Upgrading an obsolete engine control system with modern DEIF PLC architecture
When long lived offshore vessels face obsolescence challenges, system integrators must find reliable, future proof upgrade paths that meet certification requirements — without adding operational complexity. This was exactly the situation Tritek Power & Automation encountered when supporting a platform supply vessel (PSVs) operating across Southeast Asia.
Their customer’s existing system engine control platform from the early 2000s had reached end of life, and service support was no longer available. The question became: How do you retrofit a critical engine control system on active vessels, ensure class compliance, and secure stable long term operations?
Tritek found their answer in the combination of DEIF’s iE 250 front mounted PLC with integrated display and the high performance iE 650 PLC.
A system reaching obsolescence
According to Mr. Antony James, Head of Innovation & Digitalization at Tritek Power & Automation, the vessels relied on a discontinued control solution with embedded IO and safety modules that were no longer supported by the manufacturer. Tritek needed a engine control system that could:
- Replace the complete discontinued setup
- Deliver marine approved reliability
- Ensure long term serviceability
- Integrate safety and engine control requirements
- Support high engine room temperatures (up to 60–70°C)
- Minimize need for external HMIs and wiring
A modern control architecture built on DEIF PLC technology
Tritek designed the new solution using a DEIF PLC architecture that combines performance, marine approvals and operational simplicity.
iE650 – Main PLC
The iE 650 serves as the system’s primary controller, handling all core engine control tasks with fast processing and stands the harsh marine conditions. Its high-temperature certification was a decisive factor in its installation in the vessel’s engine room.
iE 250 – Backup PLC with integrated operator display
The iE250 plays two roles at once:
- It functions as a backup PLC, ensuring redundancy in case of primary controller failure.
- It provides the vessel’s main operator interface, thanks to its integrated display and physical keypads.
Antony highlights the practical advantage:
“The keys around the display make operation easier. In the engine room, hands may be oily or dirty, so physical keys are more reliable than touchscreens. And we didn’t need an external HMI.”
This dual capability reduces the number of hardware components, simplifies certification, and shortens installation time.
CIO modules – Remote I/O
DEIF CIO modules were installed to provide the required input and output capacity. Tritek highlights the CIO module’s multi-input configuration flexibility as an added advantage. According to Mr. Antony, the CIO modules offered the right balance of flexibility and configuration simplicity for this type of retrofit, making them well suited for the vessel’s new control architecture.
Built for marine conditions and classification
The iE series PLCs are type-approved for marine use and certified for operation up to 70°C — a critical requirement for installation in hot engine compartments.
Mr. Naveen Menon, Superintendent engineer – Automation, at Tritek, explains why this mattered:
“The engine room frequently reaches temperatures close to 60°C, so high temperature certification was essential for class approval. If components are certified only for 40 or 50 degrees, the class will ask questions. With DEIF, everything was approved up to 70 degrees, so they did not raise any issues.”
Naveen Menon
Tritek Power & Automation
Implementation and commissioning
Tritek began installation in late 2024. The obsolete engine control system was removed, and new PLCs, remote I/Os and wiring were fitted.
During commissioning, a few configuration points required fine tuning — typical when integrating a modern control platform into an older vessel — and were quickly resolved with support from DEIF teams in the UAE and Denmark.
After running full engine trials and completing classification approval, the vessel was handed over in early 2025.
Operational stability from day one
Since commissioning, the vessel has experienced stable, uninterrupted control system performance.
Mr. Antony, notes:
“After handing over the system, the client has not reported any issues. That is important because the vessel is roaming internationally.”
The absence of post installation service calls highlights the reliability of the new PLC architecture in daily operation.
Anthony James
Tritek Power & Automation
Simpler engineering and easier service
The DEIF PLC architecture reduces engineering time and simplifies ongoing operation:
- PLC logic and visualisation are engineered within the same Codesys environment
- EtherCAT Communication protocol provides faster communication between iE 650 and iE 250.
- No external HMI is required
- Fewer components mean fewer points of failure
- Tag mapping between separate systems is eliminated
Mr. Naveen describes the benefit:
“When WebVisu and the PLC are in the same project, it becomes much easier. You don’t need to assign tags twice or configure another HMI.”
For the operator, spare parts and support are readily available through DEIF’s global network, ensuring long term serviceability.
Looking ahead
Tritek expects to apply the same control architecture to additional retrofit projects in the marine sector and beyond. As industry requirements evolve — including cybersecurity and new standards for control systems — modern PLC platforms offer a solid foundation for long-term compliance and performance.
When asked what he would advise others considering similar upgrades, Antony’s message is clear:
“I will suggest using DEIF because the system is already proven.”
Tritek Power & Automation
- Established in 2014, Tritek is a specialist in marine automation, propulsion, and power solutions.
- Headquartered in the UAE with offices in Sharjah, Abu Dhabi and Dubai; Partner offices in Singapore & India, supported by a network of agents across Asia, the MENA Regions, USA and Mexico.
- Delivers integrated and standalone PLC-based solutions for new builds, retrofits, and upgrades under their proprietary TRICON™ product suite.
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