Moore Products Project Reference List
Following is a sample of Moore Products Process Automation projects with which we have been involved. Please contact your Applied Control Engineering, Inc. representative if you require additional information.
Quaker Chemical Corporation
ACE designed, configured, and managed fabrication of an APACS system to automate a batch reactor, a three-stage fume scrubber, and a liquid charging system. The resulting system also monitored all vessels in four tank farms. After a successful startup, ACE was contracted to supply support for software upgrades and enhancements, and to expand the automation to a second reactor.
Sun Drilling Company
ACE designed and implemented an APACS system to automate a batch reactor and associated tanks, mixers, and metering systems. The sequence was implemented in the controller, and provisions were made for operator initiation of individual phases. ACE also provided services for specification development, panel design and fabrication, and startup support.
Moore APACS, ProcessSuite Vision, and ProcessSuite Batch were used to design a system to control three reactors and auxiliary equipment. The batch system included the creation of 20 phase typicals and 40 total phase instances. The operator interface allowed the user to select and run a recipe. In addition, the user could run the phases outside of the recipe for testing. Custom shift reports were created to allow operator comments to be available to the next shift. ACE also provided startup services for this project. Following successful implementation, ACE was selected to provide an APACS-based flexible batch management solution for laboratory control. Custom reporting was also developed for this customer.
This system involved more than 60 fermenters and other process equipment in a validated research environment. Moore ProcessSuite Batch provided the batch engine to sequence the phases within the control system. The batch engine downloaded parameters to the phases. ProcessSuite History was utilized to provide real-time data collection and trending. ACE provided integration, programming enhancements, and on-site support as the fermenters were brought on-line.
ACE implemented an APACS system to control three reactors and auxiliary equipment. The system involved a fixed sequence in the ACM with downloaded parameters from the user interface. Extensive simulation in the controller allowed for operator training on both the user interface and the sequence execution. This simulation enabled startup in three days with quality product successfully produced in the first batch. This first batch also had a shorter cycle time than before system implementation.
Air Products & Chemicals
This project was implemented using a combination of resources from Air Products and ACE. While the Air Products personnel were familiar with DCS configuration, they had no experience with Moore Products’ technologies. Our resources provided technical expertise and startup support for successful implementation of this large system which included two redundant Quadlog racks, one redundant APACS rack, and four non-redundant APACS racks. Modbus communication to a Woodward governor was also implemented to provide indication and control of a GE LM2500+ gas turbine.
Colorite Specialty Resins
ACE has provided configurations for an APACS system to control a batch reactor using phase logic and ProcessSuite Batch. Services have also been provided to configure an APACS system for the tank farm, and to configure PAC-353 controllers for reactor cascade temperature control. ACE also has a 24/7 emergency support contract with this customer.
Colorado Interstate Gas
ACE was contracted to provide configuration services for two APACS DCS systems communicating over a LIL connection to four 351 triple loop digital controllers, three 352 single loop digital controllers, and two 383 multi-point display systems to control and monitor a Helium extraction process in Keyes, Oklahoma. Process visualization was implemented using iFIX 32 (CIG’s corporate standard HMI package). The iFIX32 application was then merged with CIG’s corporate operations in Colorado Springs so that the plant could be remotely monitored. ACE continues to support this site with a maintenance contract for minor control changes and enhancements.
Armstrong World Industries
APACS was used to modernize the controls at boardmill production facilities in Pensacola, FL and Marietta, PA. ACE provided design, fabrication, programming, foreign device interfacing, and startup services for the Marietta modernization project. Following successful implementation, ACE was selected to provide similar services for the Pensacola facility.
Severstal (formerly Bethlehem Steel Corporation)
ACE has successfully implemented more than 20 projects for this customer involving Moore Products APACS, MYCRO, and Local Instrument Link control systems. Most of these efforts have involved all aspects of control system project management, from system specification to design, programming, panel fabrication, installation, and startup support.
The most recent project involved an emergency replacement of a MYCRO ACS to ProcessSuite Vision for the plate mill soaking pits in Coatesville. ACE was able to configure a new interface only days after the ACS failed and the customer found that they had no usable backups. Our timely response to this customer emergency allowed them to continue producing product without interruption.
Global Tungsten and Powders (formerly Osram Sylvania) in Towanda, PA
Engineers from ACE have supported this site for more than 12 years. Projects have included most of the site unit operations and have involved APACS, MYCRO, LIL, PAC-353, Procidia, and foreign device technologies. Our engineers have helped to develop a path towards an overall integrated site control system solution, replacing the individual automation solutions that existed prior to our involvement. We have also provided emergency support to this site, enabling operations to continue without interruption when legacy systems failed.