When to Consider a Separator Retrofit

Many industrial separators continue operating with legacy control systems that limit performance, increase maintenance costs, and create compliance challenges. A well-planned retrofit can transform aging equipment into modern, efficient production assets.

Benefits of Separator Control System Retrofit

A professional retrofit delivers measurable improvements across multiple dimensions:

Operational Benefits

• Reduced downtime: Modern diagnostics enable faster troubleshooting and predictive maintenance
• Improved efficiency: Advanced control algorithms optimize separation performance
• Better visibility: Modern HMIs provide clear process visualization and trend analysis
• Remote monitoring: Monitor separator performance from anywhere via SCADA or web interfaces

Financial Benefits

• Lower maintenance costs: Standardized components reduce spare parts inventory
• Extended equipment life: Proper control extends separator operational lifespan
• Energy savings: Optimized VFD control reduces power consumption
• Reduced training costs: Modern interfaces are more intuitive for operators

Compliance Benefits

• FDA 21 CFR Part 11 compliance for pharmaceutical applications
• Current safety standard compliance (SIL-rated safety systems)
• Environmental regulation compliance
• Comprehensive audit trails and data logging

Retrofit Planning Process

Successful retrofits require careful planning to minimize production impact:

1. System Assessment

Comprehensive evaluation of existing systems:

• Document current I/O requirements
• Identify communication protocols
• Assess mechanical condition
• Review safety requirements
• Evaluate integration needs
• Document operator workflows

2. Design Phase

Develop retrofit solution:

• PLC platform selection (CompactLogix or ControlLogix)
• HMI selection and screen design
• VFD selection and configuration
• Control panel design
• Network architecture
• Migration strategy

3. Factory Acceptance Testing

Test new system before installation:

• Complete PLC programming
• HMI screen development
• VFD configuration
• Simulation testing
• Operator training on new system

4. Installation & Commissioning

Minimize production impact:

• Staged installation during planned downtime
• Parallel operation where possible
• Quick cutover procedures
• Immediate troubleshooting support
• Performance validation

Common Retrofit Scenarios

Legacy PLC Replacement

Upgrading from obsolete PLC platforms (Modicon, GE, Siemens S5) to modern Allen Bradley ControlLogix or CompactLogix:

• Program conversion and optimization
• I/O module replacement
• Communication protocol updates
• HMI integration

HMI Modernization

Replacing outdated operator interfaces with modern PanelView Plus or FactoryTalk View:

• Screen design with modern graphics
• Improved alarm management
• Trend displays and data logging
• Mobile-responsive web clients

VFD Addition or Upgrade

Adding VFDs to fixed-speed motors or upgrading to modern PowerFlex drives:

• Motor compatibility verification
• VFD sizing and selection
• Control integration
• Energy optimization

Safety System Upgrade

Implementing SIL-rated safety systems:

• Safety PLC integration
• Safety relay replacement
• Emergency stop circuit modernization
• Safety validation and testing

Supported Separator Models

YES-AL provides retrofit services for all major separator manufacturers:

Alfa Laval Separators

• BTUX Series (BTUX 305, BTUX 510)
• CLARA Series (CLARA 20, CLARA 80, CLARA 200, CLARA 750)
• MBPX Series (MBPX 404, MBPX 507, MBPX 71)
• AFPX Series (AFPX 200, AFPX 513, AFPX 617)
• HBPX Series (HBPX 5000, HBPX 8000)
• Brewery Separators (Brew 350, Brew 450, Brew 750)

ABB Separators

• ABB separator control systems
• ABB automation platform upgrades
• Legacy ABB separator modernization

GEA Separators

• Various GEA Westfalia models
• Custom GEA configurations

Retrofit Best Practices

Minimize Production Impact

• Schedule during planned maintenance windows
• Use factory acceptance testing to reduce on-site time
• Maintain backup systems during transition
• Plan for quick rollback if needed

Preserve Operator Knowledge

• Involve operators in design process
• Maintain familiar workflows where possible
• Provide comprehensive training
• Create detailed documentation

Ensure Long-Term Support

• Use standard, supported components
• Document all changes thoroughly
• Provide spare parts lists
• Establish maintenance procedures