Columbia Automation Systems designed and implemented a network gateway solution for a paper mill customer who was updating the wet end of an existing paper machine. Different contractors were selected for the process control system, quality control system, and motor control center (MCC). CAS was asked to integrate these new components into the existing control system while working closely with the other suppliers to create a viable complete system.
The customer selected a variety of vendors based upon careful analysis of each system. The chosen process control system was Fisher-Rosemount Delta V, which was preferred for its connectivity to existing Rosemount transmitters, its operator friendly graphics, and use of Foundation Fieldbus. An ABB quality control system with an Advant controller was selected for measurement. Cutler-Hammer Advantage motor starters and SV9000 drives were prearranged in a factory DeviceNet MCC package.
The customer needed a way to integrate all of these systems into the existing Allen-Bradley PLC5 control system with WonderWare and PanelView operator interfaces and Eurotherm and Westinghouse drives. For commonality of spare parts and minimization of training for the maintenance team, the customer wished to stay with the Allen-Bradley PLC5 platform. CAS engineered a solution using a PLC5 controller as a network gateway to connect all of the different systems. 1785-KE modules were used to communicate with the Fisher-Rosemount and ABB systems which each have serial DF1 protocol capability. Data Highway Plus (DH+) was used to connect to the existing PLC5 controller. Allen-Bradley 1771-SDN DeviceNet scanners were used to control the MCC from the PLC5. A SLC5/04 controller connected to DH+ was added to replace analog circuits for reference generation in the existing Westinghouse drives. The Eurotherm drives were integrated with the X-Link from SST.
In order to complete this project, CAS worked closely with the customer and the other suppliers to ensure a seamless start-up. A database of shared signals was developed and maintained to clearly define the interfaces between the systems. Modifications to the existing PLC program were made to support the new equipment. CAS joined with Cutler-Hammer personnel to fully test the MCC prior to start-up.
Due to careful planning, thorough testing, and teamwork, the start-up went extremely smoothly. Everything worked as designed and the customer was pleased. The customer was especially appreciative of the documentation and structure of the PLC program, which was designed to make troubleshooting fast and easy. Of our performance on this project, the mill project manager said, "I always have high expectations, and you exceeded them every time."
Contact Don Ruoff for more information.