AE Solutions was responsible for the complete replacement of a proprietary and antiquated control system with a Moore APACS DCS using Process Suite R4 as the HMI. System replacement included the complete paper machine Dry End, Beater Room and Wet End controls. Responsibilities include the development of the control system architectural specification for the HMI, complete HMI configuration and commissioning for approximately 1700 I/O. Project architecture included a dedicated InSQL Historian trend server, dual process servers, and 13 client stations (both standalone and dual monitors) utilizing touchscreen technology. Project scope also included commissioning and startup support.

AE Solutions executed an automation expansion and HMI upgrade for a semi-batch specialty chemical facility. Project consisted of Moore APACS configuration for an additional process reactor train and complete system HMI upgrade from Moore MYCROADVANTAGE to Process Suite Vision. Project scope also included commissioning and startup support.In-Line Blending Control System Automation Upgrade

AE Solutions was responsible for the replacement of an existing antiquated PLC and proprietary blending control system. Automation upgrade for the existing batch in-line blending process utilized ISA/ANSI S88 compliant software design. Project included complete system upgrade of control and HMI applications using Moore Process Automation Solution's Process Suite DCS (APACS + Vision). Application utilized batch, sequential and continuous control functions based on a rate pacing/optimization control scheme using totalized flow controllers. Batch recipe management and reporting were configured using custom developed Microsoft Access and Excel applications integrated to the Vision HMI application. Responsibilities include complete software design, system configuration, testing and assist client commissioning and startup.

AE Solutions replaced an existing antiquated PLC for a Liquefied Natural Gas (LNG) facility. Plant included gas purification, liquefaction, storage and vaporization processes. Project included the application of a Moore APACS DCS with approximately 405 I/O for all continuous and sequential controls. Responsibilities included software configuration, simulation and testing of the DCS.

AE Solutions performed a pharmaceutical validation impact study for a pharmaceutical facility to evaluate the impact of automation upgrades associated with a Moore Process Suite DCS (APACS +Vision). Project consisted of evaluation of existing configuration and system functions versus Moore application libraries to define specific areas requiring re-validation based on Moore algorithm modifications to the 4-mation application and other operating system coding and scripting required due to software application revisions.

AE Solutions executed a study to evaluate automation upgrade and expansions options for an existing paper machine control system. The new project control system was designated to be Moore Process Suite DCS (APACS + Vision). Responsibilities include development of the control system scope of work, system architecture, estimate and proposal.

AE Solutions upgraded two independent control systems' operator interfaces from Intellution Fix DMACS version 5.5 to Intellution Fix32 version 7.0. Also upgraded the HMI communication with the two independent Siemens/Texas Instruments 565 PLCs from serial 19.2Kbaud to 10Mbit ethernet. One system controlled a continuous specialty chemical reactor line. The second system controlled a batch specialty chemical reactor line.

AE Solutions upgraded the control system on a five (5) train batch ethyloxylator research and development facility from a limited SCADA system to a Fisher Delta V system. Configured complete control logic including batch sequences in S88 aware sequential function chart language. Interfaced remotely located Application Station running Excel with DDE link for both real time and historical reporting via ethernet. Interfaced DeltaV controller via a bi-directional Modbus serial interface to a GSE scale system.

AE Solutions performed an impact study for the demolition of a Fischer & Porter uDCI Chameleon controller serial link with an Allen Bradley PLC 2. Client desired to remove the serial link as part of the first phase of an upgrade and contracted AE Solutions to determine the impact of its removal and devise any necessary work-arounds. The Chameleon was controlling a batch ethyloxylator reactor and the Allen Bradley PLC was controlling the associated oxide storage tanks.

AE Solutions was responsible for defining, specifying and designing a new installation of a Bailey Controls Symphony DCS with Conductor NT consoles controlling a continuous process super-absorbent polymer line and its associated dry end. Responsibilities included process interlock and sequence definition and specification, control system hardware and performance specification and system architecture design.

AE Solutions was responsible for design of the field instrumentation specification, wiring design, support of the bid package development, and programming of a Honeywell TDC3000 DCS and a GE Series 6 PLC for two (2) new CLO2 Plant mechanical chillers supporting a paper mill bleach plant.

AE Solutions was responsible for specification, design and installation of bulk storage tank farm inventory monitoring system. The system included SLC 500 PLC, RS View, Webserver, PROFIBUS devices. Responsibilities included specification and design of level transmitter instrument installation, specification and design of PROFIBUS and A-B communication wiring, process interlock wiring design, control system hardware and software specification, system architecture design, configuration, testing and commissioning.

AE Solutions was responsible for automation of the Liquefied Natural Gas (LNG) facility. Plant includes gas purification, liquefaction, storage and vaporization processes. Project included the application of a Moore APACS for the Basic Process Control System (BPCS) with approximately 405 I/O and utilization of Moore's QUADLOG Safety PLC for the plant Fire & Gas detection system. Responsibilities include software configuration, simulation and testing for the BPCS and Fire & Gas detection systems. The Fire & Gas system design included the complete replacement of the existing proprietary system with a modern safety PLC based system. Design includes complete system instrumentation and electrical design was in accordance with NFPA 72 requirements.

AE Solutions was involved in the I&C design portion of a new 300 mm (12 in) semiconductor wafer fab facility. AE Solutions' Lead engineer was responsible for coordination of I&C design team of eight (8) engineers and designers. Facility included 16 50,000 cfm makeup air handlers each having preheat, primary cooling, secondary cooling (dehumidification) and reheat coils and a fog type humidifier section, 78 recirculation air handlers each controlled by its own local Allen Bradley MicroLogix 1200 PLC, 38 general air handlers with heating and cooling coils each controlled by its own local Allen Bradley MicroLogix 1200 PLC, two (2) volatile organic compound (VOC) abatement systems with concentrator disk and integral thermal oxidizer, general exhaust fans for cleanroom, support areas and interstitial space pressure control and nine (9) process exhaust scrubbing systems. Facilities Management System (FMS) included 20 Allen Bradley PLC 5/40Es with 36 GE Cimplicity HMIs. PLC peer to peer communication was via DH+. Communication with HMIs was via ethernet. Processors communicated with remote I/O racks, 110+ MicroLogix PLC's and 80 variable frequency drives via 36 Devicenet highways. Team was responsible for P&ID development, sequence of operations development, network and devicenet architecture design, control panel design, instrument specifications, instrument installation details, mechanical package coordination, and instrument location plans.

AE Solutions was responsible for a new Batch System at a battery production facility. Project included the application of a GE Series 90/30 PLC with approximately 100 I/O and a Wonderware HMI interface. Project involved communicating with a Hot Oil System, Gravimetric Feeder, 7.5 Hp VFD, Process Transmitters and Digital devices over a PROFIBUS platform. Responsibilities included specification of instrumentation, creating, organizing and developing all the support documentation for the controls equipment for CE Compliance, communication architecture, panel/wiring design, software configuration, simulation/testing for the system and startup/commissioning support.

AE Solutions was responsible for the design and installation of an automated groundwater remediation and monitoring system and existing waste water pretreatment system upgrade. The system includes monitoring and reclaim from numerous wells, a collection/transfer station, and the final stripping system to purify water for reintroduction into the facility effluent stream. The existing pretreatment automation system will also be upgraded consistent with the new control system architecture. The automation system includes multiple A-B SLC controllers communicating via a redundant fiber optic network with redundant (hot backup) RS View 32 SCADA HMI stations. PLCs communicate with multiple remote well head control panels via a radio modem network for wireless data acquisition and pump control. The SCADA system includes autodialer functionality to automatically notify and receive instructions from operations personnel via phones, cell phones and pagers in the event of system alarm conditions.

Replacement of existing control system to a Moore APACS DCS with Process Suite R4 HMI. System replacement included the paper machine Dry End and partial Wet End controls to support installation of a new ABB Gauging System. Responsibilities include development of the control system architectural specification for the HMI and controller, complete controller and HMI configuration, commissioning and start-up support for approximately 250 I/O. Project architecture included a dedicated InSQL historian trend server, dual process servers, and multiple client stations.