Case study
Canara Pride: CPP control retrofit
Replacing the main Rolls-Royce Helicon X control system while retaining the functioning backup card.
Sadhav Shipping · June 2025
The requirement
Recurring faults in the main control unit and obsolete PCB-based interfaces made the propulsion controls difficult to maintain.
Engineering scope
Onboard diagnosis at PNV Anchorage, replacement of the main controller, and new control interfaces at the forward wheelhouse, aft wheelhouse and engine control room.
Systems & technology
Siemens S7-1200 main and local PLCs, Exor HMI panels, Modbus communications and control logic developed in TIA Portal.
Documented outcome
The report describes improved serviceability, remote diagnostics and reduced cabling complexity. The functioning backup control card was retained and interfaced where possible.
Inspection and upgrade strategy
Inspection on 19 June 2025 at PNV Anchorage traced recurring faults to the main control unit.
The working backup card was retained. The obsolete main controller was replaced with a Siemens S7-1200 PLC.
Existing forward-wheelhouse, aft-wheelhouse and engine-control-room panels used CAN-connected PCB interfaces that could not be reprogrammed.
Implementation
Legacy pushbutton and indicator interfaces were decommissioned and Exor HMI panels installed at all three operating stations.
Local Siemens S7-1200 PLCs serve as remote I/O and control units, communicating with the main CPP PLC over Modbus.
Control logic was recreated using Structured Text and Function Block Diagram in Siemens TIA Portal.
Operating improvements
The HMI presents alarms and status information, with remote diagnostics available through the HMI and engineering tools.
Replacing hard-wired buttons reduced cabling complexity and made the control system easier to service.
The solution removed dependence on inaccessible legacy firmware while retaining usable backup equipment.
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