Project Name: North America SCADA & PLC

Modernization Program

Facility:

• Santa Ana, California
• Irondale, Alabama
• Ajax, Ontario, Canada (Supervisory Site)

Scope:
Complete modernization of legacy GE Fanuc Intellution/iFIX SCADA and Allen-Bradley PLC-5 control systems across three manufacturing facilities.
Work included:

• Migration from PLC-5 platforms to Allen-Bradley CompactLogix
• Replacement of legacy DH+ and RIO networking with Ethernet/IP architecture
• Deployment of Ignition 8.1 SCADA platform
• Installation of new Windows Server-grade hardware (Ajax included PowerEdge R450 rack server)
• Kepware OPC/SQL integration and database configuration
• Recreation of HMI graphics with modern interface while maintaining operator familiarity
• Trending, historian, reporting, email/SMS alarming
• Remote access via IT-managed VPN
• Full demolition of obsolete PLC hardware and protocol networks
• Conduit routing and Ethernet infrastructure (runs up to 2,000 feet)
• Commissioning, SAT, operator training, and system documentation

System:
All three facilities operated on obsolete Allen-Bradley PLC-5 processors integrated with GE Fanuc SCADA platforms. Hardware support had been discontinued, creating increasing operational risk and difficulty sourcing spare parts.

Santa Ana and Irondale utilized PLC-5 processors with DH+ and legacy serial networking. Ajax operated using PLC-5 with Remote I/O (RIO) and Flex I/O racks, serving as the supervisory location for North America operations.

CEI standardized the architecture across all sites by implementing:

• Allen-Bradley CompactLogix processors
• Ethernet/IP networking
• Ethernet Flex I/O upgrades (Ajax retained existing Flex I/O modules and replaced communication adapters only)
• Centralized Ignition SCADA server with unlimited tags and clients
• SQL historian database
• Scalable architecture for future plant expansions

Ajax was engineered as the supervisory hub capable of managing and scaling with additional North American facilities.
The new architecture provides:

• Real-time data visibility across the plant network
• Unlimited SCADA clients (desktop, tablet, mobile)
• Historian and exportable data
• Modern alarm management
• Future-proof, firmware-consistent infrastructure

Benefit:
This modernization eliminated dependence on discontinued PLC-5 hardware and aging SCADA software, significantly reducing operational risk and spare-parts vulnerability.
The upgrade provided:

• Improved reliability and scan performance
• Standardized Ethernet/IP communication
• Centralized data capture and trending
• Expandable infrastructure for future production lines
• Reduced long-term maintenance costs
• Consistent architecture across North American facilities

By completing the infrastructure upfront rather than phasing fragmented upgrades, GCP received a clean, scalable, and supportable automation platform aligned across multiple sites.