Sawmill Industry
SIMPSON
TIMBER COMPANY
.......................................................................1996
- 2006
Korbel,
California
Planer
Mill Re-build
From
concept to commissioning, this 14-month project started with the removal
of all the existing planermill mechanical equipment except the Planer,
Tray Sorter, Wet Stacker and one Strapper that were re-used. In
addition, all the MCC’s and PLC’s were removed and replaced with 2100
CenterLine MCC’s and ControlLogix PLC’s from Allen Bradley. SKS
supplied the engineering services and USNR and COE/Newnes supplied most of
the mechanical equipment. Pacificon was responsible for the entire
control system design and commissioning.
The
following mechanical equipment was installed:
-
Continuous
Tilt Hoist (USNR)
-
Wet
Stacker (re-used)
-
Planer
(reused)
-
Residual
Conveyor System for sawdust and chips
-
Bag
House system
-
Re-entry
hoist
-
Linear
High Grader (planer outfeed optimizer) *
-
3
Operator grading stations *
-
3-stage
servo-controlled fence *
-
6
to 20 foot Trimmer *
-
20-tray
sorter (reused)
-
Servo-controlled
electronically-geared sorter drive system c/w skip-a-lug &
cut-in-two feature
-
Automated
2-layer sorter removal chains c/w Spray Booth
-
High-speed
servo motor and hydraulic linear positioner controlled lumber stacker
*
-
Two
lumber strappers (including one re-used)
-
Two
paper wrap stations
*
Note: Only the mechanical equipment and optimizing system was
supplied by COE/Newnes
Pacificon’s
Project Tasks
-
Design
and program automated controls for all above equipment
-
Fabricate
and supply all control panels and operator stations
-
Commission
all vendors equipment
Control
Equipment Summary provided by Pacificon
-
3
ControlLogix PLC’s were used to control the Planer Infeed Area,
Trim-Sort Line and Package Handling areas
-
2
additional ControlLogix PLC’s were used for specialized motion
control for the following equipment throughout the plant:
-
9
Ethernet PLC modules were used to provide multiple Ethernet networks
for interfacing to all the I/O points, HMI's and MCC's
-
four
8-port and seven-24-port managed switches were used at 3 locations
with redundant fiber-optic cables between the 3 locations
-
2950
I/O points required nine 17-slot racks & 18 different Flex I/O
drops for consoles, panels, etc.
-
all
I/O devices were connected via Ethernet rather than conventional
Remote or ControlNet I/O
-
34
VFD's were controlled by an embedded Ethernet interface module in each
VFD
-
150
standard drives, each controlled by a DeviceNet E3 or E3 Plus module
-
10
MCC's interfaced to PLC via 10 EtherNet to DeviceNet (EN2DN)
converters
-
7
Panelview 400 Plus HMI’s with Ethernet interface for local status
and alarm messages
-
RSView
HMI station for trimmer & sorter setup & diagnostics via
Ethernet interface
-
client
supplied Sorter Setup and Reporting system via Ethernet interface
-
connected
to corporate network for remote access and troubleshooting via web
Even
though this project was only designed for 130 lugs per minute (LPM)
(2" x 4" lumber to 4" x 12" timbers were processed on
the same line), we are also experienced with 200 LPM equipment and the
special design considerations that are required for a control system to
run at these higher speeds.
End
Dogger for Fir and Redwood Products
Pacificon
assumed full system responsibility to:
-
Replace
existing H.P. computer based controls with Allen-Bradley
PLC 5/40E based system
-
Completely
rewired machine - Block I/O modules used extensively to reduce wiring
costs
-
Replaced
X-Y scanner (high maintenance photocell array) with two Perceptron Lasar scanners
-
Replaced
USNR optimizing system with Perceptron
optimizing system
-
Visual
Basic 6.0 operator interface for system set-up and display of cutting
solution and diagnostics
-
Productivity
increased by more than 10 % (back end of mill cannot keep up for true
test)
-
Recovery
increased by 3%
-
Upgraded
hydraulic system and charger positioners in July 2001
Barker
and Log Merchandizing Systems for Fir and Redwood Products
-
Replace
existing H.P. computer based log bucking and sorting functions with
PLC-based system
-
Upgrade
Texas Instruments PLC system to Allen-Bradley
PLC 5/40
-
Replace
two 4-foot Opcon diameter scanners with scanners from Banner
-
Visual
Basic 6.0 operator interface used for system set-up and diagnostics
and to display bucking solution
Log
Quad
-
Replaced
Texas Instruments PLC and ATI setworks controller with Allen-Bradley PLC 5/20 and 3 QB modules to control hydraulic
linear positioners on four (4) saws, picker and newly added slabber in
front of saws to remove flare on butt of logs.
-
Panelmate
1500 colour LCD added for operator interface, diagnostics and size
changes.
Tandem
Horizontal Resaw
-
Replaced
Texas Instruments PLC and Inovec setworks controller with Allen-Bradley
PLC 5/20 and QB module to control two (2) saw positioners.
-
Panelmate
1500 colour LCD added for operator interface, diagnostics and size
changes.
CANADIAN
FOREST
PRODUCTS LTD.
.......................................................2001
- 2002
Rustad
Division
Prince
George, BC
Konus
Twin Burner Thermal Oil Plant Upgrade
-
Upgraded
existing Frank Controls microprocessor based system with a PLC 5
controller
-
All
PID Loop controls were performed in the PLC rather than with add-on
controllers
-
Several
motors starters were upgraded to VFD's with speed control from the PLC
program
-
Touch
screen computer for Operator Interface with Ethernet interface to PLC
-
User
friendly, RSView 32 operator interface used for manual
and automatic controls, alarms and historical trending
-
System
included diesel backup oil pump and supplementary pellet fuel system
-
Most
of the existing process measurement devices were retained with several
new 4-20ma transmitters installed
-
Upgrades
for each burner were successfully completed over two 4-day shutdowns
Sorter
PLC Upgrade
-
Upgraded
existing Trimmer, COE Optimizer and NAC 62-Bin Sorter controls with Allen-Bradley
PLC 5/60 and RS
View 32 system.
-
Completely
rewired sorter and replaced all bin control panels and field devices.
-
State
of the art configuration and diagnostic screens are used extensively
throughout the system.
-
Very
user friendly system taking full advantage of latest hardware and
software technologies to provide many reporting and diagnostic
capabilities not possible in real time with previous products.
-
Advanced
features have been made possible through the use of standard high
speed PC computers and ethernet network, as well as the extended
memory available in PLC’s today.
-
Project
Management by International Quest Engineering and installation by
K2 Electrical Contractors.
A
complete colour demo package is available for presentation purposes.
HEATWAVE
TECHNOLOGIES Inc.................................................................2001 – 2002
Vancouver
and Crescent Valley, BC
Two
projects were completed:
RF
Oven Controls (prototype for food industry)
-
Two
Parker Linear positioners controlled with Allen Bradley Ultra 3000
Indexing drives used for adjusting the RF tuning
-
PID
loops controlled by PLC
-
FlexLogix
processor with DeviceNet interface to drives and RF power source
-
Computer
running Intellution / iFix for operator interface
RF
Kiln Controls (lumber drying system for Hampton Forest Products -
Randle, Wash.)
-
Four
Stepper motor positioners were controlled with API Motion Controls
drives and were used for adjusting capacitors used in the two RF
tuning loops
-
Two
RF sections were used to provide the thermal energy requirements for
the large lumber drying kiln
-
ControlLogix
processor controlling several PID loops with over 40 analog I/O points
and over 240 digital I/O points
-
Extensive
DeviceNet interface (24 nodes) to control remote racks and 13 motor
using Cutler Hammer starters
-
RSView
ME used for operator interface (supplied by customer)
FLAVELLE
SAWMILL COMPANY.............................................................................2002
Port
Moody, BC
Sorter
PLC Upgrade
-
Upgrade
an existing NAC 35-bin sorter controls with Modicon Quantum PLC and
Visual Basic/Windows2000 set up & reporting system with two large
production / message displays
-
This
is a second Sorter in the sawmill that sat dormant for the past 8
years. We had to replace the thickness and width/position
encoders but were able to re-use most of the existing wiring and other
sensors
-
This
Quantum sorter package has the ability to operate two sorters from the
same PLC processor and uses one Operator Interface (HMI)
-
Unlike
most other HMI's, the HMI is not required to be on-line while the
sorter is running as all shift report data is stored in the PLC
memory. Therefore, the HMI computer can also serve as a PLC
programming terminal
-
These
features were attractive to the customer and as a result, there is a
good chance Pacificon will convert the other sorter thereby
eliminating the second computer and PLC processor
L&M
LUMBER LTD.
..........................................................................................2001 – 2002
Vanderhoof,
BC
Moisture
Sort System – Process Control Upgrade
-
High
Speed (200 LPM) moisture sort line complete with stacker for studmill
-
Allen-Bradley
PLC 5/20E
-
RS
View 32 HMI for diagnostics and easy access to all system parameters
-
Dual
Message Display Boards
-
Northern
Mill Industries (NMI) Moisture Sort System
-
Project
management and mechanical design by Stolberg
Engineering Ltd.
ASPEN
PLANERS ......................................................................................................2001
Merritt,
BC
Gang
Edger
-
Electrical
rebuild after fire destroyed machine wiring and several power and
control devices including D.C. motors, servo valves, Temposonic
probes, etc.
-
D.C.
drives replaced and upgraded
-
Saw
position lasers and saw positioners were completely re-built and
rewired
-
Program
modifications to an Allen-Bradley PLC 5 program. Up-dated drawings and
documentation.
CRESTBROOK
FOREST
PRODUCTS....................................................................
2000
Cranbrook,
BC
-
Provided
commissioning assistance for client’s finger jointing plant designed
by Lucidyne
-
System
included thirty (30) networked computers communicating to a
Multi-Processor (3)Allen-Bradley Control
Logix PLC control system
WEYERHAEUSER
(was
M&B).............................................................................
1999 - 2001
Canadian
White Pine Division
Vancouver,
BC
Two
44-bin Sorters in sawmill for cedar products
-
Laser
based differential thickness sensors – a Pacificon Systems design
-
Two
(2) Grade Mark Readers – supplied by Cypress Technology
-
Two
(2) Stackers with auto fill stick hoppers
-
Modicon
Quantum PLC
with Panelmate
operator interface for motor control and diagnostics
-
Six
alphanumeric scrolling message displays used throughout sawmill
-
Visual
Basic 6.0 / Windows based operator interface setup and reporting
system
-
Ticket
Printer – to
print status of each package (Bin No., Grade, Length, FBM, etc.)
Bull
Saw and Timber Handling System
MILLAR
WESTERN.....................................................................................................
2000
Whitecourt,
Alberta
New
Dual-Ring Nicholson Debarker
INTERFOR............................................................................................................
1998 - 2000
Squamish,
BC
Twin
Vertical Resaw and Twin Horizontal Resaw, both with:
-
Allen-Bradley
PLC 5/30
with two QB modules
-
Panelmate
Interface for motor control, diagnostics and setworks configuration
ASPEN
PLANERS...............................................................................................
1995 -1996
Merritt,
BC
Edger
Optimizer & Resaw
-
Supplied
complete Allen-Bradley PLC 5/40
system, Panelmate, consoles etc. for one operator to control both Edger
Optimizer and Resaw machine centres.
-
Ten
(10) linear positioners controlled by QB modules.
-
Responsible
for PLC Interface to Scanner and Optimizer supplied by Newnes.
The
next four projects are similar in nature:
i.e. Pacificon’s PLC programming expertise was requested by the
following clients to expedite another vendor’s program installation and
start-up. Lengthy delays by
the original vendor had caused production shortfalls and the client’s
were anxious to get the mill operating efficiently.
TIMBERWEST...............................................................................................................
2001
Campbell
River, BC – Dimension Products Mill
Double
Length Infeed (DLI) Line
INTERFOR
- FLAVELLE CEDAR DIV. (now
owned by Mill & Timbers).............
1997 - 1998
Port
Moody, BC – Cedar and Fir Dimension Products Mill
Barker,
Log Bucking
and Double Length Infeed (DLI) Line
-
On
site PLC consulting and start-up assistance (original program provided by
another vendor).
-
Nine
(9) months after the sawmill modernization, mill personnel were still
struggling to achieve the desired target goals.
Production rates were 13.5% below targets.
-
Considerable
program modifications to the entire system to increase production levels.
-
PLC
documentation added to assist mill electricians with “in-house”
troubleshooting.
-
A
performance bonus was received
after increasing production rate by 18% in three (3) months to meet
sawmill monthly target goal. During
the last 2 months, the production rate was increased by a further 10%,
surpassing all expectations. In
fact, there have been a few days when production was close 250,000 FBM/shift,
with the target being 190,000 FBM/shift.
AVENOR
INC.......................................................................................................
1997 - 1998
Ear
Falls, Ontario - Stud Mill
Small
and
Large Double Length Infeed (DLI) Lines
RIVERSIDE
FOREST PRODUCTS.................................................................
1997 - 1998
Williams
Lake, BC - Stud Mill
Double
Length Infeed (DLI) Line
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