• Paper Mill Siemens S5 to DCS Upgrade

    Paper Machine S5 upgrade to ABB 800xADCS

    The Siemens S5 Processor and IO were converted to Phoenix Contact Axioline Profi-Net IO XC modules communicating with the existing ABB 800xA DCS.All siemens S5 IO relocated to new IO panels, with all outputs individually fused to meet site specifications.

    One existing ABB controller (PM861) converted to PM891 to house the new application. Modifications to Profi-Bus & Profi-Net Networks through out the plant were required to accomodate the upgrade and minimise the changeover and commissioning downtime.

    In conjunction with the Siemens S5 Upgrade, the ABB DCS System was also upgraded from V4.X to 5.2. This requires a site wide upgrade of new servers and operator stations.

  • Permanent Plume Mitigation System Switchboard

    Permanent Plume Mitigation System Switchboard

    Approx. 400 IO Switchboard and Control Panel containing the following;

    • Allen Bradley Compact Logic PLC
    • Digital IO, High Speed Counter Inputs, Remote Racks
    • ABB Automatic Transfer Switch for 3 phase supply & Generator Backup
    • Phoenix Contact Electronic circuit breakers
    • UPS
  • Industrial Bakery Allen Bradley PLC 5 Upgrade

    Non Supported Hardware required upgrading from PLC5 hardware to Allen Bradley Control Logix.

    The architecture of the original system was distributed across a local PLC 5 rack containing High speed counter card, analog and digital IO, DH+ Networks for HMI and PLC communications and RIO networks for 11 x field racks. HMI's connected to the system included 2 x PanelView Plus (Ethernet), 1 x PV 550 (DH+). Communications to other PLC's included SLC & Micrologix.

    This system was upgraded over 2 weekend shutdowns to reduce impact to production.

    The final system comprised of an Allen Bradley L71 processor, high speed counter card, and dual Ethernet cards, with local IO, Flex IO remote racks on Ethernet, and ControlNet with analog and digital IO. HMI's were reprogrammed to access the new L71 processor. The PLC code was translated to Logix 5000. Additional PanelView Plus 600's were installed to replace redundant local displays.

    The project was successfully completed with no downtime attributed to the project works.

    Duration: 2 months
    Staff: 6
    I/O count: 1000


  • MCC Replacement

    Our customers brief called for replacement of an ageing MCC and supply cabling used to power 'debarking' machinery in their timber mill.

    New electrical control panels required to upgrade the existing MCC were built at Pro-Built Controls premises prior to transporting to site.

    The project works included;

    • Complete all trenching work to accommodate the new supply including trench depth of 1500mm covered with "Quarter minus" screening compacted and covered with and additional 150mm of reinforced concrete and backfilled with remaining earth.
    • Supply and install new 150mm underground conduit (80mtr).
    • Supply and install new 100mm conduit for future cabling (40m).
    • Supply and install new 185mm 4C & E orange circ cable or equivalent.
    • Supply and install new 630 Amp MCCB bucket for the MCC 10.
    • Terminate test and energize the new supply.
    • Manufacture 4 bay distribution centre to replace the existing MCC & feeds to 16 plant items.
    • Remove existing MCC at planned shutdown (2 -3 Days)
    • Test and wire new distribution system prior to delivery
    • Supply and install 6 fortress key locks to existing guarding in the field.
    • Supply and install new fortress master key and key release system.
    • Incorporate one lockable 630 amp Circuit Breaker for single point of isolation.
    • Test and commission.
    • Create CAD electrical schematics and as built drawings

    Installation on the eve of Xmas shutdown, commissioning commencing Boxing Day.

    Overload & Contactors

  • Conveyor Control System

    Control Box & HMI Creation for Conveyor Line.

    Project Works include;

    • CAT 3 Emergency Stop
    • Siemens Touch Panel Programming
    • Siemens S7 200 PLC Programming
    • Manufacture of Control Panel

    Duration: 1 Week
    Staff: 2
    I/O Count: 30

  • Paper Machine DCS Upgrade

    Project requirements - project management, design, install and connect a DCS system to replace dated Siemens S5 and Taylor MOD systems to ABB AC800xA hardware.
    The installation was designed in parallel with the existing legacy system enabling full FATs and minimal disruption to production schedules.
    All new multicore cables were installed from the final point of field connection to MCC Marshalling panels where the IO was connected to multiple controllers depending on the machine process, prior to change over all new connections were tested from the final point of connection back to the respective controller verifying correct operation of each I/O.
    Installation included a new communications network linking all controllers via local Profi-Bus connections through converters to fibre and remote connections, additional server racks were also installed and connected to the DCS network via CAT5 cable.
    Testing included analog I/O and application of a process meter to ensure correct scaling.

    Duration: 12 Months
    Change over period: 72 hours
    Staff: 20
    I/O Count: 8000

  • CO2 Detection & Control System

    Project requirements - design, manufacture, program, install & commission a CO2 gas detection, fan & louvre control system for an enclosed winery fermentation area.

    Duration: 5 months
    Staff: 6
    I/O Count: 150

  • Bakery Roll Line Control System Upgrade

    This project presented a number of unique challenges for our engineering team including a 48 hour changeover window, missing data & CAD files and insufficient scope documentation. Our engineering staff recreated scope documentation as a forerunner to building, installing and integrating a new control system to suit operational requirements. Integration of the new control system necessitated reverse engineering existing control and equipment function, hardware consisted of approximately 300 I/O utilising an Allen Bradley Compact Logix system coupled with a PV+1500 colour touch screen. System design and layout required conforming to our customers current standards whilst ensuring all applicable industry and regulatory requirements were maintained.

    Duration: 12 weeks
    Staff: 11
    I/O: approx. 300

  • Fire Damaged Electrical Cable Restoration

    Fire had caused significant damage to electrical control & power cabling located in underground conduit & ducts.
    Pro-Built Control attended an emergency call out to bypass damaged wiring and install temporary power & control. Project restoration works necessitated reverse engineering system operation requirements and associated process control elements.
    All field, control and power wiring was traced from point to point to develop working schematics prior to rebuilding/rerouting cable runs.

    Duration: 2 days (until startup)
    I/O: n/a

  • Starch Silos Haz Ex Safety Upgrade

    Project requirements - removal, replacement, relocation and modification of plant & equipment located within a 'Hazardous Area' operating environment.

    Works included -

    • Creation of site area dossier and validation of the customers procured equipment against the site classification documentation, IECex certificates, ANZex/AUSex and current Australian standards for compliance
    • Replacement of existing motors, field sensing devices, transmitters, indicators, beacons, 3 Phase outlets, lighting, control panels, field isolator switches, ground monitoring unit, dust collector stop/start control stations with Ex-tD rated components
    • Installation/replacement of phase loss protection, Emergency Stop Switches, , intrinsically safe (I.S.) indicator units, new earth bonding conductors
    • Replacement of motors with phase loss protection, Field sensing devices, radar transmitters, pressure transmitters, weight indicators, indicating beacons, power outlets, lighting, control panels, field isolator switches, ground monitoring units and push button stations with Ex-tD, Ex-Ia/b, Ex-e, Ex-n rated components
    • Testing, dry/wet commissioning and H-class inspections of equipment to comply with current Australian standards including ITP, ITR, commissioning calibration, earth bond resistance and COES documentation.

    Duration: 5 months
    Staff: 6