Cereals
Replaced due to obsolescence and control panel age, this project firstly involved an audit of the existing control panel and its interface to other control panels and equipment. A mixture of outdated and missing drawings resulted in the partial reverse-engineering of connected panels and equipment with cable tracing performed over a number of floors. The design comprised a specially fabricated stainless steel enclosure with segregated Power & Control Sections, sloping roof with bottom cable entry, sized to sit within the footprint of the original control panel. The power section comprised incoming 3-phase power and distribution, SPD protection, 2No. AB Powerflex 525 4kW Drives with brake-control & STO safety, DOLR Slide Valve controls, AB Compact GuardLogix Safety PLC and interfacing to existing/replaced field-based instrumentation, valves, RFID safety gates and 3rd party control panels & equipment. The design is supported by electrical & thermal calculations, safety verification, parts lists, terminal plans and installation cable schedules. Local SI Panel Build and commissioning.
Rubber Production
Additional controls added to an existing Dosing Control Panel allowing for an additional ingredient to be added at the start of the overall solvent-based rubber production process. Non-hazardous stage of the overall process. The original drawings were available for this panel however they were incomplete and only in PDF format therefore a panel audit was the first step followed by circuit tracing and subsequent reverse engineering into EPLAN Pro Panel. Updated drawings provided a stake-in-the-ground for the engineering stage which included the design, build and install of a number of off-site wired sub-assemblies. Safety to PLd (BS EN 13849) using the Pilz PNOZ multi configurable safety relay with Ethernet IP, additional AB ControlLogix PLC IO modules with interfacing controls to a new 3rd party ‘Big Bag’ Discharge Station, Vacuum Skid and a Level-controlled Output Hopper. SCADA screens were subsequently added to control and mimic the new dosing process.
Background: Due to relocation, our customer required a new control system to meet existing and future increased volumes in diesel particulate filter cleaning. As a result of the increase in volume, a new facility for treatment of the water effluent was required to ensure compliance with the discharge consent levels agreed with the local water authority. Upon receiving P&ID’s an FDS and mechanical plant schedules, the control system was designed: –
Control Panel / Skid Audit & disassembly. The forthcoming relocation of the production facility required an audit of the existing skid and associated control panel. Audited drawings and physical hardware anomalies were identified and documented allowing for electrical and mechanical disassembly and subsequent re-assembly at the new location. Based on the supply of existing drawings, pre-site works included the preparation of instrument, cable schedules and RAMS. On-site works included the Control Panel/Skid audit and subsequent electrical dis-assembly.
The Design of 5No. Control Panels intended for non-ATEX Skid mounting. Based on P&IDs, plant and instrument schedules the 3-bay enclosure design incorporated 17No. Siemens G120 VSD’s with motor ratings in the range of 0.37-11kW, Siemens ET200SP PLC, E+H Pressure & Flow Transmitters and actuated valves. Designs were supported with the usual Technical File, documenting IO Schedules, protective device discrimination, load-device sizing/balancing, thermal calculations, conductor sizing and manufacturer datasheets. On this occasion, the end customer had opted to write their own PLC code.