Case Study: SAGE Automation achieves safer, high-availability explosives control with Rockwell Automation

Explosives Control System Upgrade Under Control

SAGE Automation was engaged by a leading explosives manufacturer to replace aging DCS, PLC, SCADA and control gear across multiple physically separated process areas. The challenge was to deliver a modern control and safety upgrade that complied with hazardous area, functional safety and machine safety standards, while supporting a highly critical explosives manufacturing environment.

Using Rockwell Automation PlantPAx®, ControlLogix®, AADvance™, and FactoryTalk® software, SAGE Automation and Rockwell Automation implemented a distributed, redundant control architecture with virtualized servers, fault-tolerant networking and integrated HMI, reporting and asset management. The result was a fully integrated control and safety solution that met AS61508 and AS60079 requirements, improved availability and resilience, and minimized downtime during installation through deployment around normal plant operations.

SAGE Automation

Steve Lloyd

Senior Project Manager