• Cybersecurity: Network segmentation, firewall rules, secure remote access, and account governance aligned to IEC 62443 principles.

---

Fuel and actuator options (choose your path)

We support three common migration tracks so you can balance cost, risk, and performance:

1. Retain existing star valves and OEM ECUs
   We integrate the new PLC with the existing ECU/star‑valve stack where protocol exposure allows (or via dedicated gateway options). Best when mechanical sets are in good condition and spares are available.
2. Replace star valves/ECUs with electronic fuel metering (EVO2)
   Our preferred path for reliability and emissions control. Provides modern diagnostics and tighter control—sized and tuned for your unit duty.
3. Convert hydraulic VGV to electronic VGV (EVGV)
   Retires hydraulics, reduces maintenance, and improves vane positioning accuracy. Delivered with a dedicated EVGV controller panel and PLC integration.

Not sure which to choose? We’ll assess the mechanical baseline, spares posture, and emissions/efficiency goals, then recommend the optimum route.

---

Safety, protection & condition monitoring

• Trips & ESD: Independent hardwired safety path; configurable permissives and inhibits; proof‑test procedures and evidence packs for audits.
• Overspeed: Triplex (1oo3) overspeed with certified hardware and self‑check routines.
• Vibration & dynamics: Integrated vibration DAQ/analysis with configurable bands and alarms; optional shutdown interlocks.
• Fire & Gas: Replacement of legacy racks or clean integration with site F&G (Tyco/R4 and others), with unified alarm/event presentation on the HMI.

---

HMI/SCADA modernisation (operator‑first)

• Standardised screens: Overview, start/stop, protection, fuel, VGV, auxiliaries, and diagnostics; on‑top banners with persistent status; high‑contrast colour palette.
• Alarm philosophy: Priority, shelving, and time‑stamped events; MKII‑style event mapping for continuity, plus enriched detail for troubleshooting.
• Guided start‑up: Auto‑navigation presents the screen most relevant to each phase of the start sequence to cut cognitive load.
• Historian hooks: Ready‑made tag sets for trending, performance baselining, and RCA.

---

What you get (deliverables)

• Design & governance: URS, FDS, SDS, I/O schedules, P&IDs cross‑refs, cause‑&‑effect, cybersecurity concept, and test specs.
• Build & test: Factory build with simulation‑based FAT (controller + HMI + interfaces), followed by on‑site commissioning and evidence packs (loop checks, trip tests, alarm verifications).
• Documentation & training: As‑built drawings, alarm list, maintenance/diagnostic guides, operator quick‑starts, and recommended critical spares list for the new platform.
• Lifecycle support: Remote support readiness, patching cadence, and obsolescence roadmap.

---

A typical cut‑over (risk‑controlled)

1. Assessment & data‑gathering: Pull drawings, signal lists, protections, and operating envelopes; agree instrument and trip matrices.
2. Detailed design & emulation: Map every I/O and trip path; build a digital testbed for functional checks and start‑sequence proving.
3. Factory acceptance: Witnessed FAT on the integrated controller/HMI stack with scenario‑based test scripts.
4. Planned outage & swap: Remove MKII racks, install PLC rack or cabinet, land harnesses, power‑up, and perform loop/functional checks. (Industry examples show short, planned outages for rack‑compatible solutions.).
5. On‑load tuning & handover: Trip‑proof tests, alarm rationalisation, performance baselines, training, and as‑built pack.

---

Compliance & standards

• Functional Safety: IEC 61508 / IEC 61511 (SIL verification, proof‑testing, safety case).
• ATEX / IECEx: For hazardous area devices, barriers, and enclosures.
• PLC/HMI: IEC 61131‑3 and ISA‑101 principles for maintainable code and operator‑centric displays.
• Cybersecurity: IEC 62443 hardening and governance.
• Quality: ISO 9001/14001/45001 aligned delivery.

---

FAQ

Can we keep our existing fuel valves and ECUs?
Yes—where protocols and health allow. We also offer EVO2 fuel metering upgrades for improved performance, or full EVGV conversions to retire hydraulics.

Do operators need to relearn everything?
No. We preserve MKII alarm/event semantics and provide guided start‑up with modern diagnostics, reducing training burden while adding new capability.

What about spare parts going forward?
Moving to AB or Siemens means globally available spares and long‑term platform support, avoiding obsolete card hunts.