Typical projects
The following is a brief description of some of the projects that we have tackled:
Gloria Group - Yura, Peru: Reviewed the cement plant's existing electrical and control equipment and assisted in specifying new control system and replacement power system for the existing facilities plus an addition of a new clinker production line.
Gloria Group - Juliaca, Peru: Coal grinding and kiln firing electrical and control system with Allen-Bradley PLC and CRT Panelmate MMI Package. Scope included specifying, testing, designing, programming and starting the control system.
SOUTHDOWN CORP. - Phoenix, AZ: Design of a complete cement storage and shipping terminal, electrical and control system. Modicon PLC with Panelmatic operator's interface.
Cementos De Chihuahua - El Paso, TX: Truck loading and rail unloading systems at the Cement Terminal - complete electrical and control system with Omron C= 200H PLC and LCD Operator's Interface Package. Scope included specifying, testing, designing, programming and starting the control system. Also performed subsequent revisions.
Southdown, Inc. - Victorville, CA: Modicon PLC with local and remote racks controls the Cement Kiln Solid fuel (Coal and Coke) grinding and transport system. Rosemount DCS system is used for analog control and as an operator's interface.
Arawak Cement - Barbados, West Indies: Provided leadership to a team of cement engineers evaluation the conditions of the exiting manufacturing facilities and evaluated electrical equipment for power and control system.
Arabian Cement - Rabigh, Saudi Arabia: Provided leadership to a team of cement engineers evaluation the conditions of the existing manufacturing facilities and evaluated electrical equipment for power and control system.
Southdown, Inc. - Fairborn, OH: Finish Mill Expansion: 5500 hp grinding mill system, including clinker handling and cement storage/shipment. Major electrical and control equipment included were 14MVA substation with 5kV switchgear, 5500 hp synchronous motor. Motor and starter, 480V substations, MCC's and power distribution, Allen-Bradley PLC system, Foxboro DCS system.
Yanbu Cement - Yanbu, Saudi Arabia: Reviewed bid documents prepared by Blue Circle Industries, PLC for a new control system as a part of 7,000 tpd cement kiln addition. Evaluated the tenders for control system and made recommendations.
Southdown, Inc. - Fairborn, OH: Conversion of the raw mill and kiln area of a cement plant from a Swanson control system (1970s 2-wire control scheme) to a combination control system utilizing an Allen Bradley PLC5-60 system and a Foxboro I/A distributed control system.
Trinidad cement Ltd. - Trinidad, West Indies: Addition of a new kiln and modifications to feed and clinker handling system, which included 450 kW D.C. kiln drive system and motor, 3.3 kV power distribution switchboards, 1000 kVA dry type low voltage substations, 400 kW adjustable frequency fan drive system and motor, 3.3 kV starters and motors, 480V motors and motor control centers, small and medium adjustable frequency drives. F.L.S. Automation control and Allen=Bradley PLC-5 system, 300 kW engine - generator set for emergency power.
Southdown, Inc - Brooksville, FL: Tire burning system - complete electrical and control system with Allen-Bradley PLC and Control View MMI Package. Scope included specifying, testing, designing, programming and starting the control system.
Christy Minerals - High Hill, MO: monitoring of the baghouses of calcined flint kiln for EPA emissions requirement and general baghouse operation using Omron programmable controller and a small panel display interface device.
Cyprus Warrenton - Warrenton MO: Cleaning of hot gases from the copper furnaces with conditioning towers and fabric filter using Allen-Bradley PLC and CRT panel interface device.
Southdown, Inc. - Knoxville, TN: Hazardous waste storage (solids and liquid) and handling system for cement kiln fuel
Ash Grove Cement - Louisville, NE: An additional I/O rack was added to an existing General Electric Series Six programmable controller and we modified the existing program to control the addition of the hazardous waste fuel handling system. Control was integrated into the existing kiln control panel.
LONE STAR INDUSTRIES - Cape Girardeau, MO: Kiln gas system modification and cooler vent re-circulation system, which included 2000 HP dc drive system for I.D. fan including motor, 1000 HP dc drive system for I.D. fan including motor, motor control centers and 480V motors, Allen-Bradley PLC-5 and associated I/O panels, lighting and grounding and cable trays and conduit system.
Army Corps of Engineers - Alton, MO: Lock and dam 26 on the Mississippi River. The control system consisted of Square D Programmable Controller (1600 I/O points), five conventional graphic control panels (one central and four remote).
Monsanto Chemical Co. - St. Louis, MO: Series 884 processor and conventional push-button panel were used to control the formulation process.
Inland Steel - Gray, IN: Designed and completed start-up and checkout electrical and control system of a gas cleaning car for a coke oven.
Shell Oil - Hartford, IL: Scope included design, installation check-out and start-up of a waste heat boilers' electrical and control system using Allen-Bradley PLC system.
Proctor & Gamble - St. Louis, MO: Scope included design and installation checkout of a Comet manufacturing and packing facility, that was controlled by a conventional push-button panel and Allen-Bradley PLC.
City of Edwardsville - Edwardsville, IL: An IBM 286 computer monitors and controls the water tower, the water treatment plant and half a dozen or so lift stations using modems, standard voice grade telephone lines and Omron programmable controllers. Hotline software is used on IBM computer as an operator's interface.
Village of Glen Carbon - Glen Carbon IL: An IBM 286 computer monitors and controls the 40 lift stations using standard voice grade telephone lines, modems and Westinghouse programmable controllers. We designed the software for the IBM computer for dialing, gathering data from the lift stations, logging and alarming. Award received for this project.
Consolidated Aluminum - Newjohnsonville, TN: Scope included preliminary design and specifications for the electrical power, control and instrumentation equipment for a $300 millions aluminum project.
Camargo Correa - Sao Paulo, Brazil: Addition of a complete cement manufacturing facility adjacent to the existing cement plant. Major electrical equipment included were 2-25 MVA substation transformers, 13 kV switchgear, 13 kV mill motors and control, Low voltage substations, Kiln DC drive system and motor, medium voltage motors and starters, variable speed drives, 480V motors and motor control centers, engine-generator set, distributed control system.