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Sorting System
PASS Technology Group
replaced an obsolete control system used to run a sorting
machine that automatically sorted various size objects such as
videocassettes, audiocassettes, DVDs and CDs. The items would be
sorted to 1 of 136 bins according to its UPC code using two omni
directional barcode scanners located at the head end of the
machine. The system consisted of pushbuttons, photoelectric
sensors, pneumatic linear actuators, motor controls and an
encoder tied into an Allen-Bradley PLC via DeviceNet. PASS
Technology Group programmed the PLC with the ability to read the
item’s UPC code and assign the item to a bin. Using an encoder
connected to the belt conveyor the item's position was tracked
to its destination. The item was then sorted to the bin using
the pneumatic actuator with a photoelectric sensor used to
monitor the bin’s count. The system was designed to allow up to
five different UPC codes to be sorted to each bin due to the
large variety of titles to be sorted. The belt conveyor ran at
200 ft/min sorting about 120 items per minute.
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Extruder
Control Systems
PASS Technology Group has completed many
projects involving extruder control systems. The control
systems have varied in complexity. Simple manual control
systems utilized only push button operators and single loop
controllers. More advanced systems incorporated PLC’s and
Operator Interfaces controlling heat zones, die temperature,
extruder rpm, pump/pressure control loops, etc. External chill
rolls, heat rolls, winders, etc. were often part of a fully
automated system. Projects were completed utilizing PLC’s from
various manufacturers including Allen Bradley, Siemens, GE,
Modicon and others. Operator interfaces designed and configured
ranged from simple pushbutton and single loop controllers to
full SCADA interface, control, data collection and
manipulation. Operator Interfaces/SCADA systems have included
popular interfaces such as PanelView, Panelmate, Wonderware,
Intellution, RSView32, Cimplicity, CTC, and others. PASS
Technology Group generally developed functional specifications for
its extruder design from in-house expertise and client input.
Filter/Dryer Control Systems
PASS Technology Group is the primary third
party supplier of Filter/Dryer control systems bound for the
United States. Control systems have varied from simple manual
control systems to advanced systems with automatic sequences for
filling, washing, smoothing, drying, etc. Many are interfaced
with plant DCS systems and most are installed in areas requiring
intrinsically safe design (Class 1, Div1 or 2). Most control
systems have been PLC based with a few involving DCS
configuration. Projects have been completed utilizing equipment
from various manufacturers including Allen Bradley, Seimens,
Modicon, Fisher Rosemount (DeltaV) and others. Most Operator
Interfaces have utilized some variation of graphics design for
filter control and sequence display. Operator Interfaces/SCADA
systems have included popular interfaces such as PanelView,
Panelmate, Wonderware, Intellution, RSView32, ISIS (for
hazardous areas) and others. Various drive technologies have
also been used for the filter agitator including VFDs and
hydraulic. Panels have been designed Intrinsically safe or have
been purged according to individual requirements. PASS
Technology Group generally developed functional specifications for
its filter/dryer design from in-house expertise and client
input.
European Equipment Manufacturers
PASS Technology Group is the primary third
party supplier of Filter/Dryer control systems bound for the
United States, and specializes in design and implementation of
control systems for various European equipment manufacturers.
Clients are located in Italy, Germany, France and Switzerland.
Systems are designed and implemented to US standards and client
startup and service costs are reduced.
Autopress Filter Systems
The Autopress Pressure Filter is used for separating
moderate to poor filtering suspensions efficiently. Media that need to be
treated in closed machines for reasons of sterility, toxicity and workplace
hygiene are separated safely and reliably. If required, you may also treat
the cake by washing, extraction, pressing, blow-out and drying. Low cake
thickness, complete filtration without heel volume and an exceptionally low
level of residual moisture in the pre-dried cake ensure extremely high
throughput rates.
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DataLogging and Reporting Systems
PASS Technology Group has developed numerous
systems primarily for datalogging and system reporting. Various
data collection methods have been used according to client
infrastructure and requirements. Systems have involved
communicating with existing or installing new PLC systems for
data manipulation. Storing and displaying of data has been
accomplished using various SCADA systems or Visual Basic. SCADA
systems have included popular packages such as Wonderware,
Intellution, RSView32 and others. Data has been stored locally
or to a central data server utilizing SQL Server or Oracle.
Wall Board Plant Wet End Control
PASS Technology Group’s personnel have had a
wide breadth of experience in wallboard manufacture. Wet end
control required the manipulation of various dry and liquid
additives. System recipes were utilized to control additive
quantities, and additive additions were linked to system line
speed to maintain a consistent product. The control of a
specialized printer to print batch information and production
date/time on to the wallboard was also implemented. An Allen
Bradley PLC 5 Processor was used to control the system
components, and a Intellution SCADA system was used for operator
feedback, control and recipe manipulation.
Wall Board Plant Kiln
Control
PASS Technology Group designed, engineered
and installed a wastewater sludge recovery system. The PLC
controlled system required remote racks at various plant
locations and multiple Operator Interfaces. The system
controlled all associated pumps, valves and motors utilizing
multiple temperature and level and other field data. A
centrifuge was controlled to process the final stage of sludge
recovery.
Wastewater
Control - Sludge Recovery
PASS Technology Group designed, engineered
and installed a wastewater sludge recovery system. The PLC
controlled system required remote racks at various plant
locations and multiple Operator Interfaces. The system
controlled all associated pumps, valves and motors utilizing
multiple temperature and level and other field data. A
centrifuge was controlled to process the final stage of sludge
recovery.
Wastewater Control – Chemical Plant
PASS Technology Group designed and
implemented the control system for a chemical plant wastewater
system. The system required batch neutralization of process
discharges via acidic and caustic additions. Neutralized product
was discharged to an SBR for further treatment. Control of the
system valves, motors, and processing of analog and discrete
field information was performed by and Allen Bradley PLC 5. A
SCADA system utilizing Wonderware Intouch was configured to
monitor system activity; start and stop sequences; and perform
system logging and reports. The system oxidizer, controlled by a
SLC 500, was also networked to the PLC 5 via Data Highway + and
monitored by the SCADA package. The SCADA system was networked
to the plant wide DCS and screens were added to a Moore APACS
DCS to monitor the treatment plant and its alarms from the main
control room.
Chemical Plant
Control System Upgrade
PASS Technology Group
redesigned the operator interface and system controls for a
plant-wide control system. The Moore APACS DCS control system
was reconfigured to rectify existing problems and to simplify
and upgrade the operator interface. The system upgrade required
a complete redesign of the operator stations, data logging and
report generation. In addition redesign of the system network
was completed converting the existing network to a fiber optic
solution. Multiple operator stations were networked together and
to a dedicated development station in addition to the DCS
processor.
Polymer Plant
Control System Upgrade
PASS Technology Group
redesigned, reconfigured and reprogrammed multiple plant
blending and extruding operations combining them into a plant
wide control system with a central control room. The system
process was composed of 5 blending lines utilizing common liquid
and powder bulk ingredient systems. Each blending line fed a
corresponding extrusion line for final product creation. System
design included rewriting the existing bulk material batching
system to create a solid and reliable system. The bulk system
design also included combining multiple bulk material PLC
systems into an existing Allen Bradley PLC 5 controller. The PLC
5 controller was capable, and the interdependency of the bulk
ingredients made a single controller design acceptable. The
multiple blending lines, each with a separate SLC 500 processor,
were also reprogrammed and were networked to the bulk system.
Corresponding extrusion lines were also added to allow data
collection and blending/extrusion interlocking. Field control at
each blender was modified to only allow batch status information
and activities required locally for safety reasons. A central
SCADA system consisting of two multi-monitor systems was added
to allow an experienced operator to monitor and control the
system. System reports and logging were added for batch summary
information, statistical information, and maintenance
troubleshooting assistance. This system involved programming,
networking, servicing 12 PLC systems, redundant SCADA systems,
and setting up an SPC analysis station. Batch summary and
periodic data are ported to an Oracle data server at the company
headquarters across a T1 connection.
NOTE: One primary client issue was maintaining 3 shifts of
trained blender operators for five lines. The new design
required only 3 trained operators (versus 15) to run smoothly.
Slitter Datalogger
PASS Technology Group developed a WonderWare
SCADA system for an existing PLC controlled Slitter Machine used
to cut Master thin film rolls into narrower rolls. The SCADA
application was designed for a touchscreen monitor and allowed
operators to monitor and control the functionality of the
equipment, view process data, and log process and production
data for quality control. PASS Technology Group also developed
a method for operators to indicate defects to the SCADA system.
The system was given the capability to select on of nine defect
lanes, one of six point defects, and the start and stop of three
continuous defects. We modified the PLC program and SCADA system
to take the operator input, log data a SQL Server database and
create Roll Defect Reports.
Powder
Room Material Processing System
The PLC program features included safety
interlocks, manual and automatic equipment control using recipes
for the automatic sequence. Recipes stored in a SQL Server
database consisted of step-by-step instructions to define the
sequence of controlling motors, pump and valves to weigh and mix
of material. A summary of all batch information was logged to a
SQL Server for producing reports. During project development
PASS Technology Group submitted a detailed functional
specification document giving a complete description of the
system's operation. The functional specification included
control panel specifications, human machine interface (HMI)
conventions, emergency and safety interlocks, and a detailed
description of subsystem functionality.
FGD Conveyor System
PASS Technology Group
designed, engineered, and installed a complete PLC control
system used to control a series of conveyors used to convey
gypsum material from a power plant to a wallboard plant's
storage facility. System also included a Rotary Plow, Silex and
Recycling System used to feed conveyors to transfer material
from the storage facility to the main plant. The system
contained safety interlocks such as emergency stops, speed
switches, and alignment switches to assure proper functionality.
The system was controlled with an Allen-Bradley based PLC system
connected to an Intellution operator interface with a
touchscreen monitor. The SCADA system consisted of one master
Intellution application and one view node programmed with the
ability to allow the operator to monitor and control the entire
system.
Candle Filter
PASS Technology Group
developed a Modicon based PLC control system for a Candle Filter
used to filter a liquid using filter elements arranged
vertically in a pressure vessel. A detailed Functional
Specification was submitted by PASS Technology Group giving a
blueprint for how the control system would work. It detailed
what the finished product would do, how a user would interact
with it. By creating a blueprint of the product first, time and
productivity are saved during the development stage. The Modicon
PLC was interface via ModBus with the plant's DCS system to
allow remote control of the system. The system also contained an
Allen-Bradley PanelView operator interface allowing the operator
to adjusted system setpoints and control the system in either an
automatic or manual mode.
Oil Transfer System
PASS Technology Group programmed an
Allen-Bradley PLC system to automatically transfer oil from an
outside storage tank to an inside day tank. The oil is
continuously heated with steam and a heat tracing system. When
the day tank was not calling for material the valves were
positioned in a recirculation position and the oil is
continuously reticulated. Once the day tank called for material
the valves move to a transfer position. The system also
contained Allen-Bradley PanelView interface to monitor the
system.
GE Series 6 90-70
Conversion
Project #1: Replaced a Series 6 CPU with a
9070 CPU for the main letter sorting line. The existing Series 6
I/O structure was left in place and communicates to the 9070 CPU
via a GE 9070-Series 6 PIO board (S6PIO). This project required
converting the Series 6 program to 9070 format and adding "C"
blocks to the new program to allow the 9070 CPU to communicate
with the S6PIO board. This was a turn key project, supplying all
hardware, software, programming and installation.
Project #2: Replaced a Series 6 CPU with a
9070 CPU for the #2 Paper Machine, #2 Coater. The existing
Series 6 I/O structure was left in place and communicates to the
9070 CPU via a GE 9070-Series 6 PIO board (S6PIO). This project
required converting the Series 6 program to 9070 format and
adding "C" blocks to the new program to allow the 9070 CPU to
communicate with the S6PIO board. This project will be ongoing
with incremental replacement of the existing Series 6 I/O racks.
Replaced a Series 6 CPU to with a 9070 CPU for the #2 Paper
Machine, #4 Supercalendar. The existing Series 6 I/O structure
was left in place and communicates to the 9070 CPU via a GE
9070-Series 6 PIO board (S6PIO). This project required
converting the Series 6 program to 9070 format and adding "C"
blocks to the new program to allow the 9070 CPU to communicate
with the S6PIO board. This project will be ongoing with
incremental replacement of the existing Series 6 I/O racks.
Project #3: Currently involved in a project
to replace three Series 6 CPUs with one 9030 CPU for the Bleach
Plant. The existing Genius I/O structure will be left in place
and will communicate to the 9030 CPU via three GE 9030 Genius
bus controllers. This project requires consolidating three
Series 6 programs, re-addressing conflicting I/O addresses,
converting the Series 6 program to 9030 format and removing
unused portions of the program. |
