Project Summaries and Case Studies

Every project has a unique set of challenges and objectives, including scope, budget, time frame, regulatory requirements and more. MAVERICK addresses each concern in developing custom solutions that meet each customer’s needs.

Manufacturing Projects

• Fast-Paced Modernization of Generator Control Systems Meets Increased Power Demand
  When Santee Cooper, a leading southeastern utility provider, inherited peaking generator with unreliable control systems, the company launched a modernization project to systems’ reliability and ease of operation. Unfortunately, the company lacked adequate monitoring capabilities and the documentation regarding system maintenance.
  download case study
  
  
  learn more …
• Industrial Power Plant Owner in Need of Process Control Programming — ASA
  An owner of a new power plant uncovered problems with their control system programming. Three months from startup, they required immediate assistance to resolve programming and control issues in order to meet operational requirements.
  download case study
  
  
  learn more …
• Manufacturer of Specialty Engineering Plastics Improves Process Yields through Advanced Process Control (APC)
  A major plastics manufacturer was producing multiple grades of plastic on the same production lines and needed a more efficient method of transitioning from one grade to another. The company’s existing manual transition process was slow and inconsistent, and resulted in wastage and downgrading of valuable product.
  download case study
  
  
  learn more …
• Manufacturer Implements Facility Monitoring and Control System (FMCS) for Its 200mm Wafer Fabrication Facility
  This leader in wafer technology and innovation needed a cost-effective FMCS to address issues of compliance, safety, constructability, system uptime, operability and maintenance.
  download case study
  
  
  learn more …
• Major Plastics Manufacturer Increases Production and Reduces Operator Workload through Advanced Process Control (APC)
  A European manufacturer of high-value engineering plastics needed to boost its production rate to meet increased demand for Bisphenol A (BPA), a key intermediate, and the final product, a highvalue polycarbonate resin. Although there were no immediate plans to install new equipment, and all other debottlenecking steps had already been performed, the manufacturer had to find a way to maximize its production of BPA.
  download case study
  
  
  learn more …
• Advanced Automatic Generation Controls (AGC) in Power Plant
  An independent power producer needed advanced AGC in order to achieve competitive, marketbased, remote dispatch control certification.
  download case study
  
  
  learn more …
• Cooling Water Systems Automation (CWSA ) Upgrade
  In addition to the cooling systems, the customer needed improvements in chemical treatment program performance and flexibility, as well as the measurement of tower make-up water flow. It was also necessary for MAVERICK to provide an overall redesign of the cooling system sampling, chemical handling, monitoring and control systems.
  download case study
  
  
  learn more …
• MAVERICK Technologies to Implement Data Matrix Cap Verification System for Healthcare Products Manufacturer
  Columbia, Ill., Aug. 22, 2008 – MAVERICK Technologies announced today that it has won a two-dimensional data matrix cap verification project for a global manufacturer in the healthcare industry. The project scope includes definition, design, programming, procurement and startup support services, including PLC and HMI development, factory acceptance testing and site acceptance testing.
  The data matrix verification system comprises two steps. First, a conveyor will transport vials of up to 100 milliliters past two printers that will label the vial cap with a lot number. The first printer will print the six-digit number on the side of the crimped cap, and the second printer will print a two-dimensional data matrix coded version of the same lot number on the top of the cap. Then immediately after printing, a vision system will inspect the two-dimensional code and determine its readability and accuracy. Vials with poorly printed or inaccurate codes will be rejected from the conveyor. A downstream accumulation table will collect the remaining good vials. site acceptance testing.
  
  learn more …
• MAVERICK Technologies Wins Wind Farm Systems Construction Projects
  Columbia, Ill., Aug. 22, 2008 – MAVERICK Technologies announced today that it will work as a subcontractor to manage utility substation construction projects involving new wind farm systems in two states.
  
  learn more …
• MAVERICK Technologies Provides Startup Support for University Chilled Water Plant
  Columbia, Ill., Aug. 22, 2008 – MAVERICK Technologies announced today that it will provide additional support for a chiller system installation project already underway at a major university.
  
  learn more …
• MAVERICK Technologies Wins Wonderware Information Server Configuration Project
  Columbia, Ill., Aug. 22, 2008 – MAVERICK Technologies announced today that it will begin work on configuring the Wonderware Information Server for a building products manufacturer. The project scope includes specifying the correct computer, setting up the Microsoft operating system, installing the Wonderware software and verifying that the correct license is installed. MAVERICK will also configure the overview screen, migrate the existing InTouch graphics and configure the ActiveFactory tools, allowing the client to view the process via the Internet.
  
  learn more …
• MAVERICK Technologies Performs APC Opportunity Survey at Plastics Manufacturing Plant
  Columbia, Ill., Aug. 22, 2008 – MAVERICK Technologies announced today that it is currently completing a study to review each of the processes at a large plastics manufacturer, with the intent of developing design requirements to improve the productivity through advanced process control (APC). APC provides more stable plant operation, tighter control of variables related to quality, operation closer to constraints and more diligence than the best operator. Results include greater throughput, better yields, higher quality and improved productivity.
  
  learn more …
• MAVERICK Technologies Troubleshoots Control Problems at Semiconductor Manufacturing Plant
  Columbia, Ill., Aug. 22, 2008 — MAVERICK Technologies announced today that it recently helped a power semiconductor manufacturer fix several control system problems. The plant contacted MAVERICK when it experienced operational problems with its air handling unit and chiller pneumatic controls because one of its valves did not open. MAVERICK performed troubleshooting on the PLC and HMI controls to restore correct operation, and it also relocated the humidity / temperature sensor to provide more accurate monitoring.
  
  learn more …
• MAVERICK Technologies to Install Remote Monitoring and Control SCADA System for Energy Company
  Columbia, Ill., Aug. 22, 2008 — MAVERICK Technologies announced today that it will install a remote monitoring and control SCADA system for a global energy company with several compressed natural gas and liquefied natural gas facilities. The client selected Wonderware’s System Platform 3 as the base foundation for the new SCADA system. The system has been designed to accommodate three InTouch 10.0 workstations and an unlimited number of Internet Explorer-based viewnodes. MAVERICK’s responsibilities included specifying the software and hardware requirements for the SCADA system. The 6D’s of MAVERICK’s proven methodology were used to create the project’s user requirements specification and functional requirements specification. MAVERICK created industrial application system objects based on the various types of PLC-controlled equipment, and best-in-class InTouch graphics were created for the HMI screens. The system has been designed to accommodate a variety of PLCs, including Allen-Bradley ControlLogix and SLC 500 line of controllers, GE Fanuc 9030, Modicon, Siemens, Toshiba and others. MAVERICK has included advanced historical trending, custom report generation, alarm notification via e-mail and cell phone, and remote video monitoring capabilities within this unique SCADA system.
  
  learn more …
• MAVERICK Technologies Wins Automated Flow Valve Control System Project
  Columbia, Ill., Aug. 22, 2008 — MAVERICK Technologies announced today that it recently created an automated flow valve control system for 19 chemical solution tanks at a large film processing company. The Allen-Bradley ControlLogix PLC platform and RSView HMI were selected for this project. MAVERICK developed the initial scope of work, which was then used as the driving project documentation. Working in partnership with the client, MAVERICK specified the field instrumentation for the project and developed the tag list database, including I/O addresses, naming conventions, RSLogix 5000 programming and batch recipe programming. MAVERICK also created RSView HMI screens based on a standard developed with the client. Finally, MAVERICK delivered electrical schematics, system architecture layout drawings and instrument location drawings for the project.
  
  learn more …
• Manufacturer Implements Facility Monitoring and Control System (FMCS) for Its Wafer Fab Facility — Phase 2
  The customer required the design and installation of an FMCS to provide continuous monitoring and control of the cleanroom environment, utilities plant and life safety system for the DMOS5 semiconductor wafer fabrication facility.
  download case study
  
  
  learn more …
• Manufacturer Implements Facility Monitoring and Control System (FMCS) for Its Wafer Fab Facility — R&D1 Phase 2
  The customer required system updates to double the number of tools and gas cabinets.
  download case study
  
  
  learn more …
• Semiconductor Manufacturer Implements Facility Monitoring and Control System (FMCS)
  The customer Semiconductor required the design and installation of an FMCS to provide continuous monitoring and control of the cleanroom environment, utilities plant and support areas for its wafer fabrication facility.
  download case study
  
  
  learn more …
• Semiconductor Manufacturer Implements Life Safety System
  The customer required the design and installation of a life safety system (LSS) to reliably monitor safety conditions in the facility.
  download case study
  
  
  learn more …
• Manufacturer Implements Facility Monitoring and Control System (FMCS) for Its Wafer Fab Facility — R&D1 Phase 1
  A customer required the design and installation of an FMCS to provide continuous monitoring and control for its R&D1 semiconductor wafer fabrication facility.
  download case study
  
  
  learn more …
• Airline Manufacturer Improves Accuracy of Testing with New Touch Probe Certification System
  The project goal was to design and build a three-axis test system for recertifying touch probes used in the production and assembly of airplane parts and assemblies. The touch probes are ultra-accurate, ruby-tipped sensors used to verify machining and assembly tolerances on all aircraft to .0001 inch. The yearly recertification of the probes is required to meet current Federal Aviation Administration (FAA) specifications, and the OEMs do not provide secondary testing or recertification services.
  download case study
  
  
  learn more …
• Wafer Fabricator Achieves Continuous Monitoring and Control of Cleanroom Environment
  The customer wanted a solution to continuously monitor and control the cleanroom environment, utilities plant and support areas.
  download case study
  
  
  learn more …
• Balance of Plant Controls on LM6000 Turbines

  An energy company, acting as the general contractor, awarded a contract to MAVERICK for the balance of plant (BOP) controls on four Frame 7 and six LM6000 turbines. MAVERICK installed one redundant 90-70 for the 7FA turbines and one redundant 90-70 for LM 6000 BOP. The serial interface to the GE Multilin power management system and the replication for GE S&S’s Wonderware HMI, using CIMPLICITY software, integrate to the Mark V HMI controls. There are a total of 1,900 I/Os and an extended 200 days of commissioning support. Both projects included installation of sequence of events recorders (SERs) for critical inputs utilizing Trimation software with fast input modules on the 90-30 for one millisecond event resolution reporting to the CIMPLICITY HMI.

  learn more …
• Ongoing Control Consulting

  MAVERICK provides ongoing control consulting to the power operations group at a large packaging company. MAVERICK has been asked to review and enhance the recovery boiler GE 90-70 PLC BMS, as well as install a new GE 90-70 PLC BMS on the No. 3 power boiler (oil / bark). The project requires the addition of controls for the new pulp mill screens and paper machine cleaners. Controls were provided on a GE 90-70 PLC and Bailey Infi-90 platform with Wonderware HMI. MAVERICK also provided advanced Multi-Fuel Boiler and Plant PRV Optimization Schemes.

  learn more …
• GRI Fermentation Decontamination System at Pharmaceutical Company

  At one major pharmaceutical company, the decontamination system uses software to control the decontamination of the waste produced while growing cells. The waste is cooled and pumped to the sewer, and the tank is then flushed with water. Both decontamination tanks can run at the same time, and the lead tank usage is automatically swapped to share runtime. MAVERICK has written the PLC logic running on the single Allen-Bradley SLC 5/04 processor. Both analog and digital I/Os monitor temperatures, pressures and levels while controlling valves, pumps and agitators. The SCADA system consists of an IBM-compatible computer operating Wonderware version 5 software. MAVERICK configured the LAN connection to the facility's Oracle database for batch information storage and wrote special Visual Basic routines for operator interaction with SQL database

  learn more …
• Reporting System Implemented to Increase Efficiency

  MAVERICK provided a fiberglass manufacturer with a reporting system for its plant. Specifically, MAVERICK used interfaces between two SLC 504s and a Foxboro AW70 through RSLINX. Several operating screens showing the flexible and rod line systems were created. Using data for Windows and Fox history, the Foxboro system was interfaced with Microsoft Visual Basic. Information in Visual Basic was then generated into shift and daily reports. Northern Analytical SPC software was interfaced with Visual Basic and used for generating graphs from the collected data. MAVERICK engineering services delivered a successful reporting system which met the customer's functional requirements. The reporting system provided the manufacturer with the tools to increase efficiency throughout the plant.

  learn more …
• SCADA System for a Glass Rod Manufacturer.
  In implementing this SCADA system for glass rod manufacturing, MAVERICK performed data acquisitions to collect data from the Allen-Bradley SLC 500 PLCs into a Foxboro DCS. Custom VB scripting was utilized to move historical data within the Fosboro SPC module.
  learn more …
• MEK Dewaxing Unit.
  MAVERICK designed and implemented more than 30 individual advanced regulatory and supervisory control applications (Emerson Delta-V).
  learn more …
• Sulfur Content Advanced Supervisory Controls.
  MAVERICK designed and implemented product sulfur content advanced supervisory controls for diesel hydrotreater (Foxboro)
  learn more …
• Advanced Process Control and Advanced Supervisory Controls.
  MAVERICK conducted an advanced process control (APC) definition and justification study for two FCCU gasoline hydrotreaters. The team also designed and implemented a combination of advanced supervisory controls, inferred properties and two model predictive controllers (Honeywell TDC 3000 with RMPCT™ MVC software) for the crude atmospheric and vacuum distillation unit. An APC definition and justification study was also conducted for this portion of the project. MAVERICK also performed control work for the propylene fractionation unit. Finally, MAVERICK designed and configured the TDC 3000 operator consoles and implemented APC for the new TAME unit and associated MTBE and alky.
  learn more …
• Advanced Process Control for Major Process Units at Refinery in Chile.
  MAVERICK implemented two major refinery-wide advanced process control (APC) projects across all major process units, including crude distillation, FCCU, reformer, delayed coker and hydrocracker, including an extensive list of inferred properties and RMPCT controllers on selected units (Honeywell TDC 3000).
  learn more …
• Advanced Process Control and Inferred Properties at Refinery in Germany.
  MAVERICK implemented advanced process control (APC) and inferred properties on crude and vacuum distillation units (TDC 3000).
  learn more …
• Model Predictive Control at Refinery in Chile.
  MAVERICK implemented model predictive control on two process units (crude distillation and NGL fractionation), including extensive list of inferred properties and Connoisseur controllers (Foxboro I/A).
  learn more …
• Advanced Process Control on Crude Distillation Unit at Refinery in Germany.
  MAVERICK executed an advanced process control (APC) project on a crude distillation unit (with Naphtha Splitter). MAVERICK also implemented RMPCT controllers and inferred properties (TDC 3000). MAVERICK also implemented advanced process controls (TDC 3000 AM) for a second APC project involving resid gasification, MeOH synthesis, H3 production and purification.
  learn more …
• Crude Distillation Unit Inferred Properties and APC Conversion.
  MAVERICK converted inferred properties and advanced controls from Honeywell TDC 2000/PMX to TDC 3000/AM.
  learn more …
• MTBE Unit Control Project at Refinery in Austria.
  MAVERICK conducted a basic design study for this MVC control project and implemented the MVC controller (DMCPlus™, Hartmann & Braun DCS).
  learn more …
• Refinery Modernization and Advanced Process Control at Refinery in Germany.
  MAVERICK conducted advanced control (APC) studies for all units in the refinery, including the naphtha pretreater and reformer, crude distillation, gas plant, diesel dearomatization, middle distillate hydrodesulfurization, gas oil dewaxer. MAVERICK then implemented advanced controls (TDC 3000 AM), including inferred property software — including reformate octane on the reformer — constraint-pushing on the crude distillation unit and controls for handling crude switches.
  learn more …
• Cokers Revamp Advanced Control Projects (TDC 3000) at Refinery in Germany.
  For a cokers revamp, MAVERICK implemented advanced process controls (APC) on a new Coker C, including a new set of inferred property controls. For the naphtha reformer (CCR), MAVERICK conducted an advanced control project definition and justification study. MAVERICK also conducted an advanced control project definition and justification study of two crude / vacuum and coker units and then implemented advanced controls, including cut point controls on four fractionators and model-based coke drum outage minimizers. MAVERICK also conducted project definition and justification studies and implemented advanced controls (TDC 2000 AM) for the solvent dewaxing and extraction units.
  learn more …
• Refinery Modernization and Advanced Controls at Refinery in Saudi Arabia.
  This project involved crude / vacuum units, two fixed-bed reformers, NHT / CCR, visbreaker, hydrocracker, DGA / SWS and a hydrogen plant. MAVERICK implemented advanced controls (TDC 3000 AM) on all major units in the refinery, including inferred property software and special hydrocracker reactor APC. MAVERICK migrated the crude unit DMC controller from version 5 to DMCPlus and recommissioned the DMCplus controller (new model and controller configuration file).
  learn more …
• Advanced Process Control at Refinery in Chile.
  This project involved two crude units, vacuum units, FCC, VRUs, alkylation, reformer, visbreaker, hydrocracker and NHT / CCR. MAVERICK provided topping unit advanced process control (APC) enhancements, including inferred properties and heat removal controls. A separate NHT / CCR APC project included inferred octane / WAIT controls. A third original refiner-wide APC project involved conducting a detailed control system study for the entire refinery and for the new VGO hydrocracker and the new NHT / CCR reformer. MAVERICK developed and implemented advanced controls for the entire refinery (TDC 3000 application module).
  learn more …
• Advanced Control Projects at Refinery in Chile.
  MAVERICK executed a series of advanced control projects for this Chile refinery. One project entailed a refinery-wide APC master plan study. For the ethylene plant (hot and cold sections), MAVERICK conducted detailed process analysis for advanced control definition, assisted in DCS specification and configuration and then designed and implemented advanced controls (TDC 3000 AM). Likewise, for the hydrocracker, MAVERICK conducted detailed process analysis for advanced controls and then developed and implemented advanced controls (TDC 3000 Application Module). For two crude units, MAVERICK implemented cut point controls with lab feedback using LABSYS and extended the technology to include AGO / VGO / FCC feed / H-Cracker feed. In an earlier project, MAVERICK designed and implemented advanced controls (TDC 3000 AM) for the semi-regen reformer. MAVERICK also configured the DCS and implemented advanced controls (TDC 3000 AM) and process information data link (OPSIS) for two crude units, two vacuum units, a visbreaker and FCCU / gas con.
  learn more …
• Lube Plant Advanced Control Projects.
  At the customer’s lube plant, MAVERICK conducted a detailed control system study on the MEK dewaxing unit and implemented a new set of advanced controls (TDC 3000 AM). In a separate project, MAVERICK conducted advanced control project definition and justification study and implemented advanced controls (TDC 3000 AM) for the propane deasphalting unit modernization. Finally, at the plant’s Puerto Rico location, MAVERICK modernized the refinery by conducting a project definition and justification study (incl. Lubes Hydrocracker) and implementing advanced controls (TDC 3000 AM) on the semi-regen reformer.
  learn more …
• LNG Liquids Recovery / Fractionation Unit in Venezuela.
  MAVERICK implemented advanced controls (Honeywell PMX), including model-based product quality controls, and then later upgraded and enhanced the controls (TDC 3000 AM). In an earlier project, MAVERICK implemented a similar set of controls on a third distillation train (TDC 3000 AM).
  learn more …
• Advanced Control / Optimization Projects.
  MAVERICK designed and implemented model-driven advanced controls and optimizers (Foxboro FOX 1/A).
  learn more …
• Lube Complex Modernization Project – Vacuum, Furfural, Duo-Sol, MEK Dewaxing, Steam Plant.
  MAVERICK implemented a PC network-based SQC information system (OPSQC), assisted as software maintenance engineers and process consultants and provided ongoing control and information systems maintenance support. The team conducted a control system modernization study, including development of specific advanced controls, estimate of project incentives, detailed cost estimates and evaluation of project economics. MAVERICK configured the digital control system (TDC 3000) and developed and built all touch-screen graphics, an historical database and information system (OPSIS & LABSYS) and MEK filter wash automation software. Finally, MAVERICK implemented advanced controls (TDC 3000 application module) and vacuum unit inferred properties controls (VAX and AM).
  learn more …
• Textile Finishing Plant.
  MAVERICK Technologies provided DeltaV programming and application development for the tentor frame and prep range areas of this textiles facility. Project specifics included fieldbus technology, ASi Bus, bi-directional serial interface (Modbus) to Allen-Bradley PLC, hardwired I/O, I-Fix graphics, advanced temperature control algorithms, MS Access database VB programming with OPC, commissioning, and startup.
  learn more …
• Sulfuric Acid Plant.
  MAVERICK Technologies provided complete scope development, equipment specification, configuration services, installation engineering, construction services, and startup support for a control system replacement in a world class Sulfuric Acid and SO2 Generation facility in Houston, Texas. The project required the complete replacement of an existing control system utilizing a Toshiba DCS and a Gould Modicon 584 Burner Management System on the sulfur decomposition furnace. The new control system consisted of an Emerson DeltaV Process Control System utilizing five M5 processors and a Siemens/Moore QUADLOG Burner Management System. Total I/O count consisted of approximately 400 analog inputs, 50 analog outputs, 200 digital inputs, 100 digital outputs, and two serial links with the Siemens/Moore QUADLOG and a Continuous Emissions Monitoring System (CEMS). MAVERICK Technologies provided the expertise and experience to integrate the Process Control System with the Burner Management System using the single operator interface of the DeltaV system.
  learn more …
• Aluminum Heat Treating Furnaces.
  MAVERICK Technologies provided engineering, configuration and control system cabinet integration services for a DeltaV control system on four electrically heated vertical heat treat furnaces in Spokane, Washington. The control system includes four M2 processors, a ProPlus Station, three operator stations, and an application station. MAVERICK configured the batch control sequence for automated metal tracking, sequence timing and heat soaking parameters, and generation of load reports at the conclusion of a heat treat/quench sequence. MAVERICK Technologies programmed an interface in the DeltaV Application Station using OPC software to communicate with the client’s data tracking system for automatic batch sequence downloading and batch performance tracking. Total system I/O included 160 thermocouple inputs, 136 analog inputs, 40 analog outputs, 192 digital inputs, and 128 digital outputs.
  learn more …
• Sulfuric Acid Plant.
  MAVERICK Technologies provided complete scope development, equipment specification, configuration services, installation engineering, construction services, and startup support for a control system replacement in a world class Sulfuric Acid and Spent Acid Recovery Plant in Baytown, Texas. Project involved documenting the existing ABB Bailey INFI 90 Process Control System (PCS) and Burner Management Control System (BMS), including both field hardware and application software, and dividing the plant controls by function for implementation in a DeltaV Process Control System and a Siemens/Moore QUADLOG Burner Management System. The NFPA 8501 standard was followed closely to define the control system split between the PCS and the BMS. MAVERICK Technologies has provided complete control system configuration services for the DeltaV, the QUADLOG, and the interface of the two control systems. The operator interface for both control systems was implemented on the Emerson DeltaV HMI.
  learn more …
• Pharmaceutical Production Building Retrofit.
  MAVERICK Technologies provided instrument, electrical and mechanical engineering and design services. Initially, MAVERICK was responsible for working with Corporate Engineering in developing the preliminary design for the project that is an automatic nitrogen blanketing and purge system for the process equipment in the pharmaceutical chemical plant. Subsequently, MAVERICK was awarded the final design contract and worked closely with the client to develop instrument, electrical, and mechanical purchasing and installation packages for the new process equipment and their associated controls. All new instrumentation and mechanical piping/valving was specified and designed in detail using the latest available database and CAD technologies. The interfaced controls include both DCS and PLC hardware. MAVERICK is also providing engineering design for the additional upgrade of all process controls in the building. This was a controls retrofit to a 25-year-old process facility using the newest state-of-the-art controls offered by Emerson.
  learn more …
• Polyols Batch Reactor.
  MAVERICK Technologies provided complete scope development, equipment specification, cabinet integration, configuration services, installation engineering, construction services, and startup support for a control system replacement in a Polyols batch facility in Houston, Texas. MAVERICK had total system responsibility including development of a set of project P&IDs to define the project scope boundaries prior to project award. The existing control system was a conglomeration of pneumatics and analog electronics, and the project included specification of new field instrumentation to replace the existing pneumatic devices. The new control system included a DeltaV control system that utilized ten pairs of redundant MD controllers and over 1400 I/O points, and a Siemens/Moore QUADLOG safety shutdown system was provided to detect and prevent runaway exothermic reactions. The majority of the conversion from the old control system to the new control system was handled with the plant in full operation. MAVERICK employees assisted the owner in analyzing which systems could be implemented without impacting plant operations, and managed the effort to minimize the systems to be converted during a plant shutdown. In addition to the process control configuration of the DCS, MAVERICK engineers were also responsible for implementing the Batch Executive, Batch Historian and recipe management systems for the various Polyols products produced at this particular chemical plant facility.
  learn more …
• Major University Cogeneration Physical Plant.
  MAVERICK Technologies provided engineering, configuration, control system cabinet integration services, and startup services for a DeltaV control system for the expansion of a major university physical plant. The existing physical plant power generation facility included six coal-fired steam boiler/generator sets, and the plant was expanded with a pair of 13.2 MW Solar Titan combustion turbine generators (CTGs) with Heat Recovery Steam Generators (HRSGs) providing steam for an additional two Steam Turbine Generators and four new chilled water systems. The system included five pairs of MD controllers and over 800 analog and discrete input and output points. In addition to the process control of the DeltaV control system, MAVERICK provided a high-speed power management and load shedding system for the university. This system is capable of continuously calculating which loads are to be shed as a function of a variety of scenarios of generation capacity losses or losses of tie-lines to utility transmission lines, and shedding the required load within 200 milliseconds. This system was implemented in an Allen-Bradley ControlLogix redundant processor PLC, and interfaces with over 200 GE Multilin Universal Relay devices and over 200 breakers for data acquisition and load control. All of the power management and load shedding system is integrated into the DeltaV operator stations and application stations to provide the plant operators with one seamless window to the physical plant operations.
  learn more …
• Bio-Gen Panel Manufacturing.
  MAVERICK Technologies completed panel design and layout of DeltaV components in addition to power and control wiring diagrams for Fluor/Bio-Gen. These panels also included the required HMI Panels and Drive Panels to support this system. The DeltaV equipment was supplied by Bio-Gen, and MAVERICK supplied the remaining equipment, including the Allen-Bradley Drives. All panels were continuity tested followed by a complete power-up test by the customer with manufacturing assistance. All of this equipment was for a new process facility in Research Triangle, NC.
  learn more …
• Duke-Fluor Daniel Engineering.
  Duke-Fluor Daniel Engineering designed, constructed and commissioned three Co-Gen plants over a period of four years in which MAVERICK participated in the panel design of DeltaV components in addition to control wiring diagrams. These cabinets were NEMA12 design in a continuous line-up containing all the required DeltaV. All Panels were continuity tested followed by a complete power-up test by the customer with MAVERICK’s assistance.
  learn more …
• Controller for an Aluminum Dross Press.
  Project consisted of programming and debugging for a Siemens S5 control system on an Aluminum Dross Press. Control flow charts and ladder logic were used for the code development. Approximate I/O count was 32.
  
  Dorlastan (Spandex) for Textile Industry: Project (two year) consisted of Start-up, commissioning, programming, and maintenance support for a Siemens PLC and Fisher Provox Control System for the Dorlastan process. Applications included polymerization, extrusion, and winding of the fiber. Three (3) 155U, Six (6) 135U, and forty (40) 90 processors were used on the project. Project responsibilities included finalizing, modifying, troubleshooting the PLC logic, start-up and commissioning. statement lists and ladder logic were used in the code.
  learn more …
• 3B3BX Project - X-Ray Film Coater.
  Project consisted of integrating two Coater Drives together with Siemens S5 PLC. Project included over 1000 I/O. Statement list and ladder logic were used to develop the code. The Siemens PLC interfaced with Dupont’s Bailey DCS.
  learn more …
• Dupont Technologies Transfer (Multiple Applications).
  Project consisted of developing code and applications to test various Fiber Machines. Application was initially developed and tested in an Allen-Bradley PLC-5. Upon completion of the testing, the logic was converted to a Siemens S5 (135U) PLC. Statement lists were exclusively used in the development.
  learn more …
• Process and Building Safety Systems Upgrade.
  Project consisted of developing Siemens S7, Siemens 505, and Triconex control code for the Process and Building Safety Systems. Developed re-usable code libraries for Siemens S7 (ES-Tools), Siemens 505 (APT), and Triconex (Tristation 1131). MAVERICK continues to provide on-going work for this facility.
  learn more …
• Sand Core for Casting Pipe.
  Project consisted of Siemens S5 programming for the process equipment. Project included over 10 remote racks and 700 I/O. Statement lists and ladder logic were used to develop the code
  learn more …
• Control System Upgrade.
  MAVERICK replaced a customer’s existing control system with a Siemens Moore APACS DCS following a quality assurance program to satisfy FDA guidelines, utilizing 4Mation and the ProcessSuite HMI system. The scope of work included the creation and / or modification of detailed design drawings, configuration of approximately 125 I/O data points, system control, process alarms and interlocks, and the development of graphic displays to provide operators with an interface to the system, internal staging, customer acceptance testing, checkout / startup and installation of the APACS system.
  learn more …
• New Compressor and Control Upgrades .
  MAVERICK connected new and existing compressors to a facility’s Siemens Moore APACS control system. The project scope included DCS equipment specification; electrical, instrument and control system design; and installation and configuration of the new compressor. MAVERICK upgraded the controls of the existing compressors, replaced the instrumentation and connected it to a new APACS I/O panel. Engineering deliverables included detailed design drawings, specifications and schedules, the I/O list and DCS configuration (170 I/Os), HMI graphics utilizing Wonderware, customer acceptance testing, installation and documentation.
  learn more …
• Documentation and Control System Configuration
  One recent MAVERICK project required comprehensive engineering design services to “reverse engineer” the complete electrical, instrumentation and control system documentation for the customer’s facility, including a Siemens Moore APACS DCS, Allen-Bradley and Siemens PLCs and Wonderware HMI terminals. MAVERICK reviewed the existing documentation for accuracy and then modified and created additional drawings and / or design documentation to improve and support the reliability, operation and maintenance of the system. The entire control system configuration, containing approximately 2,000 I/O points, was defined by logic diagrams, cause-and-effect matrices and narrative description. The existing APACS and HMI configuration was reviewed for conformance to logic diagrams and complex loop definitions.
  learn more …
• Design and Documentation for New DCS
  MAVERICK was recently involved in the design phase of a plant automation project in which a Siemens Moore APACS DCS was installed. The project scope included updating the P&IDs with CAD-generated drawings through field verification, including all DCS symbology. A complete instrument index with I/O listing was generated.
  learn more …
• Design Engineering for Plant Automation Project
  This project required design engineering, including modifications to the P&IDs, a preliminary I/O list and a complete detailed design and construction package for a plant automation project. The electrical design package included I/O drawings showing the complete routing between the APACS DCS I/O modules and the field devices for approximately 600 I/O points, approximately 400 loop drawings, junction box and panel wiring diagrams, instrument location drawings, conduit and cable routing plans, and conduit and cable schedules.
  learn more …
• Complete Control System Recode.
  MAVERICK recently performed a complete control system recode, utilizing an existing Siemens Moore APACS DCS combined with modifications to the systems architecture. MAVERICK also verified and corrected the supporting design documentation, including P&IDs, I/O listing and termination drawings. The project required a fully documented configuration, per current good manufacturing practices (cGMP), that could then be validated for FDA compliance. The new configuration was performed using a detailed control system specification and current APACS system design standards. The project included 1,200 I/Os and the development of 45 detailed process graphics, dozens of supporting graphics and approximately 2,500 tags using Wonderware FactorySuite 7.1. The configuration was subjected to documented testing, as the system was internally staged, was customer-witnessed factory acceptance tested (FAT) and was site acceptance tested (SAT), to assure compliance to specification.
  learn more …
• Complete Control System Recode.
  The project included a complete control system recode, utilizing an existing Siemens Moore APACS DCS. The project required a fully documented configuration per current good manufacturing practices (cGMP) that can then be validated for FDA compliance. This recode was for one of three existing plants in the facility consisting of 750 I/Os. The new configuration was performed using a detailed control system specification and current system design standards on an extremely aggressive schedule. The project also included reconstructing 40 detailed process graphics, dozens of supporting graphics and approximately 2,000 I/O tags using Wonderware FactorySuite 7.1. In accordance with MAVERICK’s quality standards, the configuration was subjected to significant documented testing, as the system was internally staged, was customer-witness factory acceptance tested (FAT) and was site acceptance tested (SAT), to assure compliance to specification.
  learn more …
• Control System Enhancements for Improved Reliability.
  MAVERICK has participated in several projects and numerous site support trips to assist a customer’s facility with its control systems, which include a Siemens Moore APACS DCS, Allen-Bradley PLCs and a Wonderware HMI. This facility has been undergoing process enhancements for two years in order to achieve a higher reliability factor. These enhancements have been performed both offline during plant shutdowns and during full operation. The systems have approximately 2,000 I/Os with about 7,000 WW database tags.
  learn more …
• Control System Retrofit for Air Separation Unit.
  One recent MAVERICK project included a control system retrofit to upgrade an air separation unit from an aging Bailey system to a Siemens Moore APACS platform, with design documentation to support FDA validation. Control system design and configuration consisted of approximately 650 field I/Os to be connected to the new DCS. The initial scope included the verification and correction of existing P&IDs and the development of a complete construction design package, including an I/O list, location plans, instrument specifications, wiring and connection diagrams, loop sheets and a construction specification.
  learn more …
• Control System Retrofit for Air Separation Unit .
  MAVERICK performed a control system retrofit to upgrade an air separation unit from pneumatic and relay-based controls to a Siemens Moore APACS platform with design documentation to support FDA validation. Control system design and configuration consisted of approximately 565 field I/Os to be connected to the new DCS. The initial scope included the verification and correction of existing P&IDs and the development of a complete construction design package, including an I/O list, location plans, instrument specifications, wiring and connection diagrams, loop sheets and a construction specification.
  learn more …
• Control System Design and Configuration.
  For one customer with three sites, MAVERICK utilized several control systems: Siemens Moore Quadlog Safety PLCs for emergency shutdown applications, Modicon Quantum PLCs for the basic process control system as well as substation automation applications, and a single Allen-Bradley PLC for substation automation. The new systems were interfaced to various existing equipment, including Omni flow computers with control and energy management systems (Honeywell TDC3000 and Bailey Infi90) at each of the three customer sites. The control system design and configuration consisted of approximately 540 field I/Os across the three sites. The initial scope included the verification and correction of existing P&IDs and the completion of a construction design package, including an I/O list, location plans, instrument specifications, wiring and connection diagrams, loop sheets and a construction specification.
  learn more …