Control System Modernization

INDUSTRIES
  • Pulp & paper
SERVICES
  • Project Management
  • PLC
  • Field Networks/Process ControlNetworks
  • Document Management
  • DCS
  • Control System Migration
  • BMS
TECHNOLOGIES
  • Project Management
  • PLC
  • Field Networks/Process ControlNetworks
  • Document Management
  • DCS
  • Control System Migration
  • BMS

The Challenge

The client, a leading producer of high quality kraft pulp, was facing production reliability risks associated with aging and obsolescence of existing control systems. Several factors were impacting reliability including component failure rates, spare parts availability, availability of training for skilled maintenance workers and access to external expertise. The impact was increasing over time as problems compounded to result in more frequent incidents of increasing severity.

Autopro's Role

In order to maintain the reliability of the facility, the control system hardware was replaced with new Honeywell controls hardware, the first North American installation of a Honeywell MasterLogic PLC. The upgrade also included replacing network infrastructure, operations stations, operations furniture, control network infrastructure, controllers, and field termination assemblies.

In the woodroom specifically, the control system was replaced with Rockwell controls hardware.

All existing controls software was examined to determine functionality and documented for inclusion into the Experion and ControlNet control systems as required. This check also required extensive coordination with and involvement from the client.

Some of the challenges faced by Autopro’s project team included:

  • Multiple overlapping project phases which required extensive planning
  • Very short shutdown windows (8 to 12 days)
  • Very short startup time (2 to 3 days to work out any bugs)
  • New control system had to interact seamlessly with old system between construction phases                                      

Specific tasks undertaken by Autopro’s project team included

  • Replacing Recaust control strategy/software, control system hardware and packages to rewire all IO
  • Replacing Recaust BMS control strategy/software, control system hardware and packages to rewire all IO
  • Rewriting / updating all associated documentation

Project Success Criteria

  • Autopro’s team successfully met schedule expectations.
  • Autopro’s team exceeded budget expectations; the project was completed 9.7% under budget on an overall engineering budget of almost $2.3 million.

Project Metrics

Project Completion Date