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 A powerful but outdated system that was originally developed by in-house staff was replaced using a heavily customized implementation of Ignition software.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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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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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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Bonneville Dam Station Service Improvements

Overview

In October of 2011, Olsson Industrial Electric completed a prime contract to upgrade the Station Service electrical systems at the Bonneville Lock and Dam. Improvements included: the replacement of three double ended 480 V substations, associated medium voltage cabling, integration with GFE transformer and controls, high resistance ground systems, and panel boards. Additionally, this project included the application of temporary power sources to ensure continued power plant operations during all construction and commissioning phases.

Scope

  • Removed existing 480 V switchgear lineups
  • Designed, supplied and installed new 480 V switchgear lineups
  • Installed transformers and addition of air terminal chambers for double ended substations
  • Analyzed, designed and installed surge capacitators
  • Replaced 13.8 kV feeders
  • Installed and integrated remote operating panels
  • Installed and programmed digital protective device relays and automatic transfer controls
  • Supplied remote racking devices and training on new switchgear

Highlights

  • Zero safety incidents while working in an energized power production facility
  • “Outstanding” performance rating from the U.S. Army Corps of Engineers
Client: U.S. Army Corps of Engineers
Location: Cascade Locks, Oregon
Timeline: October 2011 – March 2013
Divisions: Construction, Controls & Engineering
Value: $4,600,000

Category:

Heavy Industrial Electrical Construction
Hydro Design
Hydro Maintenance

Industry Served:

Hydroelectric & Hydropower

Area Served:

Oregon
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Seneca Sawmill Dimension Kilns Electric Installation

Overview

In May of 2015, Olsson Industrial Electric initiated a mill expansion project for Seneca Sawmill in Eugene, Oregon. The expansion included multiple additions and upgrades. New dimension kilns were one of the expansion’s projects. OS Engineering provided controls integration and electrical design oversight. Olsson Construction Crews furnished and installed conduit, wiring and miscellaneous electrical hardware required for full operation of the new kilns.

Scope

  • Furnished and installed conduit and cabling to support the new kilns
  • Provided detailed one-line drawings, submittal reviews and as-built documentation
  • Installed owner furnished PDCs for the new dimension kiln boilers, planer mill, and compressor/sorter/stacker

Highlights

  • Zero safety incidents
Client: Seneca Sawmill Company
Location: Eugene, Oregon
Timeline: 2015 – 2016
Division: Construction & Engineering
Value: $292,000

Category:

Heavy Industrial Electrical Construction
Plant Automation
Power System Design & Analysis

Industry Served:

Timber & Forest Products

Area Served:

Oregon
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ATI Cast Products Intermediate Robot and Conveyor System Project

Overview

In January of 2015, Olsson Industrial Electric served as general contractor for the Intermediate Robot and Conveyor project installed at ATI Cast Products/Pacific Cast Technologies in Albany, Oregon. Olsson’s Engineering personnel provided several services to facilitate the project. This included overall project management and coordination of 5 subcontractors to design and deliver subsystems (robot, conveyor, structural support for conveyor, and building modification) for installation at the ATI site. Olsson also provided electrical engineering design, panel build, electrical install, and software development for project.

Scope

  • Provided overall design concept to increase investment casting line productivity
  • Designed storage and transfer conveyor to move parts from one cell to another. Use of an intermediate robot to move parts through a production process
  • Conveyor provided multiple hook storage locations for part transfer and drying from one cell to another
  • Designed and built drying tunnel (forest of 200+ fans) around conveyor to provide drying airflow on each part in storage

Highlights

  • Zero safety incidents while working in an active casting facility
  • Completed project on time and met production goals
Client: ATI Cast Products
Location: Albany, Oregon
Timeline: January 2015 – October 2015
Divisions: Controls & Engineering
Value: $3,155,000

Category:

Heavy Industrial Electrical Construction
Power Distribution
Power System Design & Analysis

Industry Served:

Metal & Recycling

Area Served:

Oregon
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Detroit and Big Cliffs Dam Reliability Upgrades

Overview

Olsson Industrial Electric completed a project to upgrade integral electrical components at the respective powerhouses for Detroit and Big Cliff Dams. Olsson replaced vintage 13.8 kV gallery switchgear in both powerhouses. The Detroit Dam switchgear was previously destroyed in a fire, lowering the dam’s output potential. This project restored Detroit Dam to full potential and provided much needed reliability upgrades to the respective dams.

Scope

  • Replaced 15 kV switchgear
  • Replaced 15 kV non-segregated bus
  • Replaced 15 kV isolated phase bus
  • Replaced DC panel boards
  • Replaced MCCs and CLRs
  • Designed and installed emergency backup generators (diesel)
  • Control board upgrades
  • Transformer replacements

Highlights

  • Zero safety incidents with more than 36,000 hours of on-site work
  • “Above Average” performance rating from the U.S. Army Corps of Engineers
Client: U.S. Army Corps of Engineers
Location: Marion County, Oregon
Timeline: September 2007 – December 2011
Divisions: Controls & Engineering
Value: $11,300,000

Category:

Hydro Maintenance

Industry Served:

Hydroelectric & Hydropower

Area Served:

Oregon
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McNary Lock & Dam Station Service Improvements

Overview

In May of 2014, Olsson Industrial Electric was awarded a prime contract to modernize the station service electrical distribution system at the McNary Lock and Dam – a four year effort to replace nearly all of the existing 4160 V Station Service equipment. Construction began with two iso-phase bus taps feeding new 15 kV switchgear assemblies for redundant distribution to new 480 V substations. Twenty-eight 4160 V governor oil pumps will be rewound to 480 V for compatibility with the new station service distribution.

Ultimately, the modernization will convert the entire powerhouse to a redundant 480 V system. With the majority of new equipment installed in green field locations, the new system can be commissioned and energized in advance to minimize outages and disruptions to the plant. OS Engineering and Olsson Controls will provide significant support throughout the project making this a complete team effort.

Scope

  • Remove nearly all existing 4160 V components
  • Install seven 15 kV and five 480 V switchgear lineups
  • Install 12 high resistance grounds and two 15 kV CLRs
  • Install two 4.16/13.8 kV 5MVA transformers, ten 13.8 kV/480 V transformers, one 13.8 V/12.47 kV 750 kA PSJ transformer, a 13.8 kV/480 V 1000 kVA transformer, two 13.8 kV/480 V 500 kVA transformers and two 480 V/208Y-120 V 225 kVA transformers
  • Install thirteen 480 V AC MCCs
  • Install 7 main unit switchboards

Highlights

  • Design and implement temporary power solutions for continuity of powerhouse operations
Client: U.S. Army Corps of Engineers
Location: Umatilla, Oregon
Timeline: May 2014 – Current
Divisions: Construction, Controls & Engineering
Value: $35,000,000

Category:

Heavy Industrial Electrical Construction
Hydro Design
Hydro Maintenance
Power Distribution

Industry Served:

Hydroelectric & Hydropower

Area Served:

Oregon
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The Dalles Dam Station Service Improvements

Overview

Olsson Industrial Electric completed a comprehensive modernization of the station service electrical distribution system at The Dalles Dam, a 2100 MW hydroelectric power generation facility, as the prime contractor. Olsson upgraded the existing 1950’s vintage control system, rerouted and installed new power distribution feeders, replaced wire distribution to improve the quality of the cable infrastructure, and connected a secondary power source to create internal redundancy. The electrical upgrades improved turbine control, power generation efficiency, system reliability and serviceability.

Scope

  • Replaced 4160 V station service protective relaying and breaker controls
  • Installed 2 new 5000 kVa station service transformers
  • Replaced 13.8 kV CLR & vacuum switchgear at main unit Isolated Phase Bus (IBP)
  • Retrofitted five 480 V station service substations and MCC sections
  • Installed 5 new 500 kVA transformers, switchgear sections, and 4160 V switchgear
  • Retrofitted all existing 4160 V switchgear sections
  • Designed, installed and tested redundant DC and preferred AC systems

Highlights

  • Zero safety incidents while working in a hydroelectric generation power production facility
  • “Outstanding” performance rating from the U.S. Army Corps of Engineers
Client: U.S. Army Corps of Engineers
Location: Klickitat County, Washington
Timeline: September 2008 – December 2013
Divisions: Construction, Controls & Engineering
Value: $26,000,000

Category:

Heavy Industrial Electrical Construction
Hydro Design
Hydro Maintenance
Power Distribution

Industry Served:

Hydroelectric & Hydropower

Area Served:

Oregon
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