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DiGeronimo Aggregates Electrical Design and Control System Automation
Independence, Ohio

DiGeronomo Aggregates, Independence, Ohio Client: DiGeronimo Aggregates

Hull provided electrical engineering and control system automation services for a 45 TPH lightweight aggregate Kiln upgrade. Three new Baghouses added with a new ID Fan and Lime Slurry system were added to replace the existing obsolete baghouse. Coal was added as a fuel source which required a complete coal conveying system and mill. Finally as part of the facility upgrade the kiln, clinker cooler and combustion system were also upgraded.

A control and automation system was required to allow equipment provided from multiple vendors to communicate, monitor and control operation, and report critical operating data required by the Environmental Protection Agency (EPA). The system needed to be developed to allow plant operators, maintenance and management to access appropriate information, control, diagnostics, and critical process values. Energy monitoring was also a desire to allow for efficient operation.

In order to meet these challenges Hull developed an automation system utilizing Allen Bradley Control Logix Programmable Logic Controller (PLCs) and Wonderware© Industrial Application Server for the Human Machine Interface (HMI) system.

The automation system required Allen Bradley PLCs to communicate with ABB drives via Controlnet, and power distribution equipment via modbus. The existing facility required a complete control system upgrade with new I/O and instrumentation. The HMI system was developed to allow for redundant computers, I/O servers and HMI object servers. A wireless system was implemented with a tablet PC to allow local control of equipment using the HMI system. Terminal services were implemented to allow multiple users to access and control the system. This allowed plant operators, maintenance and management to access appropriate information, control, diagnostics, and critical process values. Certain data was historically logged and reported to an SQL database. Instrumentation with Hart protocol communicates with the PLC and HMI system, making configuration and calibration possible remote from the instrument. Video camera displays of the process were embedded into the HMI to provide visual feedback, allowing adjustments to be made from the control room.

One of the technical goals Hull met was upgrading the power distribution system to properly distribute loads and allow for future expansion, while maintaining power to the existing facility during construction.

To find out how Hull can help, please contact Hull's Electrical Engineering Division Leader, Andrew Holtom, PE at (614) 793-8777.