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 A powerful but outdated system that was originally developed by in-house staff was replaced using a heavily customized implementation of Ignition software.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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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
Download a PDF of this page

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