Feel free to click on the project summaries below to expand them. These are just a sampling of the solutions we have provided to our customers over the years. Our proven methods have allowed us to take on both large and small control projects and successfully implement them for our customers.

• BLENDING/LOADOUT SYSTEM FOR CUSTODY TRANSFER

  • The loadout/blending system also required state custody transfer certification. CAM developed the procedures and has worked with the state and plant personnel to perform the initial certification as well as to re-certify the system for the past five years. Each load includes automatically generated reports with the loaded amounts of each consituent for the end customer as well as internal inventory recordkeeping.

    This customer is very pleased with the system's performance and this has led to additional loadout/blending projects as well as plans for expanding the current systems to accomodate more blends.

    This system utilizes Allen Bradley PLC's, Micromotion Mass Flow meters, and additional intrinsic safety hardware to allow usage in the Class 1, Div 1 rated loadout area. The operator is able to run the system from two loadout stations or from the main station in the control room area. The operator only needs to enter the desired load amount and select the blend, the system calculates how much of each constituent is needed to blend to the required specifications. The system will load the desired amount while proportioning the flow rates to ensure a consistent, accurate blend is achieved. Once the load is completed, the lines are purged in preparation for the next load which may be a completely different product.

• AMMONIA PRODUCTION FACILITY

  • CAM’s work on the boiler conversion at this facility led to a subsequent contract to provide support in the plants’ conversion of the ammonia production facilities instrumentation to a distributed Moore APACS system. This current project involves a two year phased upgrade of the entire ammonia and acid plants. Phase I included Moore 352E control stations, Moore 383 MUX displays, 6-channel Moore paperless recorders, all of which integrated to a Moore APACS DCS system. The Moore APACS system includes two local racks with an ICM/ACM and remote rack, all with redundant power supplies. The Moore 352 master and slave controllers also provide redundant control and indication on critical loops. FIX DMACS is being used on two computers for an operator interface, alarm and reporting. Following the instrumentation upgrade and installation, the plants’ downtime due to instrumentation control failures was dramatically reduced, which led to increased revenue for the plant.

    Phase II will include APACS for control of the Urea 1 & 2 plants, the acid plant, the CO₂ plant and Loop 2 for the ammonia plant. CAM is providing engineering technical support, CADD support, panel fabrication, SCADA configuration, Moore controller configuration and Moore APACS configuration.

• CITY MUNICIPALITY – WATER DISTRIBUTION PLANT

• CAM has been contracted since 1989 to provide maintenance and calibration service on all instrumentation for the water distribution system. The filter plant was upgraded in 1993 and CAM installed the initial SCADA system which monitors filter turbidities and outputs the running turbidity average to satisfy EPA regulations.

  The filter plant was upgraded again in 1996 to reduce the solids discharge. CAM configured and installed a full function SCADA MMI for the Solids system which operates without operator intervention. The new system also included integrating and upgrading the 1993 SCADA system. The system was networked with the plants’ administrative computer and currently provides reporting required by EPA automatically. In the future, the plant will be on-line with a city-wide network, as well as from a remote dial-up system.

  In 1998, the City water distribution system installed a forced main to an industrial meat processing plant 15 miles from the Filtration Plant. CAM worked as the general contractor and installed Spread Spectrum radios connecting two of the Cities towers and the industrial plant with the Filtration Plant. The data provides instantaneous flow and pressure readings, as well as, flow totalization used by the city for billing water usage. The system was designed to allow future expansion to include placing the remaining water towers as well as pump distribution system on the radio link and controlled from the plant control room SCADA system.

• CORN BY-PRODUCTS FACILITY

• This facility includes two steam powered turbines for in-house generation of electricity. CAM interfaced to an existing Modicon PLC and installed a SCADA system which forecasts electrical usage over the next 30 minutes. The system alerts operating personnel, who in turn identify plant process equipment which must be shutdown to prevent exceeding the "Peak Limit" established by the utility company. If the plant were to exceed the "Peak Limit", all electrical usage for the month would be billed at the "Peak Limit" rate.

  The facility includes its own water treatment facility. CAM was contracted to install a SCADA system for the water treatment plant which included tying it into the plant wide network. The data from the water treatment plant is accessible to the Power House which  monitors the plant during the third shift thus reducing manpower requirements at the facility. An additional node was installed for the operations supervisor. CAM also provided engineering, design support, labor and materials to install a new burner management system and relocated controls for one of the boilers used for in-house power and steam generation.

• CORN PROCESSING PLANT

• CAM designed, built and commissioned four boiler control systems using Moore 352 controllers and Fireye E100/300 Burner Management System (BMS). Other projects included conversion of (3) pulverized coal/gas low NOx burners using Allen-Bradley 5/20 PLC for burner management and TI-D3 for analog control; five fiber dryers, with three using Moore 352’s and Fireye E100/300 BMS and two using Allen-Bradley PLC, Fireye E100/300 and either FIX DMACS or a TI-D3 DCS Operator Interface System. CAM provided all IRI submittals for these projects. We are also involved with TI-D3 upgrades in the still house and mill. We currently finished, in 1997, a truck load-out and pellet mill control system using Allen-Bradley PLC and Wonderware SCADA software with five nodes on an Ethernet network.

• INDUSTRIAL HEATING PLANT

• CAM was initially contracted by the specification engineers to design and specify control system architecture, process control strategies and product recommendations for a massive rehabilitation of a four boiler control system. CAM was then commissioned to design, build, startup, tune and maintain the boiler control system as a sub to the mechanical contractor for this plant-wide rehabilitation.

  Each of the four 150K pph Spreader Stoker boilers an d two Zurn Baghouses are controlled with Moore 352E single loop digital controllers (SLDC) for combustion, fuel/air, oxygen trim, opacity, drum level, furnace draft, baghouse and balance draft control. All controllers are operating on a RS422 Network that is communicating with a SCADA computer for alarm reporting, trending, boiler efficiency calculations and shift reports, etc.

  The SCADA system at the Heating Plant includes two SCADA computers communicating with field I/O and one SCADA node used for operator data entry. A Windows NT server stores the daily operating reports from the remote SCADA nodes and automatically generates operating reports used by the supervising engineer.

  CAM has been the contractor of choice for the Heating Plant for calibrations and maintenance, instrumentation upgrades, operational technical support and is currently contracted to maintain the SCADA system.

• PACKAGE BOILER UPGRADES

• CAM provided controls on three 80K pph, gas or oil fired package boilers. Controls used were Bailey Single Loop Controllers providing header pressure, fuel/air ratio, oxygen trim, and drum level control. A data link was connected to a SCADA computer running FIX DMACS software for visualization and data collection.

• STARCH REFINERY PLANT

• CAM has supplied all design work, equipment, installation supervision, startup and maintenance throughout several plant system upgrades. These have included Allen-Bradley PLC 5/20 and 5/40 systems with Wonderware SCADA PC's with touch screen displays on the grind steeps, flash dryers, and high speed corn dump. In addition, we implemented a Moore 352 based control scheme on the plant's boilers. This has all been networked through Allen Bradley's DH+ or the plant Ethernet system and integrated with the existing Fisher Provox system used in other departments.

  Specific projects have included boiler control conversion using Moore 352 controllers and Fireye E100/300. CAM supported converting a gas-fired gluten flash dryer using Fireye E100/300 BMS, Allen-Bradley PLC 5/30 with a remote rack for interlock, stop, starts, and control which used Wonderware MMI software on a Pentium computer with a touch screen. CAM is currently converting six Hiels rotary kiln dryers using Moore 352E controllers and the Fireye E100/300 BMS.

• COMMON TO ALL PROJECTS

• CAM’s proven design and implementation methodologies and hands on process expertise allow us to provide complete systems including engineering, design, Management of Change (MOC) documentation,  transmitters, analyzers, controllers, recorders, computers, software, Burner Management Systems, wiring, and panels for any project. Along the way, project documentation is complete and concise from initial submittals to Operations & Maintenance and training manuals.

  We also work with the end customer, when requested, to provide just project engineering support. This allows our customer's personnel to perform electrical, mechanical or other installation, thus reducing the cost of the project. We pride ourselves on being able to discuss engineering, operations, budget, legal requirements, installation, start-up, testing, training and maintenance requirements with all levels of personnel in our client's plants as needed. Good working relationships with our clients are important to CAM so upon project completion, CAM will continue to provide technical support and outline maintenance requirements of the system/equipment installed. CAM can also provide monthly, quarterly, semi-annual or annual calibration/maintenance programs.