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Small to Medium Retrofit Applications
We have successfully replaced many outdated control
systems that were based on hardwire relay logic with PLC (Programmable
Logic Controllers) or DCS (Distributed Control Systems)-based
systems. Often old systems become maintenance intensive, with
high failure rates and intermittent problems that are difficult
to track down. The new computer-based systems are highly reliable
and have built in diagnostics that make troubleshooting faster
and easier.
To automate a process, we first must understand
what it does -- or is supposed to do. We carry out extensive fieldwork
to identify the existing control requirements. Our engineers and
field technicians trace the wiring to verify exactly what the
system is currently doing (reverse engineering). We can then develop
a new system to provide improved functionality.
Once we have completed the documentation, we determine
the appropriate inputs and outputs to the new system, specify
the components and determine how to install them. This phase of
the project includes layout drawings of the system cabinets, as
well as detailed wiring diagrams for the I/O.
In some cases, we have the panel built at our facility,
so we can test the panel wiring prior to installation. Many projects
require that the old system be removed to make room for the new
controls. Either way, we work closely with the contractor to complete
the demolition and new installation within your shutdown time.
Finally, we offer operator training,
either on-the-job or in a classroom setting, for operation and
maintenance. In some cases, we have programmed simulations and
"online" manuals for complex systems or strategies.
Once the new system is installed and the new programming
is loaded, we work with mill E/I technicians to perform an I/O
checkout to verify the new field wiring and a logic check to test
essential interlocks before start up - and to give them experience
with the system.
We then staff the startup around
the clock until it is running satisfactorily. Following
startup we provide you with a final record drawing package and
all documentation. We provide both operational and maintenance
support until the mill staff is comfortable with all phases of
the system.
Your success is our success
When we upgraded the end process of a pulp dryer
using PLCs to automate the cutting, stacking, and transfer of
pulp bales to the wrapping line, the number of trouble calls dropped
from two or three per month to less than one per year.
Sample projects include
- Digester Control Conversion from Single
Loop Analog Pneumatic Controls to Honeywell DCS
Domtar Woodland, ME
- Pulp Bale Line Conversion from relays and
Pushbuttons to PLC with PanelView Domtar
Woodland, ME
- Detailed Design and Programming For Laboratory
Laminator using A-B Soft PLC Huhtamaki
Packaging, Waterville, ME
Contact us for more information.
More Specialty Applications
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