MCC Upgrades

Project Details

  • Coalinga, CA
  • Almond Hulling
  • Harris Woolf Almonds

"Intelligent" retrofit saves 50% cost of new replacement while providing a reliable modern state-of-the-art system encompassing 200 motors.

Project Overview

An out-of-date and unreliable control system plagued Harris Woolf Almond company with excessive and costly downtime. Salvaging the existing MCC, iCAD re-engineered and retrofitted the system at a substantial cost savings -- both upfront and over time.
First, the old electrical system was removed, and all motor leads and conduits were resized according to NEC code.

The existing MCC was retrofitted to use DeviceNet, replacing hardwiring, to control the motor starters. The results: Much wire saved and more data presented to the PLC. Whereas before, the PLC could only tell if the motor starter had actuated, now the PLC also sees the amps and OL settings of the starter.

To accomodate the enormous MCC, 6 DeviceNet networks were made accessible to the PLC by using ControlNet to DeviceNet gateways. The result: Just one cable runs between the PLC and MCC to control the entire MCC.

Additionally, a new Allen Bradley ControlLogix unit, replacing a GE 90-30 PLC, communicates with the MCC starters using a single ControlNet scanner. Changing out the existing GE Quickpanel HMIs with industrial touchscreen PCs running Wonderware allows all screens to be managed at once from a remote location. Changes made to the program one screen can be propogated automatically to the other screens located throughout the factory. This setup also allows for historizing and future reporting of the data to management.

All engineering and panel building performed by iCAD. All installation performed by Lighthouse Electric. After installation, both Lighthouse and iCAD jointly started the system up.

Benefits

Retrofit saved money. 50% in fact!
Productivity increased as downtime decreased.
More specific alarms pinpoint malfunctions and allow for quick responses.
Visability of the electrical system's operating parameters of a "smart MCC" gives operators view to more diagnostic imformation pertaining the the health of the system.
Reliability, documentation, historization, and data reports please management.
Sister companies, iCAD and LIghthouse Electric, can complete the whole job!

Technologies Used