Composer Upgrade

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This project involved upgrading an existing plywood composer to use a modern control system.

It involved interfacing with a team of machine vision specialists, whereby they provided information to the control system which then performed the required cuts. Balancing speed of operation with mechanical stability was the crux of the control. While it was possible to achieve cut times in the order of 300ms; it was found that ~350ms produced more consistent stability.

From an advanced control point of view, the switch to using modern PLC components that allowed for precise high speed motion control of hydraulic servo valves coupled with some minor mechanical changes and upgrading to current generation servo motors proved to be the key elements to improving the process.

The controls for the rest of the machine were also updated to meet current site standards.

The end result of this project was an increased number of daily cuts from ~26,000/day before the project, to ~40,000/day after the project.

• Client: Don Watson Electrical Engineering
• Date: Jan-Feb 2017
• Category: PLC CONTROL

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Boiler Control Upgrade

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The control systems on two wood fired boilers were upgraded; these fed into a common steam header that supplied plant steam to a plywood mill. Prior to the upgrade these boilers were controlled by stand alone PID controllers. The upgrade saw 3 PLCs (rockwell control logix) installed to control these boilers and the fuel system. Upgrading motors to VSDs, replacing or upgrading instruments and adding new instrumentation was also carried out. We were part of a team of engineers who completed this project where our role was to complete the control system.

The control system was developed using a staged approach including; establishing initial requirements, generating a functional descrption, writing the code, simulating the basic operation, preparing HMI, presenting the simulation system to the client, providing operator training. Once installed, the control system was tuned to meet plant requirements, with assistance from a boiler control expert. Before the upgrade, low boiler level trips and inconsistant steam pressure were a significant issue on site. After the upgrade, plant steam pressure was more reliable and able to handle load changes; low boiler level events are all but eliminated.

The entire plant runs smoother due to more consistant steam flow and pressure. This was a significant project involving the control of all aspects of two boilers and the plant that supplies the fuel and water to those boilers.

• Client: Don Watson Electrical Engineering
• Date: 2012 Jan - June
• Category: CONTROL SYSTEM

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CAD Workstation

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Built a custom workstation for MCTL dedicated to run mechanical 3D CAD software

The system was supplied to the client ready for application software to be installed

Turnaround time from order placement to delivery was less than 2 weeks

• Client: Matt Crisford Technologies Limited
• Date: November 2018
• Category: Custom Built PC

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PMB Upgrade

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Provided electrical drawings for construction of PMB plant upgrade at a bitumen plant. Electrical engineering design support and project management was also provided which required liasion with the end user, contractors and utility owners.

• Client: DWEENG Limited
• Date: May 2018 - February 2019
• Category: Design, CAD, Project Management

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Continuous Process Improvements

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Dynamic Automation provides ongoing engineering support, PLC maintenance and non-project upgrades for various clients.

These jobs are site and process specific and can involve a variety of skills including system design, implementation of software, code auditing, product tracking, process optimisation, fault finding, safety system design, process network design, PLC upgrades and more…

• Client: Various
• Date: Ongoing
• Category: Process Control

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Dynamic Automation Website

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Designed this website for Dynamic Automation using Hugo. Involved modifying html code, understanding client requirements and designing the look and feel of the website to suit these requirements.

• Client: Dynamic Automation
• Date: November 2018
• Category: Web Development

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Bulk Carrier Dispensing Hopper

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Provided engineering support during the commissioning and testing of a bulk carrier dispensing hopper at the Port of Tauranga.

Skills required included understanding the process and its requirements then confirming the operational specifications.

Main controller was a Schneider M340 PLC which interfaced to a hydraulic control unit via CANBUS.

• Client: Realtime Software
• Date: Nov 2016
• Category: Commissioning and Engineering Support

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Pump Seal Water System

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Programmed the control system for the cooling water pumps’ seal water system at a geothermal power station and assisted with construction supervision and management.

This required liasing with the asset owner, contractors and OEM suppliers to ensure technical specifications were met.

Programming involved integration into an existing ABB xA800 DCS using AC800M controllers and VSD drives.

• Date: Jan - Feb 2015
• Category: PROGRAMMING & CONSTRUCTION MANAGEMENT

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Kinetika 2014 Scared Animal

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Worked with mechanical and pneumatic engineers to design and implement the creative vision of an artistic designer’s entry into Kinetika 2014

Used an Allen Bradley Micro 820 to control pneumatic valves in response to recieved magnitude of sound.

This involved programming, control system design, CAD, electronic design and pneumatic interfacing.

• Date: Nov 2014
• Category: AUTOMATION

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