Introduction: The need for modernization of existing facilities
Aging industrial facilities, often referred to as “brownfields,” pose a major challenge for companies in the aerospace and energy sectors. While these systems still work, they pose security, energy efficiency, and regulatory compliance risks. The ATEX standard, regulating hazardous environments, imposes strict requirements on electrical equipment. Modernizing these facilities is therefore imperative to ensure safety, compliance and operational efficiency.
Assessment of existing systems: Key criteria to consider
Before any retrofitting project, it is essential to analyze the original systems. This assessment must cover several technical and regulatory aspects. The following table summarizes the criteria to be examined:
| Criterion | Evaluation | Standard / Regulation |
|---|---|---|
| ATEX compliance | Examination of certificates, markings and technical specifications | CE, ATEX 114 112, NF EN 50035 |
| Energy efficiency | Power consumption, power factor, overall efficiency | CE, EN 50035, EU Ecodesign |
| Reliability | Mean time between failures (MTBF), failure rate | EN 60068, ISO 14001 |
| Compatibility with modern systems | Interface, protocol, software compatibility | EN 50170, IEC 61131-3 |
| Availability of spare parts | Existence of parts, delivery times | EN 15085, ISO 17025 |
Modern Alternatives: Comparison of Old and New Systems
Replacing an outdated system with a modern model offers significant gains in safety, reliability and efficiency. The offered modern component, Siemens 7MF0400-1TE01-5AM2-ZA00+B20+C11+E00+H02 power terminal, is designed to meet ATEX requirements and improve overall performance. Following table compares the technical specifications of the two systems:
| Parameter | Old system | Modern system |
|---|---|---|
| Type | Analog power terminal | Digital power terminal |
| Food | 24 V DC | 24 V DC |
| Power consumption | 2.5W | 1.8W |
| Response time | 10ms | 5ms |
| Reliability (MTBF) | 20,000 hours | 40,000 hours |
| ATEX compliance | Non-compliant | d>Compliant|
| Compatibility standard | EN 50035 | EN 50035, IEC 60068 |
Calculation of return on investment (ROI): Detailed analysis
ROI is a critical factor for Capex decision makers. A precise analysis of operating costs, energy savings and reduced downtime helps assess the feasibility of the project. The following table presents the basic data for a realistic scenario:
| Parameter | Value |
|---|---|
| Cost of purchasing the modern component | €1,250 |
| Cost of purchasing the old component | €800 |
| Energy cost (kWh) per year | 2,000 kWh |
| Cost of electricity (€/kWh) | €0.15 |
| Annual energy savings | €250 |
| Average annual downtime (h) | 8 a.m. |
| Hourly labor rate (€/h) | €50 |
| Reduced annual downtime | €1,200 |
| Net annual ROI | €1,450 |
| Payback period | 8.6 months |
Implementation plan: Phased approach to minimize disruption
Upgrading an existing facility should be planned in stages to avoid production interruptions. The following approach provides a structured plan:
- Preliminary study: Analysis of existing systems, identification of components to replace, assessment of costs and risks.
- Planning: Definition of work phases, necessary resources and commissioning deadlines.
- Procurement: Ordering modern components via UNITEC-D E-Catalog, checking certifications and specifications.
- Installation: Replacement of components, verification of connections and settings.
- Commissioning: Functionality tests, performance validation and ATEX compliance.
- Training: Staff training on new features and maintenance procedures.
Technical Challenges: Common Problems and Solutions
Retrofitting projects can encounter several technical obstacles. Here are the most common ones and their solutions:
- Software Compatibility: Older systems may not support modern protocols. Solution: Use of protocol converters or adaptation modules.
- Availability of spare parts: Old components are becoming increasingly rare. Solution: Use modern components designed for compatibility and serviceability.
- Electromagnetic interference: Modern systems can generate interference. Solution: Implementation of EMI filters and shielding.
- Integration with existing systems: Interfaces may be incompatible. Solution: Use of converters or gateways.
Case study: Before/after with key indicators (KPI)
An aeronautical factory modernized its control system using the Siemens 7MF0400-1TE01-5AM2-ZA00+B20+C11+E00+H02 component. Here are the results obtained:
| Indicator | Before modernization | After modernization |
|---|---|---|
| Annual electricity consumption (kWh) | 2,000 | 1,750 |
| Annual energy cost (€) | 300 | 262.5 |
| Response time (ms) | 10 | 5 |
| Mean Time Between Failures (MTBF) (h) | 20,000 | 40,000 |
| Average annual downtime (h) | 8 | 2 |
| Reduction in annual maintenance costs (€) | 1,200 | 2,000 |
| Reduction in energy consumed (kWh) | 250 | 250 |
| Overall efficiency gains (%) | 12.5 | 12.5 |
Commissioning and validation: Procedures and acceptance criteria
The commissioning process must be rigorous and compliant with technical standards. The following steps must be followed:
- Functionality tests: Verification of component performance, safety parameters and ATEX standards.
- Validation of certificates: Verification of CE, NF, ATEX certifications and technical documents.
- Energy efficiency tests: Measurement of electricity consumption and comparison with specifications.
- Reliability tests: Load simulation, stress tests and verification of average lifespan.
- Final acceptance: Signature of the validation report by the maintenance manager and the technical manager.
Conclusion: Your partner for modernizing your installations
Modernizing Brownfield facilities is a critical step in ensuring safety, compliance and operational efficiency. UNITEC-D GmbH offers you a complete range of components and solutions certified to meet ATEX requirements and technical standards. For quality components and maintenance services, view our UNITEC-D E-Catalog.
References
- Siemens AG. (2023). Migration guide for ATEX compliance.
- CE, NF, ATEX, EN 50035, IEC 60068, EU Ecodesign.
- UNITEC-D GmbH. (2023). Catalog of certified components.
Consult our UNITEC-D E-Catalog to obtain quality components and solutions adapted to your technical needs.
