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.

Pulp and Paper

• MAVERICK Technologies Provides Ongoing Alpha System and Programming Tech Support

  Columbia, Ill., Aug. 22, 2008 — MAVERICK Technologies announced today that it has won a continuation of its staffing service contract to support various ongoing engineering needs at a paper mill.

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• Demineralizer Controls Upgrade Project

  MAVERICK recently provided a paper mill with the Foxboro I / A systems configuration for a boiler feedwater demineralizer controls upgrade project.

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• Installation and Configuration of Foxboro I / A System

  In a recent project at a large paper mill, MAVERICK was responsible for the installation and configuration of the Foxboro I / A system interfaced with a GE Mark V turbine control system. During initial stages of the project, MAVERICK laid out the Foxboro I / A cards and supervised the building of the control cabinet. The cabinet and operating system were shipped to MAVERICK for configuration, and a Mark V simulator was used for configuration purposes. A communication system between the two systems was set up to allow an easier checkout. MAVERICK was also responsible for a cooling water control system, which was configured to utilize the Foxboro I / A, as well. This allowed the Foxboro to not only be a monitor and control for the new turbine, but also for the two cooling towers. Mill representatives visited MAVERICK facilities and performed a thorough checkout, ensuring a smooth startup. After completion of startup, MAVERICK created a performance test data collector by interfacing Microsoft Excel with Foxboro I / A using data for Windows. This provided initial performance data for the new turbine generator system.

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• Major Controls Retrofit

  MAVERICK has completed a major controls retrofit for a large paper mill. In a series of consecutive projects, MAVERICK completed conversion to Foxboro I / A / A-B PLC, the Nos. 21, 22, 23 and 24 coated paper machines. The project included ABB paper machine controls through the Foxboro I / A Series 50 DCS with redundant control processors. The new distributed control system interfaced to existing Allen-Bradley Series 5 and GE Series 70 PLCs, with an approximate point count of 600 analog and 550 discrete. The new control system included the size presses, coating kitchen and stock and broke systems.

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• Controls for Pulp Mill Screens and Paper Machine Cleaners

  MAVERICK completed a controls project for the pulp mill screens and paper machine cleaners for a large pulp and paper manufacturer. The project utilized a Bailey Infi-90 DCS and a Wonderware HMI.

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• Upgrades to Rapid Drain and Black Liquor Diversion Control Systems

  MAVERICK completed an engineering project to upgrade the rapid drain and black liquor diversion control systems on three recovery boilers. A two-step ESP system was implemented as part of the design. The new control system employed Allen-Bradley PLC-5/25, Wonderware MMI, 8 graphics and 130 I/O points, and monitored operation of the recovery boilers during emergency shutdown procedure and rapid drain.

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• Demineralizer System Retrofit for a Paper Company.
  MAVERICK helped this company convert from its GE 90/70 PLC and Microtie HMI to RSView and a ControlLogix PLC using Ethernet and ControlNet.
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• Coated Board Machine Retrofit for a Paper Company.
  This company wanted to convert from its old bench board, relay controls and older vintage Allen-Bradley PLCs. MAVERICK assisted by implementing a Bailey Net90 DCS (analog), Allen-Bradley PLC-5 (discrete) and DCS to PLC interfaces. MAVERICK provided complete design engineering, installation and startup services.
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• 400 / 620 TPD OCC for a Paper Company.
  In this greenfield facility, MAVEIRCK implemented a Bailey Infi-90 DCS (analog), an Allen-Bradley PLC-5 (discrete), DCS to PLC interfaces and advanced control strategies.
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• NC4 and NC5 Fine Paper Machines Retrofit for a Paper Company.
  This company wanted to convert from its bench board, relay logic and various older PLCs. MAVERICK implemented a Bailey Infi-90 DCS (analog), Allen-Bradley PLC 5/60 (discrete), DCS to PLC interfaces, Measurex MX open interface and Allen-Bradley drives interface. MAVERICK was responsible for all control logic, SAMA diagrams, programming, HMI development and startup services.
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• Coated Machines (21, 22, 23, & 24) Retrofit for a Paper Company.
  MAVERICK implemented a Foxboro I/A system, Allen-Bradley PLC and DCS to PLC interface. MAVERICK technicians provided complete startup services.
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• Groundwood Mill Retrofit for a Paper Company.
  This project involved an Allen-Bradley PLC 5/80 connected to 900 field I/Os, an Allen-Bradley coprocessor running a custom C program and seven networked Wonderware nodes on Ethernet. The controls consisted of 70 PID loops using PLC functions (many cascaded) and 120 Wonderware graphics. The script was embedded within graphics to allow modification of the rate and load grinding algorithms. A custom Modbus interface was also created to the Westinghouse WDPF highway via a PC for operation and performance monitoring of the groundwood mill and power generators. Finally, the control system for the mill wastewater treatment plant incorporated an Allen-Bradley PLC 5/40 with 350 field I/Os and five networked Wonderware nodes with 30 graphics.
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• BMS Retrofits for Multiple Customers.
  Allen-Bradley PLCs (PLC 5) have been utilized for burner management system controls and DCS interface for the combustion controls of more than 25 boilers within the pulp and paper industry. MAVERICK has been responsible for working with insurance carriers to ensure that the proper recommended requirements are followed (NFPA, BLRBAC, NEC, etc.). Several conversions from various PLC systems, bench boards and relay systems have been performed.
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• Off-Machine Coater.
  MAVERICK Technologies provided DeltaV programming, screen development, commissioning, and startup for an off-machine specialty paper coater application.
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• Paper Sizing Application.
  Project consisted of developing Siemens S5 (115U) batch code for a Homogenization and Emulsification paper sizing application. Statement lists, Control Systems Flow Charts, and ladder logic were all used to develop the code. Project included over 1000 I/O for three (3) PLCs.
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