Projects

GASCO

GASCO

SCADA

Columbia Export Terminal

Columbia Export Terminal

Automation

Discovery Corridor

Discovery Corridor

Control System

Great Western Malting

Great Western Malting

Design Build

Louis Dreyfus Commodities (LDC)

Louis Dreyfus Commodities (LDC)

PROGRAMMING

City of Stayton

City of Stayton

Design & PROGRAM

IS Hero

GASCO

SCADA

Columbia Export Terminal

Automation

Discovery Corridor

Control System

Great Western Malting

Design Build

Louis Dreyfus Commodities (LDC)

PROGRAMMING

City of Stayton

Design & PROGRAM

Description

This facility treats contaminated ground water that is drawn from a series of wells along the Willamette River and discharges the clean water into the river. Industrial Systems designed, supplied and programmed the control system for this ground water treatment process. The system employs an Ethernet network of Allen Bradley Compact Logix processors, Powerflex VFD’s, touch panels and a Factory Talk View SE server/client SCADA system. The SCADA system also includes Win 911 alarm dialing and XL reporter to automatically create reports for all daily operations. This control system also includes an integrated maintenance reporting system and full control and monitoring is made available to the operations staff through redundant remote access methods. Three years after the initial installation based on Factory Talk ME and employing mostly remote manual control capability in accordance with the owner’s initial direction, ISINC was retained to upgrade this system from Factory Talk ME with several standalone operator stations to the current Factory Talk SE client/ server arrangement. This update also included the implementation of automatic control of all processes and allows for non-attended 24 hour operation of the facility.

Location

Portland, OR

Team

Troy Collison
Mark Lietzke
John Sowards

Description

Columbia Export Terminal, located in Portland OR, is one of the most automated and integrated grain export facilities in the Northwest.  Industrial Systems Inc. (IS, Inc) has just completed the SCADA additions for an expansion of their cleaning and storage capacity. IS Inc also provided the PLC and Wonderware programming for an update of their Plant wide Hazard Monitoring system. The I/O multiplexers installed can handle a total of 1728 thermocouples which monitor bearing and conveyor rub block temperatures for plant alarm notification.  The automation control system comprises multiple Modicon PLC’s linked by a fiber network. All I/O is monitored by two redundant Wonderware tag servers which handle the over 22,000 tags used by the graphic system. This data is displayed on multiple view stations located in the main control room.


 

Location

Portland, OR

Team

Mark Lietzke

Description

This project included the final design and supply of the electrical and control systems for five pump stations that serve to connect the Ridgefield WA Wastewater system with the Clark Regional WWTP in Salmon Creek WA. The five pump stations include pumps from 7 ½ HP to 200 HP all of which are VFD controlled. The 200 HP VFD’s at the 209th street pump station are 18 pulse drives to minimize harmonics. This was a public bid project based on typical pump station drawings that had been modified with notes to include the intent of operation for each individual pump station. Industrial Systems completed the detail design of the PLC and VFD control system and for each pump station and provided the VFD’s, control panels and radio communication equipment. Three of the pump stations were retrofits and two were new construction. The control panel and VFD’s of one pump station were reconstructed in the field using Industrial Systems design and oversight while the other four control panels were of new construction. Each pump station includes the requirement for hardwired float control back up and pump station overflow alarm.  All pump stations communicate to the Clark Regional Wastewater SCADA system via Ethernet radio.

Location

Vancouver, WA

Team

Troy Collison
John Sowards

Description

We at Industrial Systems have worked with Great Western Malting on various projects for over 20 years. We were honored when GWM contacted us to assist them with the design and construction of a new malting facility at their Pocatello Idaho site. This was a fast track project that was to be in production within 18 months of our intimal involvement and concrete was already being poured by the time we began work. Our design efforts focused on staying ahead of the contractors and the concrete for many months before we could change our focus final control system design and programming.  We designed a multi level fiber network to ring this site and provide separate physical network layers for SCADA, peer to peer and PLC I/O and VFD com needs. All motor driven equipment in this facility including pumps fans and conveyors are equipped with VFDs to provide maximum flexibility in production. The control system backbone was the latest 1 GB Ethernet capable PLC processor from Allen-Bradley. This single processor controls 100 VFDs and nearly 2000 I/O points all over Ethernet IP.

Location

Pocatello, ID

Team

Troy Collison
John Sowards
Mark Wirfs

Description

LDC chose to rebuild their facility while only retaining a small amount of the original equipment.  This meant replacing all the PLC hardware and install a new SCADA system.  R&W Engineering designed the plant electrical and programmed the PLC hardware.  Industrial Systems, Inc. designed and programmed the SCADA system.  The SCADA integration included 8 PLC’s, Compressor, 3 Weigh Scales communicating over Ethernet using a mix of hard wire and fiber optics.  Equipment such as Belts, Drags, Legs, Dust Systems etc. are wired to the PLC that is local to that area.  Hazard temperature monitoring of bearings, rubs and ambient are wired to Mux’s with the Mux units communicating to a single PLC via Ethernet. The SCADA system is also integrated into a separate Plant SQL Inventory system to display Inventory Levels, Grades and status of production. In all, the SCADA system includes 20k+ points, 1000+ graphic objects, 44 types of equipment and over 6K alarms. The objects are designed with the future in mind.  Any changes needed to equipment can be made in one place so that modifying or adding equipment is quick, consistent with all other equipment and without loss of production time.

SCADA PC integration includes a Server, 3 - 42” Operational Viewers, 1 – 21” Desktop Viewer, 1 – 21” Federal Grain Inspection Viewer, 4 concurrent user license for complete Web Page access to any operational graphic from any desktop on the Plant Intranet.   SQL Server is used to track all equipment operation and temperature values.

SCADA operation includes monitoring of all equipment control and status.  Alarms for equipment are routed per equipment with animation and alarm list.  The hazard monitoring temperature alarms are separately monitored and display with an alarm icon near the appropriate equipment.  Selecting the alarm icon will open a graphic detail of that specific equipment.   Additionally, selecting an alarm in the alarm list will also open the graphic detail where that alarm is located.

Location

Portland, OR

Team

Mark Lietzke

Description

Industrial Systems provided the control system design and programming to expand this facility by approximately 50% while updating the Allen-Bradley PLC 5 based control system to the Control Logix platform. The SCADA system for this facility is based on Wonderware and includes remote access and data logging.

The original PLC 5 control system at this facility was of CH2M Hill design and included redundant processors but with a single, serial, communications system. Our redesign of the control system provided the facility with a fiber optic Ethernet network configured in a ring topology. This approach guards against a plant wide communications failure due to a single communications path interruption.

The PLC and HMI programming for this facility was ported from the original CH2M programs and was then modulized to the greatest extent possible. This included the creation of PLC ladder logic blocks for common control functions such as fixed speed pump/blower control and variable speed pump/blower control.  Similar custom configurable blocks were created for common HMI objects such as tanks, pumps, blowers and similar equipment.

Location

Stayton, OR

Team

Troy Collison
Mark Lietzke
Jim Mitchell, P.E.
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We have implemented simple systems with less than 50 I/O points and systems with over 20,000 tags. What can our experience and knowledge help you with?