Scada Upgrade

Georgia Pacific Paper Converting SCADA System Upgrade

Overview

OS Engineering completed a large-scale SCADA migration from the initial feasibility study and preliminary design, to the development of the new system, all the way through final startup and commissioning. A powerful but outdated system that was originally developed by in-house staff was replaced using a heavily customized implementation of Ignition software.

The new system was built on a large architecture consisting of more than
ten new virtualized servers, and relied heavily on “High Performance HMI” graphical standards that were developed in partnership with mill engineering staff.

Scope

  • Developed a communication architecture supporting more than 150 PLCs and other control system devices from many manufacturers and spanning several generations.
  • Migrated more than 100,000 tags, many of which were packaged into custom data formats
  • Identified and replaced interfaces with business systems, reporting applications, and product labeling and scanning systems
  • Established interfaces with several SQL-based databases and a PI historian
  • Worked closely with mill staff to create detailed graphical standards, documented in a style guide
  • Developed nearly 200 graphical screens, created from a library of dozens of custom template objects, allowing for consistent graphics throughout the facility
  • Created custom graphical tools allowing for rapid classification and categorization of system alarms
  • Worked closely with mill and corporate IT staff to ensure compliance with company IT policies and industry best practices for cyber security
  • Provided nearly three weeks of hands-on and classroom training to operations, maintenance, and engineering staff

Highlights

  • New system operated in parallel with old system for lengthy, thorough debugging period
  • SCADA system upgrade was completed with no planned outages
Client: Georgia Pacific
Location: Halsey, OR
Timeline: November 2015- June 2017
Divisions: Controls & Engineering
Value: $844,201
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Category:

SCADA Systems Programming

Industry Served:

Timber & Forest Products

Area Served:

Oregon

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International Paper – Paper Machine Productivity Improvements

Overview

Olsson Industrial Electric served as the lead electrical and controls contractor for a >$100M capital improvement project, increasing production capacity by more than 40,000 tons of containerboard per year. The Olsson construction management team worked hand-in-hand with the customer to plan and execute a complex construction sequence, maximizing pre-outage construction opportunities, streamlining the outage construction schedule, and minimizing overtime costs. Installation, testing and commissioning was handled by a robust team of experienced Olsson electricians and controls technicians. Featuring more than 60 on-site during critical outages, the Olsson team completed this project with craftsman quality and zero safety incidents. 

Scope

  • Extensive demo of existing systems. Installation, checkout, and commissioning of the following items:
  • One 4600 13 K/600 V transformer, two 1250 HP VFDs, one 450 HP VFD, and several smaller VFDs
  • Extensive temporary power upgrades (MCCs to be used for temporary power during outages)
  • New boiler port rodders, gas skids and start burners; New roll handling system; New winder safety system
  • Thirty-five PLCs and control panels built in-house by our UL-508 panel shop and installed on site
  • Numerous process control instruments
  • 1,200 feet of cable tray, 34,000 feet of conduit and 280,000 feet of cabling
  • Engineering/Project Management for cable pull calcs, labor forcasting, work sequencing, etc.
  • One engineer specifically dedicated to recovery boiler commissioning

Highlights

  • No lost time, injuries or accidents
  • All work completed on or ahead of time and under budget
  • Over 60 personnel worked safely 24/7 during a 5-week shutdown
Client: International Paper Company
Location: Springfield, Oregon
Timeline: 2015-2017
Divisions: Construction, Controls & Engineering
Value: > $6,250,000

Category:

Heavy Industrial Electrical Construction
Plant Automation
Automation System Analysis

Industry Served:

Pulp & Paper

Area Served:

Oregon
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Superior Energy Arctic Challenger

Overview

In September of 2012, Olsson Industrial Electric completed a 10-month electrical installation project for Superior Energy’s Arctic Challenger. Olsson field crews installed, tested and commissioned nearly all of the electrical power distribution equipment for the vessel. Electricians worked around the clock to complete the project on time. Scheduling included a 4-month period of time in which 40 Olsson electricians worked seven, twelve-hours shifts.  

Scope

  • 480 V power distribution
  • Class I Division I and II electrical installation
  • Extensive instrumentation device calibration and installation
  • Instrumentation tubing installation
  • Cable tray design
  • 24 VDC process control

Highlights

  • Zero safety incidents
Client: Superior Energy
Location: Bellingham, Washington
Timeline: Completed September 2012
Divisions: Construction, Controls & Engineering
Value: $4,600,000

Category:

Heavy Industrial Electrical Construction
Power Distribution
Power System Design & Analysis

Area Served:

Washington
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electricians

Kapstone #11 Paper Machine HCR Refiner and ENP Press Project

Overview

In 2013, Olsson Industrial Electric completed a project for Kapstone involving a commissioning shutdown that required 48 electricians on a 24-hour schedule for 4 days.

Scope

  • 13.8 kV power distribution
  • 13.8 kV soft start
  • 575 V switchgear
  • 12,000 HP motor and control installation
  • Basler Field exiter enclosure
  • 1,200 HP DC drives and motors
  • 480 V MCC’s
  • Assemble and install PLC panels
  • 575 VDC motor wiring
  • 120 VAC control wiring
  • 24 VDC control wiring
  • Communication infrastructure
  • Lighting system

Highlights

  • Zero safety incidents
  • Involved a commissioning shutdown that required 48 Electricians on a 24-hour schedule for four days
Client: Kapstone
Location: Longview, WA
Timeline: 2012 – 2013
Divisions: Electric, Engineering & Controls
Value: $1,200,000

Category:

Hydro Design
Power Distribution
Power System Design & Analysis
Automation System Analysis

Industry Served:

Pulp & Paper

Area Served:

Washington
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Schnitzer Steel Mega Shredder – Electrical Installation

Overview

In 2007, Olsson Industrial Electric completed an electrical installation at Schnitzer Steel’s brand new facility in Portland, Oregon.

Scope

Olsson installed the following items:

  • 12.5 kV power distribution
  • 4160 V power distribution
  • 3,400 concrete encased duct bank
  • Substation building electrical
  • Shredder Building electrical and controls
  • Water system power, controls and instrumentation
  • Fiber-optic communication system
  • Camera system

Highlights

  • Zero safety incidents
Client: Schnitzer Steel
Location: Portland, Oregon
Timeline: 2007
Divisions: Construction, Controls & Engineering
Value: $2,950,000

Category:

Hydro Design
Power System Design & Analysis
Automation System Analysis

Industry Served:

Metal & Recycling

Area Served:

Washington
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Substation

Vera Water & Power 16th Avenue Substation

Overview

While working with Vera Water and Power, OS Engineering determined that additional system capacity was needed to meet growth requirements to provide quality reliability in the near and long-term future. OS Engineering prepared complete design drawings for the construction of Vera’s 16th Avenue Substation as well as provided services during construction including relay settings and start-up assistance.

Scope

  • Prepared and distributed Power Transformer Contract Documents followed by evaluation and award recommendation (service included witnessing transformer testing)
  • Prepared and distributed Circuit Switcher Contract Documents followed by evaluation and award recommendation
  • Prepared and distributed Relay and Control Panel Contract Documents followed by evaluation and award recommendation
  • Prepared complete project design drawings
  • Prepared and distributed Substation Construction Contract Documents, including pre-bid meeting presentation followed by evaluation and award recommendation
  • Provided services during construction to respond to and resolve any issues that arose during construction
  • Provided relay settings, programming and start-up assistance

Highlights

  • The substation was energized in October 2016 and has been reliable to Vera customers since
Client: Vera Water & Power
Location: Spokane Valley, Washington
Timeline: February 2015 – October 2016
Division: Engineering
Value: $2,400,000

Category:

Heavy Industrial Electrical Construction
Power Distribution
Power System Design & Analysis
Automation System Analysis

Industry Served:

Utilities

Area Served:

Washington
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equipment upgrade

Seneca Sawmill Mill Equipment Upgrade/Installation

Overview

In May of 2015, Olsson Industrial Electric initiated a mill expansion project for Seneca Sawmill in Eugene, Oregon. This expansion project incorporated multiple additions and upgrades, specifically to “Mill A” where Olsson installed new conduit, wiring and associated electrical hardware for more than 75 motors on a new trimmer/sorter line. In addition, Olsson also installed control wiring for two new edgers.

Scope

  • Furnished and installed new conduit and cabling for nearly all of the motors in the new trimmer/sorter line
  • Installed control wiring for two new edgers
  • Provided detailed one-line drawings, submittal reviews and as-built documentation

Highlights

  • Zero safety incidents while working in an active sawmill
Client: Seneca Sawmill Company
Location: Eugene, Oregon
Timeline: May 2015 – Current
Divisions: Construction, Controls & Engineering
Value: $715,000

Category:

Heavy Industrial Electrical Construction
Power System Design & Analysis
Automation System Analysis

Industry Served:

Timber & Forest Products

Area Served:

Oregon
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Seneca Sawmill Co-Gen Facility

Overview

Olsson Industrial Electric was hired to complete the electrical installation of Seneca Sawmill’s Co-Generation facility located in Eugene, OR.

Scope

  • Installed 15 kV plant-wide distribution
  • 480 VAC MCC installation in the following locations: Truck Dump Area, Fuel Handling and Storage System, and Co-Gen building
  • PLC/Control System installation in the following locations: Truck Dump Area, Fuel Handling and Storage System, and Co-Gen building
  • Documented and rewired controls on 19 MW generator
  • Installed a plant-wide lighting system

Highlights

  • Zero safety incidents
Client: Seneca Sawmill Company
Location: Eugene, Oregon
Timeline: 2010
Divisions: Construction & Controls
Value: $2,600,000

Category:

Heavy Industrial Electrical Construction
Plant Automation
Power Distribution
Power System Design & Analysis

Industry Served:

Timber & Forest Products

Area Served:

Oregon
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ATI Intermediate Work Cell

Overview

Olsson Industrial Electric completed a project to install a conveyor storage and robot work cell system in the ATI Titanium Foundry in Albany, Oregon. This project involved concept design, engineering and installation of a storage conveyor and robot work cell to process parts through the foundry mold process. The robot work cell was designed to process parts through a slurry dip, sand operation and transfer finished parts to the storage conveyor.

Olsson was the general contractor for this project and was responsible for all engineering (structural, electrical and mechanical) and construction of the system. The Olsson project management team coordinated five subcontractors to facilitate a complete system design from concept to production operation. The system was implemented with the latest controls equipment (Allen Bradley, ABB, Ignition SCADA and Fanuc Robots).

Scope

  • Developed system concept to meet customer process requirements
  • Concept system with simulation software (Simu8) to provide realistic simulated system performance
  • Olsson developed a team of subcontractors to provide a robust design to accomplish requirements from concept
  • Management of project to deliver on milestones, budget, and tasks required to implement the design
  • Provided engineering and construction for electrical components and software needed to run the system
  • Managed subcontractors to deliver design and engineering for mechanical, structural, and construction of the system
  • Worked with the customer to facilitate construction schedules to minimize current production impact during installation
  • Coordinated design and engineering between multiple subcontractors to provide the conveyor system which would store, dry (airflow around parts) and transfer parts between different robotic clips

Highlights

  • Managed installation of Fancu M-2000iA/900L Robot.
  • System in full production two days before scheduled production date.
Client: ATI
Location: Albany, Oregon
Timeline: September 2014 – November 2015
Divisions: Construction, Controls & Engineering
Value: $3,155,000

Category:

Heavy Industrial Electrical Construction
SCADA Systems Programming

Industry Served:

Metal & Recycling

Area Served:

Oregon
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commissioning of a paper mill

Greenberry Cosmo Specialty Fibers Paper Mill Start-Up

Overview

Olsson Industrial Electric completed a project in the spring of 2012 that included the start-up and commissioning of a paper mill that had been shuttered for the past five years. Due to a compressed construction schedule, the Olsson field crew worked around the clock in order to complete the project. The project featured 24-hour staffing. 

Scope

  • Replaced 2,478 total instruments
  • Inspected conduit and fittings, and repaired any issues found
  • Instruments were tested for functionality and to verify information to PLC or DCS
  • Damaged instruments and wires were repaired or replaced
  • 250 process critical instruments were bench calibrated, the remaining 2,228 were field calibrated
  • Performed point check for all I/O points and DCS loops
  • Made PLC, HMI, and DCS programming changes as needed for the new owner’s process
  • Repaired or replaced PLC, HMI, and DCS as needed
  • Replaced 1,163 total motors
  • MCC buckets were inspected and cleaned, and repaired any issues found
  • Meggered all motors, and replaced or repaired any issues found
  • Bumped each motor to verify rotation
  • Medium Voltage Switch Gear was inspected, cleaned and tested
  • Transformers and breakers were tested, and all issues were repaired or replaced

Highlights

  • Zero safety incidents
Client: Greenberry Industrial
Location: Cosmopolis, Washington
Timeline: 2012
Divisions: Construction, Controls & Engineering
Value: $4,000,000

Category:

Hydro Design
Power System Design & Analysis
Automation System Analysis

Industry Served:

Pulp & Paper

Area Served:

Washington
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