Projects

Longbeach Export Terminal

Longbeach Export Terminal

Control System Update

Roza Irrigation District

Roza Irrigation District

Canal Flow Optimization

GREAT WESTERN MALTING

GREAT WESTERN MALTING

DESIGN BUILD

Josephine County Juvenile Detention Facility

Josephine County Juvenile Detention Facility

CONTROL SYSTEM

DISCOVERY CORRIDOR

DISCOVERY CORRIDOR

CONTROL SYSTEM

GASCO

GASCO

SCADA

COLUMBIA EXPORT TERMINAL

COLUMBIA EXPORT TERMINAL

AUTOMATION

LOUIS DREYFUS COMMODITIES (LDC)

LOUIS DREYFUS COMMODITIES (LDC)

PROGRAMMING

CITY OF STAYTON

CITY OF STAYTON

DESIGN & PROGRAM

IS Hero

Longbeach Export Terminal

Control System Update

Roza Irrigation District

Canal Flow Optimization

GREAT WESTERN MALTING

DESIGN BUILD

Josephine County Juvenile Detention Facility

CONTROL SYSTEM

DISCOVERY CORRIDOR

CONTROL SYSTEM

GASCO

SCADA

COLUMBIA EXPORT TERMINAL

AUTOMATION

LOUIS DREYFUS COMMODITIES (LDC)

PROGRAMMING

CITY OF STAYTON

DESIGN & PROGRAM

Description

Industrial Systems designed and commissioned a control system for Koch Mineral’s bulk handling facility at the Port of Long Beach California.  The facility uses a series of conveyor belts and belt feeders to receive and ship bulk material. Material is received via truck, stored in silos, and finally loaded onto vessels via a shiploader. At the time of this project the terminal was loading approximately 50 vessels per year.  Extended down time due to a system failure would have been very costly in terms of dollars and the ability to meet customer commitments.

The purpose of the project was to improve reliability.  The old system had run for over 25 years, largely untouched, utilizing Allen Bradley PLC-5 hardware and a custom made graphical interface system. The graphics would often freeze and cause delays in operation. Many control and monitoring functions either did not work or were inaccurate. After a site evaluation it was agreed upon that the best path forward would be to replace the PLC and HMI system while still utilizing existing electrical equipment and instrumentation.

Allen Bradley ControlLogix platform was selected for the PLC hardware.  Allen Bradley FactoryTalk View Site Edition was selected for the HMI system.  A fiber optic network was installed across the plant to interconnect remote PLCs and HMIs.  The general approach to operating the plant was maintained but modified to be more intuitive for operators and to include additional monitoring, inventory tracking, alarming and reporting. Remote access to the control system was also installed to allow the facility faster and less expensive support. 

Minimizing down time during installation of the new control system was very important. Rather than relying on a window of shutdown time an alternative approach was required.  The new control system was installed side by side with the existing one. Periodically there would be a day or two where the facility did not need to run – this is when parallel wiring between the systems was installed.  Field equipment, wiring and programming were all tested and monitored well before the new system assumed control. Operators were also trained ahead of time.  This approach allowed all the unknowns to be flushed out while the facility was still running. The old system was powered off when the facility had a two day break in operations. The transition between control systems ended up being seamless and did not require a planned shutdown.

Location

Longbeach, CA

Team

Troy Collison
Michael Wallis
John Sowards
Mark Lietzke

Description

 

Roza Irrigation District constructed a 1,600 acre-foot capacity reservoir near Sunnyside, Washington. This re-regulation reservoir allows them to more efficiently use water and better control canal levels. This project included a pump station with five vertical turbine pumps and multiple valves – water is either pumped up to the reservoir or discharged back to the canal through a series of valves. The PLC based system allows for automatic control of downstream canal level.

Industrial Systems provided the detailed control system design and programming. The pump station’s Schneider/Modicon M340 PLC was programmed for controlling the five pumps that lift water from the canal to the storage reservoir and the five discharge valves that control the gravity flow of water back into the canal when demand requires it.

The control system also monitors flow, pressure and level instrumentation.  The program was written to automatically control the equipment to either maintain canal level or a desired flow rate between the reservoir and canal. A Cellular communication link allows the district to remotely control and monitor the pump station.  The pump station includes a Red Lion Touch panel for local control. The pump station controls were also integrated into the existing Wonderware SCADA system, including alarming and trending. Three remote solar powered control stations utilizing point to point radios were installed to monitor canal and reservoir levels.

Location

Sunnyside, WA

Team

Troy Collison
Michael Wallis

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, P. E.

Description

This juvenile Facility was taken out of service for several years. When the County realized the need to utilize it once again the door locks and door control systems were updated.

The facility installed all new AirTeq ™ locks and utilized all existing field wiring. We also installed a new PLC based control system. The outdated Bogen intercom system remained in service due to budget and schedule constraints.

The Control system we designed, built, installed and programmed, replaced a proprietary board level door control system that used toggle switches and indicator lights. The new system uses a touch screen computer and incorporates the automatic connection of intercom stations in an area when that area is selected on the touch screen.

Our system was based on the GE RX3i PLC, included a 21” in console mounted touch screen computer running Cimplicty HMi software. We also included a custom designed and fabricated landing system for the existing field wiring that eliminated the need to re-terminate and land the existing field wiring. All the field wiring simply plugged into the new control panel.

Location

Grants Pass, OR

Team

Mark Lietzke
Troy Collison
Minh Huynh

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.

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 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 system and VFD’s of one pump station were rebuilt 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

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 includes 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 of 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

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-Bradly 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 were ported from the original CH2M programs and were 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 sped 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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