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.

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  • 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 constituent 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 accommodate 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.

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  • 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.

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  • 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.

  • Water Filtration Plant Upgrade

  • Radio Telemetry Project

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  • 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.

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• 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.

• Dryer P&ID Example

• RTO P&ID Example #1

• RTO P&ID Example #2

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  • CAM was initially contracted by the specification engineers to design and build a new PCS (Process Control System) to replace the current obsolete single loop controllers on two of a four boiler control system.
    
    The new control system is an Allen Bradley ControlLogix 1756 (per boiler).  The old obsolete transmitters were replaced with Rosemount smart process transmitters that are Hart protocol programmable along with Rosemount I/P’s.  The existing obsolete HMI was replaced with Rockwell Automations – RSView. The control system is operated from 19” panel mounted touch screens. High temperature air Cooled Cameras are used to monitor the coal bed and stoker throw.  New Underthrow Detroit Stokers replaced old stokers with limited adjustments.  The new stokers have the capability to be controlled individually via the HMI to aid in burning the coal more efficiently.  A new O2 trim control of the under fire air and over fire air was added using two side wall mounted high temperature and particulate combustion analyzers.
    
    The ControlLogix Rack for each boiler contains two Allen Bradley Ethernet modules – One on an isolated control network and the second on the plant Ethernet (read only) for engineers to monitor and automated reporting via RSView, Microsoft Excel, Microsoft Access and VBA. Some reports are saved as HTML and embedded into RSView screens allowing the most up to date report data available to operator as well as engineers through the HMI. Report’s that once where manually created by hourly operator readings are now generated automatically and saved to a network server.
    
    The boiler water system and plant wide steam meters where eventually added using remote Flex I/O racks.
    
    The first two boiler control systems worked so well that a third was added similar to the first two.
    
    CAM has been the contractor of choice for the Heating Plant for calibrations and maintenance, instrumentation upgrades and operational technical support.
     

  • Coal Fired Stoker Boiler Example #1

  • Coal Fired Stoker Boiler Example #2

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• 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 FIX32 software for visualization and data collection.

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• 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.

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  • CONTROL APPLICATION & MAINTENANCE, INC. (CAM) is an independent service contractor qualified in providing customized instrument and control systems for industry of today and yesterday. Industrial process control instrumentation is the dedicated specialty and we are not sales representatives of any manufacturing line. This gives CAM the ability to offer you the best process control product recommendations for your application. It has also allowed CAM to gain a very broad range of product knowledge and experience, a feature rarely found in factory sales or service staffs. CAM provides an open mind to assisting the selection of any product on the market that fits your needs, application and budget. We do not attempt to make your application or needs fit our product line as most vendors do. We base our selection on real world evaluation of reliability and maintainability, as well as operator acceptability.

     Our service staff is experienced in digital, analog and pneumatic instrument systems design, installation and maintenance. CAM can deliver the certainty that your process control instruments are operating at their maximum performance levels. The industries that we serve include power plants, water and wastewater treatment facilities, chemical industries, and food and drug processors, to name a few. Our goal is to provide properly designed automation that will lower operating cost, increase system reliability and raise the quality of the end product. 
     CAM can provide new equipment studies and recommendations; assistance in specification review; control system design, including SCADA; computer aided design drafting (CAD) services; project management and startup services; system troubleshooting and repair; system installation and startup; on-going maintenance service; calibration and certification services; programming - PC / PLC / SLDC / DDC / SCADA; panel fabrication; custom software development; full documentation - submittals, drawings, operation and maintenance manuals; automated calibration and maintenance files; and ISO 9002 compliance.

     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.

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• Reactor Screen Example

• Control Network Example