Objective
Expand an existing fabrication shop into a dedicated potshell lining and de-lining facility by designing and integrating a complete process control system, motor control, and steam heat trace system.
Solution:
Tusk Automation played a key role in developing the process control and motor control systems for the new facility, ensuring seamless integration with modern automation standards.
- Process Control System Design & Supply – Assisted in designing and delivering a complete control solution, including a ControlLogix PLC, Stratix networking, and a suite of process instrumentation.
- Motor Control & Power Distribution – Integrated 300HP soft starters, Ethernet/IP-enabled E300 motor controllers, and a Protection & Control panel to manage critical equipment.
- Steam Heat Trace System – Designed and implemented a heat trace control system to maintain process temperature stability.
- Field Commissioning & EPCM Support – Provided testing, commissioning, and on-site support for the EPCM engineering team.
- Programming & System Adaptation – Resolved legacy automation challenges by adapting standardized add-on instructions, originally built for obsolete hardware, to function with modern Ethernet/IP-enabled devices.
Our Role:
- Process & Motor Control System Integration – Designed and supplied a fully integrated automation and instrumentation package.
- Programming & Firmware Adaptation – Updated and reworked control logic to support new Ethernet/IP-enabled hardware.
- Field Testing & Commissioning – Validated system performance and provided startup support.
Tusk Automation’s expertise ensured the successful expansion of the potshell repair facility, delivering a modernized, reliable, and efficient control system that supports long-term operational success.