Controlmax Limited

Client: AMEC M&E

Role: Design & drawing production, Manufacture Management, PLC programming, FAT Documentation and Factory Testing, SAT documentation, as installed Drawings and Operation & Maintenance manuals

Brief: Controlmax developed the design for the electrical control scheme, produced the detailed drawing package, managed the manufacture of the control panels and MCC, provision of technical backup to the panel builder as required. Controlmax also wrote Factory Acceptance Test and the Site Acceptance Test and performed the FAT. Controlmax updated design drawings to as-installed status and produced operation and maintenance manuals.

Description:

Controlmax carried out the design of the ventilation upgrade control system to the specification, providing detailed design drawings, cable schedules and instrument set up briefs.

Controlmax managed the manufacture of the control system by a third party panel builder and develop and preliminary tested the PLC program.

Controlmax wrote Factory Acceptance Test document and carried out the end client witnessed FAT at panel builder’s works.

Controlmax wrote Site Acceptance Test document.

Controlmax updated the drawing package from approved for manufacture, through as built to as installed status, for some 400 drawings and wrote the Operation & Maintenance manual, provided in paper and searchable electronic formats including all manufacturers’ literature.

The upgraded ventilation system consisted of:

MCC (Cutler-Hammer F660 withdrawable MCC, dual incomers, bus couplers, fan starters, sub feeders, and instrumentation).

Control Room Control Panel (bespoke console, mimic, annunciators, analogue process indicators, manual controls, and separate UPS cubicle).

Fire Vent Control Panel (bespoke dual sided through wall control panel, fire damper controls, PLC failover system, PLC override system, system status indication, manual controls and integrated steelwork UPS cubicle).

Main Vent Control Panel (bespoke control panel, annunciator, analogue instruments, Eurotherm 2604 PID controllers, Sarco SX75+ PID controllers, system status indication, manual controls, hard wire safety circuit, Allen-Bradley FlexLogic PLC duty controls, motorised damper controls, modulating damper controls, steam valve controls and integrated steelwork UPS cubicle).

Waste Processing Glove Box Control Panel (alarm detection, indication and isolation controls)

Field mounted modulating damper for air flow and depression control.

Field mounted modulating steam valves for process heating.

Field mounted differential pressure and flow instrumentation.