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WWTP SLUDGE SCREW PRESS SYSTEM
Installation of two (2) new sludge screw presses and associated
equipment for a paper mill waste water treatment plant. Project Scope includes a new building to house the new
equipment, new screw presses, rotary screen thickeners, flock tanks, new sludge
blending system, pumps, conveyors, new control system, and all associated
support equipment. ASE scope of work included the detailed electrical and instrumentation engineering. ASE's scope of work began
with developing a set of P&ID's for the entire waste water treatment plant
from scratch; updating the P&ID's with all new equipment and process
modifications, and developing a mass balance of the new system. ASE
provided detailed E&I engineering for the entire project, including
specifying and designing of a new control system with the ability to expand to
include the entire waste water treatment plants future needs.
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PAPER MACHINE WET-END DCS
Installation of a new ABB AC450 DCS system for the wet-end of a
paper machine. Engineering for Phase 1 & 2 was completed by mill
personnel. ASE assisted the mill with the Phase 3 detailed design, which included detailed engineering to
convert all motors over to DCS control. ASE Responsibilities: Developed
480VAC and 2300VAC motor elementaries and I/O panel drawings, and provided
construction management support.
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PAPER MACHINE COMPACT WET-END REBUILD
Detailed engineering to rebuild the wet-end of a paper machine utilizing compact
wet-end technologies (POM systems). Project scope was to reduce the
entrained air in the white water feeding the headbox. Two PomP model 400's
were installed in the white water circuit. The piping system was fully
evaluated to ensure that the hydraulic balance was maintained. The mass
flow balance was developed to represent actual operating conditions of the
system. The piping was evaluated to ensure that line sizes were
adequate to provide a balanced system for all foreseeable operating
conditions. Deliverables included: P&ID's, mass balance
flowsheets, instrument specifications, and installation drawings.
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PAPER MACHINE COMPACT WET-END REBUILD
STUDY
Preliminary engineering and development of a capital
cost estimate to rebuild the wet-end of a paper machine utilizing compact
wet-end technologies. The project scope included the following new
equipment: a POMix, POMp, POM head tank, seal tank, fan pump, machine screen,
johnsson screen, excess white water chest, all new cleaners and associated
pumps, MCCs, DCS and instrumentation. The following systems were to be
modified: the blending system, refining systems, dye delivery systems, and
broke system. ASE personnel provided process,
electrical and instrumentation preliminary engineering and cost estimating for
the project.
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PAPER MACHINE REBUILD
STUDY
Preliminary engineering and development of a capital
cost estimate to evaluate an entire paper machine. Scope included
evaluating and making recommendations to convert the machine from a pulp machine
into a fine paper machine. The project scope included the following new
equipment: headbox, gauging system, profiler, moisture control system, dye
system, paper machine AC drives and gearboxes, size delivery system,
cleaners, refiner, MCCs, DCS, and re-instrumentation of the entire
machine. The following systems were to be modified: the blending
system, size press, winder, saveall, machine white water systems, broke system,
and hole detector. ASE personnel provided process,
electrical and instrumentation preliminary engineering and cost estimating for
the project.
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COATING MAKEDOWN SYSTEM
Installation of a new 5000 gallon coating makedown system. The batch
coating makedown system included the ability to add 17 ingredients, with multiple recipes,
2 new storage tanks, and a run tank system under the paper machine. Controlled with
a Rosemount RS3 DCS and all new instrumentation. Responsibilities: Detailed
Instrumentation engineering, MCC room expansion, and startup support.
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DRY CALCINED CLAY STORAGE & DELIVERY SYSTEM
Installation of a new 200,000 lb dry calcined clay storage silo and
delivery system. Controlled with a Rosemount RS3 DCS, a new unloading control panel,
and all new instrumentation. Responsibilities: Detailed Instrumentation
engineering, and startup support.
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COATING MAKEDOWN PLC REPLACEMENT
Replacement of an existing Modicon 484 PLC with a new Rosemount RS3 DCS
system, controlling a coating makedown system for a paper machine. The batch coating
makedown system included the ability to add 15 ingredients, with multiple recipes.
Controlled with a Rosemount RS3 DCS, and all new instrumentation.
Responsibilities: Detailed Instrumentation engineering.
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PAPER MACHINE WET-END DCS
Installation of a new Rosemount Delta V DCS system for the wet-end of a
paper machine. Phase 1 included detailed engineering to control stock blending from
the ABB DCS. Phase 2 included system design to connect all wet-end controls to the
new Delta V DCS. Responsibilities: Wet-end system audit, P&ID development,
system architecture & and I/O panel design, refiner starter control upgrades.
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FRESH WATER TREATMENT PLANT PLC
Construction of a new fresh water treatment plant including 6 new fully
automated water softeners. Controlled with a new Allen Bradley PLC-5/40C, two
10.5" TCP Quickpanel Operator Interface Panels, a new PLC control panel, and all new
instrumentation. A PLC interface from the Allen-Bradley PLC to a Rosemount RS3 DCS, along
with two Quickpanel (TCP) operator interface panels were utilized for a operator graphics,
event logs, and alarming. Responsibilities: Detailed PLC system and control panel
engineering, PLC programming, operator interface programming, DCS configuration, and
startup support.
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BLEACH PLANT SCREENING REPLACEMENT
Installation of new three stage screening system with throughput capacity
of up to 350 TPD. The new screening system included the installation of 4 new Voith
Screens to replace 11 existing Finch Screens, all new screen feed pumps and piping, all
new instrumentation and controls. Controlled with a Rosemount RS3 DCS.
Responsibilities: Detailed E&I engineering, and startup support.
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DRYER CONDENSATE CONTROLS
Installation of new controls for an existing dryer condensate system on a
paper machine. Controlled with a Rosemount RS3 DCS, all new level transmitters and
valves. Responsibilities: Detailed Instrumentation engineering, and startup
support.
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PLC SYSTEMS AUDIT
Complete audit of all PLC's in a paper mill facility. Documentation
included a full inventory of all 57 PLC's within the mill (including processor type, I/O
card types, power supplies, programming software requirements, etc.). Identified
which Hardware was no longer supported by the manufacturer, and helped develop a plan to
replace legacy systems. Developed a plan to address Y2K concerns with all hardware
and software. Upgraded PLC programming software to a Y2K compliant version.
The PLC database was also used to identify storeroom items that were no longer
needed, and uncover potential problems with existing hardware incompatibilities.
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FLOATATION OVEN PLC REPLACEMENT
Replacement of an existing PLC with a new Allen-Bradley PLC 5/40C for
floatation oven controls on a paper machine. PLC/DCS Interfacing via DH+.
Mapped the I/O from the PLC to the Rosemount RS3 DCS for graphics displays, event
logging, and troubleshooting. Responsibilities: PLC programming and DCS
configuration.
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STRETCH WRAPPER CONTROLS
Installation of a new stretch wrapper in an existing conveyor line.
Interfaced the new wrapper Allen-Bradley MicroLogix 1000 PLC with an existing
Modicon 484 PLC. Responsibilities: Detailed electrical and instrumentation
Engineering and PLC programming.
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PAPER MACHINE WET-END DCS
Installation of a new Rosemount RS3 DCS system, new control room, and
re-instrumentation. A PLC interface from the Rosemount RS3 DCS to a Modicon 984-120 along
with a Quickpanel (TCP) operator interface panel was utilized for a local pulper control
panel. Responsibilities: Scope development, capital cost estimate, detailed engineering,
construction management, DCS configuration, operator interface and PLC programming, and
startup support.
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CALENDER STACK AND PROFILER REPLACEMENT
Installation of a new Voith calender stack and ABB thermal profiler, along
with associated equipment. Controlled with a new Allen Bradley PLC 5/40C, a TCP
Quickpanel operator interface, an existing Rosemount RS3 DCS and a Rosemount PLC
interface. Communications utilized were: A-B DataHighway Plus, RS3/PLC interface,
and ABB serial communications. Responsibilities: Detailed E&I engineering,
construction scheduling, PLC programming, operator interface programming, Rosemount PLC
interface programming, and startup support.
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MATERIAL PREPARATION DCS UPGRADE
Installation of a new Bentonite makedown system, two new starch cookers,
and the upgrade of many other systems to DCS control utilizing new instrumentation and
MCC’s. Controlled with an existing Rosemount RS3 DCS system with new remote I/O, as
well as smart instrumentation. Responsibilities: Detailed electrical and instrumentation
engineering.
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POWERHOUSE DCS REPLACEMENT
Installation of a new Rosemount RS3 DCS system, new control room, and
re-instrumentation. Responsibilities: Scope development, capital cost estimate, detailed
engineering and startup support.
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POWERHOUSE SECONDARY CONTROLS UPGRADE
Upgrade of boiler feedwater system to DCS control. Controlled with an
existing Bailey Infi90 DCS. Responsibilities: Detailed engineering.
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BOILER CONTROLS DOCUMENTATION
Controls documentation for two existing 100,000 lb/hr boilers.
Boilers were converted from coal fired to gas/oil burners. The boilers are
controlled with local Bailey controllers and tied into a Bailey Infi90 DCS via module bus
for data acquisition. Responsibilities: Developing P&ID's, loop
sheets, control panel drawings, and calibration sheets.
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STARCH COOKER CONTROLS UPGRADE
Replace the existing PLC and local control panel with Rosemount RS3 DCS
controls for an existing starch cooker. Add additional field devices and upgrade the
existing field instrumentation where necessary to automate the system.
Responsibilities: Detailed electrical and instrumentation engineering, sequence and logic
diagrams, and construction scheduling.
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PLC REPLACEMENT
Replacement of an existing PLC on a CF Coater with a new Modicon 984 PLC.
Responsibilities: PLC specification, design, programming, and startup support.
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PAPER MACHINE REBUILD – PHASE II
Installation of a new Valmet press section, Valmet dryer hoods, tail
cutter, couch pit, and vacuum systems. Controlled with a new Allen Bradley PLC 5/40C, two
TCP Quickpanel operator interfaces, an existing Rosemount RS3 DCS with new Remote I/O and
a Rosemount PLC interface. Communications utilized were: ControlNet, A-B DataHighway
Plus, A-B Remote I/O, RS3/PLC interface. Responsibilities: E&I construction
scheduling, DCS configuration, PLC programming, operator interface programming, Rosemount
PLC interface programming, and startup support.
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PAPER MACHINE REBUILD – PHASE I
Installation of a new BTG size press, Solaronics IR dryer, Spooner
air-turn and air-bar, Fibron threading system, and Wesspat rope threading systems.
Controlled with two new Allen Bradley PLC 5/40C’s, three TCP Quickpanel operator
interfaces, an existing Rosemount RS3 DCS with new Remote I/O, and a Rosemount PLC
interface. Communications utilized were: ControlNet V1.0, A-B DataHighway Plus, A-B Remote
I/O, RS3/PLC interface. Responsibilities: E&I construction scheduling, DCS
configuration, PLC programming, operator interface programming, Rosemount PLC interface
programming, and startup support.
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PAPER MACHINE REBUILD
Rebuild Wet-End of Paper Machine, including: a rebuilt saveall, new
screening and cleaning systems, a new Valmet headbox, addition of Measurex CD weight and
moisture control systems, new DC Drives (Couch, First and Second Presses).
Controlled from
a Measurex DCS system. Responsibilities: Scope development, study and capital cost
estimate, detailed E&I engineering, construction management, and startup support.
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PAPER MACHINE REBUILD STUDY
Capital cost estimate for the instrumentation portion of a full paper
machine rebuild. New equipment to include a new approach flow system, a new headbox and
table, new steam and condensate system, and dryer hoods. Rebuilt equipment to include the
fordrinier table, the press section, the vacuum system, the dryer section, and the size
press. Controlled with an existing Measurex DCS system.
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DCS REPLACEMENT
Replacement of an existing Rosemount Diogenes DCS system with a new
Rosemount RS3 DCS system. Detailed E&I engineering.
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WASTE TREATMENT CONTROLS UPGRADE
Upgrade of existing controls for waste treatment plant,
including a new control room, and new field instrumentation. Installation
of new fiber optic cables from each of four process areas to the control
room. Utilized Moore Industries cable concentrators, for remote
I/O. All new controls were tied into a Rosemount RS3 DCS. Responsibilities:
scope development, capital cost estimate, detailed engineering, construction
management, DCS configuration, and system commissioning.
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STEAM/CONDENSATE SYSTEM UPGRADE
Complete replacement of steam feed and dryer drainage system on
fine paper machine. Work included bid specification development,
process/mechanical design review, loop sheets, elementary and single-line
diagrams.
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ON-MACHINE COATER REPLACEMENT
Detail design to install replacement coater on fine paper
machine. Scope included coating feed system, DC drives, IR dryer, controls
and Allen-Bradley PLC-5 programming. Furnished functional descriptions for
controls, start-up assistance and construction documentation.
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WET-END IMPROVEMENTS
Three (3) projects to improve water balance on two (2) fine
paper machines. Provided scope, estimate, and detail design to replace
various pumps, piping and chests around cleaners and savealls. Developed
P&ID's, instrument specifications, loop sheets, elementary diagrams, layout
drawings and completed PLC programming.
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WASTE WATER TREATMENT PLANT INSTRUMENTATION UPGRADE
Project included new lab/control room, fiber optic multiplexers
and Rosemount DCS. Work consisted of scope development, capital cost
estimates, procurement, and construction management.
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STOCK BLENDING SYSTEMS
Replacement of three (3) beaters with continuous Measurex DCS
controlled stock blending systems. Work consisted of scope, estimates,
specifications, procurement, construction management and start-up.
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VACUUM SYSTEM RENOVATION
Installation of three new Nash vacuum pumps w/1000 HP motors, along with
associated equipment. Controlled with an existing Rosemount RS3 DCS system with new
remote I/O, as well as smart instrumentation. Responsibilities: Detailed electrical and
instrumentation engineering.
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AIR FLOTATION DRYER
Installation of a TECH air flotation dryer. Analog controls from a
Rosemount RS3 DCS and discrete controls from a new Modicon 984 PLC. Responsibilities:
Detailed engineering, PLC specification, design, programming, construction management,
and startup support.
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WINDER REBUILD - PHASE 2
Installation of a new unwind stand, 200 HP DC drive, new operator
interface panels, relocation of existing benchboard, and communications between Automax
DCS, Modicon 984 PLC, and Quickpanel (TCP) operator interface panels. Responsibilities:
Detailed E&I engineering, PLC and operator interface programming, construction
management, and startup support.
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WINDER REBUILD - PHASE 1
Rebuild and relocate 190" winder. New equipment included:
Valmet
slitter section, dual spreader, automatic threading system, Reliance DC drives, and
operator benchboard. Controlled from on a Modicon 984 PLC. Responsibilities:
Detailed
E&I engineering, PLC programming, construction management, and startup support.
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BOOKSTOCK REFINER
Installation of a 1000 HP Beloit DD refiner. Controlled with a Rosemount
RS3 DCS. Responsibilities: Detailed instrumentation engineering, sequence and logic
diagrams, and startup support.
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UHLE BOX VACUUM PUMP
Installation of a 600 HP Nash vacuum pump. Controlled with a Rosemount RS3
DCS. Responsibilities: Detailed instrumentation engineering, and startup support.
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LOW CASIEN CONVERSION
Installation of (3) Kady Mill Mixers, calcium carbonate and latex storage
systems, and all associated instrumentation and controls. The majority of the controls
were through a new Foxboro DCS system, and others through new local control panels.
Responsibilities: Detailed E&I engineering.
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GREENFIELD MILL
Preliminary engineering including assistance in the DCS specification and
vendor selection.
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REMOTE I/O INSTALLATION
Installation of Rosemount remote I/O. Responsibilities:
Detailed
engineering, DCS configuration, and I/O checkout.
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COATING KITCHEN PLC REPLACEMENT
Documentation of an existing undocumented PLC program prior to the
hardware replacement.
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SECONDARY FIBER SYSTEM
Upgrade of an existing secondary fiber system. Controlled from a Measurex
DCS system. Responsibilities: Detailed E&I engineering.
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OCC SYSTEM
Installation of a 265 TPD OCC system. Controlled from a Valmet DCS system.
Responsibilities: Detailed E&I engineering.
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KRAFT STOCK SYSTEM
Installation of a 300 TPD cleaning and screening system. Controlled from a
Valmet DCS system. Responsibilities: Detailed E&I engineering, and DCS factory
acceptance testing.
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HYDRAPULPER CONTROLS
New hydrapulper operator benchboard, field instrumentation and valves.
Controlled from an A-B PLC5. Responsibilities: Detailed E&I engineering.
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