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Case Study - Reverse Engineering French PLC Code

SAFEgroup Automation (SGA) has been proudly working with one of Northern New South Wales’ major local governments to upgrade an Ozone generator PLC for an essential Water Treatment Plant. This project involved one of our Senior Control System Engineers to reverse engineer the existing PLC code, which was written in French.

Project Requirements:

  • To remove the risk of an obsolete PLC failing.

  • To reverse engineer the existing PLC code.

  • To gain an understanding of the functionality of the existing code.

  • To provide greater insight into the operation of the machine, especially for fault finding.


Solution:

  • To reverse engineer the existing PLC code, which was written in French.

  • To install new a PLC and HMI.

  • To integrate the PLC into the plant’s SCADA system.



Key Benefits:

  • SGA and our clients’ operators gained a greater understanding of machine operations.

  • Implemented machine features that were not previously installed, including historic trending and detailed alarm management by integrating into plant’s SCADA system.

  • It has provided the client peace of mind by implementing reliable hardware, 24/7 support, and replacement options.

  • With the code now written in English, it can provide the client with reliable code backups, in the unlikely event of hardware failure.

Technology Used:

  • ClearSCADA.

  • Industrial Networking.

  • Schneider Electric PLC’s.

  • Local HMI/touchscreen operator interface panel.


SGA Testimonial:

“It was great to deliver a project that developed my own personal experience, through reverse engineering code written in French, but also highlighted SGA's commitment to delivering industry-leading solutions for our clients..” – Josh Miller - Northern NSW Senior Engineer.

Outcome:

SAFEgroup Automation successfully upgraded the Ozone generator PLC for the Water Treatment Plant. The upgrade allows our clients to work with a more functional and reliable system. It has also:

  • Provided our clients with a documented functional description detailing the operation of the Ozone generator.

  • Provided integration into an existing plant SCADA system.

  • Allowed implementation of standard function blocks.

  • Removed manual process controllers, achieved by integrating analog signals into the new PLC and enabling control through the HMI and SCADA system.

  • Provided the client peace of mind by implementing reliable hardware, 24/7 support, and replacement options.


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