Project List
Landfill Gas Projects -- Cement Manufacturer, Sugar Creek, MO
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This project was to add additional Landfill Gas burning capability at a cement plant.
Responsible for PLC & HMI programming, and check-out & start-up. The system consisted of a land fill gas dehydration skid, and a landfill gas compressor skid. The initial PLC programming from the equipment vendor required major rework to interface into the end users existing control system. Each skid was controlled by an Allen Bradley Compact Logix. The operator interface was Wonderware v10. A second phase of the project migrated the HMI graphics into the plant’s existing Intellution iFix system.
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Industrial Waste Shredding Facility -- Cement Manufacturer, Sugar Creek, MO
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The project was to add a facility to shred industrial paper and plastic waste to be burned as an Alternative Solid Fuel at a cement plant.
Responsible for electrical project management, engineering, instrument specification, PLC & HMI programming, construction supervision, and check-out & start-up. The system involved a primary hydraulic shredder, a secondary dual VFD controlled electric shredder, a series of conveyors and bucket elevators, walking bed storage building, and a pneumatic conveying system. The system was controlled by a Modicon Quantum PLC and the Operator Interface was Intellution iFix.
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Cement Blending Upgrades -- Cement Manufacturer, Sugar Creek, MO
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The project was to replace existing cement silo slide gates with vendor supplied tri-rotary feeders in order to provide more accurate cement blending.
Responsible for PLC & HMI programming, and check-out & start-up. The system was controlled by a Modicon Quantum PLC and the Operator Interface was Intellution iFix.
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SCADA System Replacement -- Water Utility, Tucson, AZ
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This project was to replace an existing proprietary and antiquated SCADA system for a water utility company.
Responsible for PLC & HMI programming, and check-out & start-up. The system consisted of a Master PLC and HMI at the Operation building, and 10+ remote PLC’s at reservoir and well pump sites. The PLC communicated via Microvwave Data Systems Ethernet Radios. The Master PLC was an Allen Bradley SLC 505 and the remote RTU PLCs were Allen Bradley Micrologix 1500. The operations building HMI was RSView32.
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OEM -- OEM, Tucson, AZ
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This project was to provide service to an OEM that made custom machines for use by an automotive parts supplier.
The typical machinery components were a chemical pumping skid and one or more mixing and vacuum filling skids. Responsible for PLC & HMI programming, and check-out & start-up. Typical systems were controlled by one or more Allen Bradley CompactLogix PLC and the Operator Interface was RSViewME.
Additionally, I was responsible for analyzing the end users original PLC / HMI programs and "splitting" a single PLC with Flex IO remote racks into multiple PLC’s. This was done in an effort distribute control.
Some versions of the equipment had a small custom robotic system to automatically feed trays from a stack into the fill chamber. The robotic movement was controlled by RoboCylinders that were interfaced to the PLC.
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SCADA System Maintenance -- Various Water Utilities, Tucson, AZ
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These projects were to maintain and make small modifications to SCADA systems for various small water utilities.
Typical systems consisted a Master PLC and multiple remote PLC’s at reservoir and well sites. Communication between sites was via Radio using serial protocol. Typical systems were controlled by an Allen Bradley SLC-500 Master PLC and several Allen Bradley Micrologix1500 RTU PLCs. The Operator Interface was Rockwell Software’s RSView32.
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Randolph Park WRF -- Water Utility, Tucson, AZ
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This project was to provide onsite engineering & instrumentation expertise for reconstruction of a Wastewater Recovery Facility. The facility was damaged by a flood due to a valve malfunction. 90% of the instrumentation was destroyed, and required replacement.
Responsible for verifying the instrumentation replaced matched the specifications of the damaged instrument. The instrument list included 200+ valves, meters, analyzers, controllers, etc, spread over the 2+ acre facility.
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Chino Mines -- Mining Industry, Silver City, NM
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This project was to replace an existing Fischer ROC SCADA system with an updated Allen Bradley control system for the water supply system for a large copper mine.
Responsible for system design, project estimating, panel fabrication, PLC & HMI programming, and check-out & start-up. The system consisted of an Allen Bradley Control Logix Master PLC and multiple remote Allen Bradley Micrologix 1500 RTU PLCs at reservoir and well sites. Communication between sites was via Datalinc Ethernet radios . The system was originally designed to integrate 60+ remote well sites. Radio communication backbone was established, and 3 initial sites were commissioned. Remainder of sites were to be commissioned by owner.
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Plastic Bottle Palletizing System -- Tucson, AZ
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This project was to provide PLC expertise for a plastic bottle manufacturing facility.
Responsible for PLC troubleshooting and minor modifications to their finished bottle palletizing and conveying system. The system was controlled by several Allen Bradley SLC-500 PLC’s.
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Air Handling Equipment OEM -- Tucson, AZ
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This project was to provide PLC expertise to an OEM that made Air Handling Equipment .
Responsible for minor PLC modification, and pre-shipment panel check-out. Typical systems were controlled by an Allen Bradley Micrologix controller.
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Batch Reporting -- Fiberglass Manufacturer, Athens, GA
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This project was to reverse engineer an Operator Interface and Reporting System that had been partially converted from Allen Bradley Control View to Rockwell Software’s RSView32.
The incomplete conversion had broken numerous features. Data logging by Rockwell Software’s RSSQL was added to log production data to MS Access. This project involved significant MS Access Re-Work, and significant RSView32 re-work.
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Washwater System -- Fiberglass Manufacturer, Athens, GA
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This project was to replace an obsolete hardwired system with PLC / HMI controls.
Responsible for PLC & HMI programming and check-out & start-up. The system involved a water spray system to collect waste fiber from the insulation process, and scrubbing to control emissions. The system was controlled by a Allen Bradley ControlLogix PLC and the Operator Interface was Rockwell Software’s RSView32.
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Web Reporting -- Fiberglass Manufacturer, Kansas City, KS
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This project was to develop a custom web based reporting system to display production data.
Responsible for PLC, Operator Interface & web page programming. PLC Data was logged to MS SQL Server 2000 via Wonderware scripts. Custom ASP.net web pages were developed to access data in the SQL database and display the data on the plant intranet.
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HMI Upgrade -- Pretzel Plant, PA
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This project was to convert a USDATA FactoryLink DOS application to version 6. This was especially challenging as the existing application files were corrupt. Additionally, a serial driver between FactoryLink and a dough bin feeder had to be reverse engineered.
Responsible for FactoryLink conversion, and check-out & start-up. The system was controlled by a several TI PLCs and the Operator Interface was USDATA FactoryLink.
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HMI Upgrade -- Aircraft Parts Stamping Plant, St. Louis, MO
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This project was to convert a USDATA FactoryLink DOS application to version 6 for equipment in an aircraft parts stamping facility.
Responsible for FactoryLink conversion, and check-out & start-up. The system was controlled by an Allen Bradley PLC-5 and the Operator Interface was USDATA FactoryLink.
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Process Monitoring & SPC analysis -- Electronics Manufacturer, Chacago, IL
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This project was to add data monitoring, data logging, and SPC analysis to the process of a cell phone chip manufacturer.
Responsible for PLC and HMI programming, and check-out & start-up. The system consisted multiple pieces of stand alone vendor equipment. The HMI was to gather various process data from the vendor equipment, log the data to an Oracle database, perform SPC analysis of batch data, and finally serve SPC data to client PC’s in the form of SPC analysis trends. Some equipment required custom serial comm. interface. Operator Interface was USData FatoryLink v7.
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Consulting / HMI Maintenance -- Chicken Feed Facility, Lima Peru
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This project was to provide HMI expertise and maintenance at a chicken feed facility.
Responsible for minor PLC and HMI programming modifications. The system consisted of multiple pieces of grain grinding and blending equipment. The system was controlled by an Allen Bradley SLC-504 PLC and the Operator Interface was Wonderware v6.
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HMI Additions -- Water Utility, Kansas City, KS
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This project was to expand the capabilities of an existing USData FactoryLink v6 application to mimic a large existing pusbutton operator panel at a water utility company.
Responsible for PLC and HMI programming and check-out & start-up. The system consisted of numerous pumps and valves for a river water intake system. The system was controlled by a Allen Bradley PLC-5 and the Operator Interface was USData FactoryLink v6.
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Soap Skid Expansion -- Soap Manufacturer, Mexico
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This project was to provide ability to add additional ingredients at to an existing in-line blending system at a soap manufacturer.
Responsible for engineering, engineering designer supervision, PLC and HMI programming, construction supervision, and check-out & start-up. The system consisted of numerous ingredient tanks, each with discharge flowmeters and VFD controlled pumps. The system was controlled by an Allen Bradley ControlLogix PLC and the Operator Interface was Wonderware v9.
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Plant Start-Up -- Cement Manufacturer, Sugar Creek, MO
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Responsible for PLC Programming, check-out & start-up for a new Cement plant. The plant was controlled by a 15+ PLCs that were primarily Modicon Quantums. Operator Interface was Intellution iFix.
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Washwater System -- Fiberglass Manufacturer, Kansas City, KS
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Responsible for engineering, instrument specification, PLC & HMI programming, check-out & start-up. The system involved a water spray system to collect waste fiber from the insulation process, and scrubbing to control emissions. The system was controlled by and AB PLC 5/40, and the Operator Interface was an AB Panelview 600.
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Plant Maintenance -- Cement Manufacturer, Sugar Creek, MO
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Responsible for PLC & HMI programming for ongoing plant maintenance & troubleshooting. The plant was controlled by a variety of PLCs including several Modicon Quantums, a Soft PLC, three AB PLC 5/40s, and several AB PLC-2s. Operator Interface was USData FactoryLink.
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Raw Mill PLC Clean-Up -- Cement Manufacturer, Sugar Creek, MO
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The project involved removing obsolete graphics, programming, and wiring for equipment that had previously been removed from the system.
Responsible for engineering, and PLC & HMI programming. The system was controlled by and AB PLC 5/40, and the Operator Interface was USDATA FactoryLink v6.
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Automatic Order Change -- Fiberglass Manufacturer, Kansas City, KS
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The project involved coordinating recipes, interlocks, handshaking and timing between 20+ PLCs to automatically change product orders on the fly.
Responsible for design, and PLC & HMI programming. The system was controlled by a Master PLC which was an AB PLC 5/80. The slave PLCs were AB PLC-5s and SLC-500s. Operator Interface was RSView 32 and AB Panelview 1400e.
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Binder & Batch Upgrades -- Fiberglass Manufacturer, Kansas City, KS
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These projects provided upgraded controls & functionality for Binder Mixing and Batch (glass melting) Mixing.
Responsible for engineering, instrument specification, PLC & HMI programming, check-out & start-up. The system was controlled by two AB PLC 5/40s. Operator Interface was Wonderware v7.0.
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Oil Spray System -- Fiberglass Manufacturer, Kansas City, KS
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The project involved flow & pressure control of oil as it was sprayed onto the fiberglass product.
Responsible for PLC & HMI programming, check-out and start-up. The system was controlled by an AB Control Logix 5000 PLC, and had an AB Panelview 1400e for the Operator Interface.
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Other projects completed under previous
employers
CertainTeed Corp, Kansas City, KS
– K21 Insulation Line
Responsible for PLC and Operator Interface Programming, for
multiple PLC systems on the "Hot End" of the new K21
insulation line. The projects consisted of 3 "wigwag"
PLCs, Washwater, Cullet, Asphalt. The PLCs were AB PLC-5s and
SLC 500's. Operator Interface was Allen Bradley Panelview 1400E
& 550s, and Wonderware.
Anheuser-Busch, Los Angeles, CA – Stockhouse Cooling
Responsible for PLC and Operator Interface Programming, supervision
of other PLC programmers, check-out and start-up. The project
consisted eight cooling / dehumidification units, four outside
air cooling units, and one desiccant reclaim system. The system
was controlled by 3 AB PLC 5/40Es. Operator Interface was USData
FactoryLink on a UNIX AIX platform and one AB Panelview.
Anheuser-Busch, Houston TX – Boiler Monitoring
Responsible for PLC and Operator Interface programming, start-up
and check-out. The system involved monitoring data from six
natural gas boilers. Operating curves were graphed, and deviations
from as-tuned fuel air curves triggered alarms. The system was
controlled by an AB PLC 5/40E with AB Panelview Operator Interface.
Anheuser-Busch, Houston TX – NH3 Compressor Plant
Master Load Shedding
Responsible for design, instrument specification, PLC and Operator
Interface Programming, check-out and start-up. The project created
a master system for loading, unloading, starting and stopping
ten NH3 compressors based on changing load requirements The
system was controlled by an AB PLC 5/40E processor. The Operator
Interface was US Data FactoryLink 4.0 on UNIX AIX platform.
Anheuser-Busch, Houston TX – Chilled Water System
Responsible for design, instrument specification, PLC and Operator
Interface Programming, check-out and start-up. The project provided
additional chilled water capacity by adding two new NH3 chillers
and an associated tank farm. The system also included chemical
treatment of the water. The system was controlled by two Allen
Bradley PLC 5/40E processors. The Operator Interface was US
Data FactoryLink 4.0 on UNIX AIX platform.
Anheuser-Busch, Willaimsburg, VA – Belt Bed Pasteurizer
Responsible for design, instrument specification, PLC and Operator
Interface programming, check-out and start-up. The system involved
a belt bed pasteurizer, infeed and discharge conveyors. The
system used a PLC 5/40 for the pasteurizer control as well as
an Allen Bradley Panelview for Operator Interface. The Discharge
conveyor system used a second PLC 5/40, and interfaced to a
pair of existing can packers.
Anheuser-Busch, Tampa, FL – Hops Extract Syrup Injection
Responsible for design, PLC programming, supervision of the
Operator Interface Programming, check-out and start-up. The
system involved injecting a hop extract syrup into the finished
beer line and blending based on flow rate. The programming involved
additions to an existing AB PLC-3 and an existing AB PLC 5/25.
The Operator Interface was FactoryLink 3.0.
Anheuser-Busch, Fairfield, CA – Can Line 40 full can
system
Responsible for design, PLC and Operator Interface programming,
check-out and start-up. The system involved a full can conveyor
system, 12/12 can packer machine, 2/12 tray packer machine.
and a full case conveyor system. Each of the four systems used
an Allen Bradley PLC 5/40. The packers used Allen Bradley Panelviews
for Operator Interface.
Anheuser-Busch, Fairfield, CA – Can Line 50 empty
can system
Responsible for design, PLC and Operator Interface programming,
check-out and start-up. The system involved an empty can cable
conveyor system, can rinser, and "airveyor" to feed
an existing can filler. The system also included a section of
filler discharge conveyors. This system used an Allen Bradley
PLC 5/40.
Anheuser-Busch, Fairfield, CA –Bottle Line 20 Responsible
for check-out and start-up. The system a full case conveyor
system, one new and two existing slitter/sealer machines. This
system used an Allen Bradley PLC 5/40.
Anheuser-Busch, Houston, TX – Bottle Line 06
Responsible for design, PLC and Operator Interface programming,
check-out and start-up. The project installed a complete bottle
line packaging line. Equipment included, empty glass depalitizer,
rinser, empty bottle and carton conveyor, filler, pastuerizer,
full bottle and case conveyors, three labelers, two drop packers,
two targeteer packers, and full case palletizer. The line was
an aseptic filling line and required special programming, instrumentation,
and procedures to insure integrity of sterilized areas The line
was controlled by 25 Allen Bradley PLC 5/25s and used numerous
Allen Bradley Panelviews for Operator Interface.
Anheuser-Busch, Houston, TX – Can Line 63
Responsible for design, PLC programming, check-out and start-up.
The system involved a new full can conveyor system, new 12/12
can packing machine, three existing relocated packers, and a
new full case conveyor system. Each of the relocated packers
involved converting an Allen Bradley PLC-2 to an Allen Bradley
PLC-5/25. The new packer was controlled by a PLC 5/25. Controls
for the new full can system were added to and existing AB PLC-2.
Anheuser-Busch, Houston, TX – Bottle Line 06 Filler
Modifications
Responsible for design, instrument specification, PLC and Operator
Interface programming, check-out and start-up. The system involved
replacing a vendor supplied high speed control module with an
Allen Bradley PLC 5/20. This system controlled the high speed
operations of the filler and crowner including filling valve
actuators, exploded bottle detection, high speed controlled
low-fills, and crown release. The system compensated for changes
in machine speed. The project also replaced the existing stand
alone level and pressure loop controllers with PID control via
an AB PLC 5/25. The system used an Allen Bradley Panelview for
Operator Interface.
Anheuser-Busch, - Bottle Laser Code (all plants)
The project involved retrofitting all labelers in the company
(100+) with a Laser Coding Unit to replace an existing Inkjet
coding system. Responsible for check-out and start-up of the
first 3 units. Following these successful installations, served
as engineering liaison to the individual plants, and provided
electrical support, vendor coordination, and plant training
for the remaining units.
Merico Bakery, Indianapolis, IN – Refrigerated Pie
Crust Line
Responsible for vendor program coordination, as well as check-out
and start-up. Refrigerated pie crust line involved batch ingredients
mixing, extruder / sheeter control, and control of various packaging
equipment. This system was controlled by several SLC-500 PLC’s.
Ford Motor Company, Kansas City, MO -
Responsible for interfacing PLC systems with Ford MIS System
for job verification throughout entire Truck Facility. (Body
Shop, Paint Shop, and Trim & Chassis)
Anheuser-Busch, Tampa, FL – Water Reclaim System
Responsible for project scoping and preliminary design. The
system involved reclaiming water from carbon filters and can
/ bottle rinsers. The system was controlled by a PLC 5/40 and
used USData FactoryLink on a SCO UNIX platform as an Operator
Interface.
Anheuser-Busch, Houston, TX – Can Line 67
Responsible for system design. The system involved two new belt
bed pasteurizers, new full can conveyor system, two new can
packers, and new full case system. Each system was controlled
by an AB PLC 5/40. Operator Interface was Allen Bradley Panelviews.
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