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BLENDING/LOADOUT SYSTEM FOR CUSTODY TRANSFER
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CAM provided engineering, panel building
and programming for a customer who needed the ability to blend several
constituents during the loadout process. Up to 10 different blends can
be blended during the loading process to either Rail Tanker cars or
Semi Tanker Trucks. This eliminates the need for interim blending tanks
and reduces inventory on hand for infrequent products.
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.
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AMMONIA PRODUCTION FACILITY
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CAM provided control conversion on
(2) 100K pph gas or oil fired packaged boilers. Moore 352E
controllers and Honeywell 700 BMS controlled the 350 PSIG and 50
PSIG header pressure, boiler load allocation, fuel/air ratio,
oxygen trim, drum level and continuous blowdown. For the boilers,
a data link was provided for future interface to the plant SCADA
system.
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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CITY MUNICIPALITY – WATER DISTRIBUTION PLANT
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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.
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CORN BY-PRODUCTS FACILITY
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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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CORN PROCESSING PLANT
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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.
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INDUSTRIAL HEATING PLANT
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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.
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PACKAGE BOILER UPGRADES
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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 FIX DMACS software for visualization and data
collection.
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STARCH REFINERY PLANT
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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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COMMON TO ALL PROJECTS
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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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