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Design & Install of a Distillery Dryhouse Project

A major US distillery recently increased the capacity of the Dryhouse equipment in its facility, while maintaining operation until the new equipment was commissioned and fully operational.  The process control solution for the new Dryhouse equipment was designed and installed by ECS.  The Rockwell Automation 1756 ControlLogix platform, together with Citect HMIs, were selected as the basis of the solution.  The system was designed to control fourteen pieces of process equipment in the Dryhouse, including an evaporator, mixer, dryer, centrifuges, a CIP rinse tank and an evaporator cooling tank.  Some of the OEM components had a dedicated controller and required specific means of control.

The system was configured to operate with faceplates and HMI objects similar to those in use in the facility.  All designs for the control system, including drawings of the network, control panel, and electric I/O, were provided by ECS, together with programming, start-up, and commissioning services.  ECS also provided the controller hardware and all I/O components, which included desktop flat screen monitors, Logics Supply Industrial PCs, and a Windows 7 operating system.  Citect licenses were obtained by ECS as an extension to the existing Citect application.

The I/O for the new equipment was configured to be remote to the existing controller. ECS modified the existing ControlLogix controller program to ensure that the new equipment was controlled to meet the required functions.  ECS also fully tested the new HMI screens to verify that all input devices, numeric fields, animation, and faults were functioning as required.  Certain components of the system, e.g. sequences, procedures, and process variables for controlling devices, were simulated to test the logic in the controller.

Documentation and drawings for the new equipment were delivered by ECS including I/O schematics showing field devices, communication/network schematics and a system manual containing all literature provided by the manufacturers of the components of the system.


Posted In: Case Studies