Future-Proofing Omaha’s Infrastructure Through Strategic Control System Upgrades
Omaha, Nebraska
Control System Upgrade
A local company in Omaha faced a critical challenge: their pump system relied on an OEM control board that had become obsolete, discontinued, and unsupported. With no replacement available, ESCO Automation was tasked with providing a fully functional, future-proof solution while minimizing downtime and ensuring seamless integration with existing operations.
Replacing obsolete OEM control board with modern, scalable PLC/SCADA-based infrastructure.
Work performed
1. Design Phase:
- Worked closely with the customer and electrical contractor.
- Created a practical, efficient panel design.
- Conducted on-site acceptance testing and iterative redesigns based on feedback.
3. Futureproofing:
- Aligned with the customer on future PLC/SCADA platforms, networking, MES/OEE/ERP integration, and I/O data needs.
- Designed the system with scalability and maintainability in mind, using off-the-shelf PLCs and components.
2. Software Development & Simulation:
- Developed PLC control logic.
- Built a simulation model to test operational scenarios, faults, and exceptions.
- Performed robust virtualization and testing to reduce downtime.
- Hosted a Factory Acceptance Test (FAT) with live HMI demonstration and stakeholder interaction.