| Kitchen Automation |
ECS has performed multiple kitchen controls automation projects including new installations,
upgrades and conversions of control systems. ECS designed the automation, specified and provided the hardware and instrumentation,
developed the software, and commissioned the systems. The automation included all control, IT, instrumentation, drives and valves,
used to control the production and CIP processes. |
- ControlLogix
- PLC-5
- Modicon
- Powerflex 70
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- PC based HMI2
- PanelView
- FactoryTalk View
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Details |
| Mixer Control |
ECS has successfully controlled batch and in-line mixers. |
Control performed with various PLCs, HMIs, drives and instrumentation. |
Request |
| S88 Batch Systems |
ECS can help you apply and benefit from the
ISA S88 standard
in many ways. |
ECS' innovative product, Batch Integrator,
reduces cost and errors while improving consistency and compliance. |
Request |
| Recipe Management |
ECS has worked on and provded recipe management systems of a wide range of complexities. |
- Batch based3
- Excel
- Access
- SQL
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- PC based HMI2
- PanelView
- ERP/MRP based
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Request |
| CIP |
CIP systems have ranged greatly in their complexities. The CIP automation sequence can often be more complex
to automate than the production process itself. We have used several approaches to implement CIP solutions, each with limitations.
Our Batch Integrator (based on S-88 concepts) uses an approach that makes the CIP automation straight forward and provides the
modularity and flexibility needed to capitalize on CIP improvements, increase efficiencies and effectiveness. |
The ECS Batch Integrator provides operators a
sophisticated interface for mapping any number of CIP sources to any number of cleaning routes. |
Request |
| Packaging |
ECS is not an equipment manufacturer. We integrate OEM equipment and conveyor systems, add controls and monitoring
capabilities, and report data that provide production and management a means to streamline the process, eliminate bottlenecks,
and reduce downtime. The wide range of packaging solutions ECS has provided includes loose (bulk) and oriented products.
Tracking, sorting, counting and interface to ERP/MRP inventory are common. |
- Box/carton erection
- Labeling
- Vision inspection
- Inventory management
- Reporting
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- New equipment
- Retrofits
- Palletizing
- Downtime tracking
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Request |
| Data Collection and Historians |
Weights, volumes, temperatures, times, operator actions, and supplier lots are examples of the volume of data generated by a food process.
ECS has experience with several tools for collecting and keeping such data securely. |
- FactoryTalk Transaction Manager, Gateway, Historian
- GE Proficy Historian
- ECS Historian for Microsoft SQL Server
- CiTect Historian and several others
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Request |
| Data Visualization and Reporting |
It does no good to collect and store data if you cannot use it to be more effective. ECS has helped customers
visualize, trend, track, alarm and report. We have sorted and summarized raw, compressed, time-series data into batches,
lots and shifts. |
- FactoryTalk ViewPoint and VantagePoint
- GE Proficy Portal
- Microsoft SQL Server Reporting Services
- Crystal Reports and several others
- Microsoft .NET web pages and other custom solutions
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Request |
| Instrumentation |
Mass flows, levels, pressures, temperatures, viscosity, and weights are common applications for which we have specified instrumentation. |
- Endress & Hauser
- Emerson / Rosemount
- Honeywell
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Request |
| Label inspection |
High speed, high accuracy systems to confirm serial and lot numbers, count, track, and report. |
- Single dimension bar codes
- Two dimension codes
- Machine Vision
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Request |
| Packaging/Handling improvements |
ECS can provide stations and/or modifications to your existing packaging line. |
- Integration of new stations to your line
- Modificaiton of existing stations
- Complete control systems
- Information integration
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Request |
| Smelting |
ECS has provided software development and hardware designs for multiple control systems in the Smelting area. |
- ControlLogix
- PLC-5, PLC-3
- GE 9030
- GE PACSystems RX3i
- Redundant processors
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- CiTect SCADA
- GE iFix
- ControlNet
- Data Highway Plus
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Request |
| Casting—Continuous Ingot, HGC, pig and billet |
ECS has provided software development and hardware designs for multiple control systems. |
- ControlLogix
- PLC-5, PLC-3
- GE 9030
- GE PACSystems RX3i
- Redundant processors
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- CiTect SCADA
- GE iFix
- ControlNet
- Data Highway Plus
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Request |
| Furnaces/Ovens—Annealing and Preheat |
ECS has delivered numerous annealing and preheat furnace control packages. Working with Burner Dynamics,
ECS has provided burners and advanced fuel mix management controls to reduce NOx and improve efficiency. |
- ControlLogix
- PLC-5, PLC-3
- GE 9030
- GE PACSystems RX3i
- Redundant processors
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- CiTect SCADA
- GE iFix
- ControlNet
- Data Highway Plus
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Request |
| Scalpers |
ECS has provided hardware designs and software development for the migration of a contol system from a PLC-3 to ControlLogix. |
- ControlLogix
- PLC-5, PLC-3
- Redundant processors
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- CiTect SCADA
- ControlNet
- Data Highway Plus
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Request |
| Reversing Hot Mills |
ECS converted (2) PLC-3's and one PLC-5 and merged them together into one new ControlLogix.
We converted legacy code and used a tag naming scheme that closely resembles the legacy address registers the electricians
and engineers were used to. We provided hardware designs and installation packages. We developed the HMI in CiTect. |
- ControlLogix
- PLC-5, PLC-3
- Redundant processors
- CiTect SCADA
|
- ControlNet
- EthernetIP
- Data Highway Plus
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|
Request |
| Continuous Hot and Cold Mills |
ECS converted a (2) PLC-3's and one PLC-5 into a single ControlLogix, including all 45 remote I/O racks on a
Continuous Mill. We converted legacy code and used a tag naming scheme that closely resembles the legacy address registers
the electricians and engineers were used to. We provided hardware designs and installation packages. We developed the
HMI in CiTect.
The new ControlLogix system went into production after only one trial ingot. |
- ControlLogix
- PLC-5, PLC-3
- Redundant processors
- CiTect SCADA
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- ControlNet
- EthernetIP
- Data Highway Plus
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Request |
| Shears |
ECS converted a PLC-3 into a ControlLogix. We converted legacy code and used a tag naming scheme that
closely resembles the legacy address registers the electricians and engineers were used to. We provided hardware designs
and installation packages. We developed the HMI in CiTect. The new system had to interface with the old GE DMC drive system
via serial link and the new GE ISC drive system over Profibus. |
- ControlLogix
- PLC-5, PLC-3
- Redundant processors
- CiTect SCADA
- GE DMC / GE ISC drive systems
|
- ControlNet
- EthernetIP
- Data Highway Plus
- Profibus
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Request |
| Mill lubricant and coolant systems |
ECS has provided hardware designs and software development for the migration of a contol system from a PLC-3 to ControlLogix. |
- ControlLogix
- PLC-3
- CiTect SCADA
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- ControlNet
- EthernetIP
- Data Highway Plus
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Request |
| Roll Grinders |
ECS has provided hardware designs and software development for the migration of a contol systems.
We have upgraded systems with obsolete encoders to new off-the-shelf encoders. |
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- ControlNet
- EthernetIP
- Data Highway Plus
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Request |
| Finishing—Coating and Slitting |
ECS converted a redundantredundant PLC-3 into a ControlLogix. We converted legacy code and used a tag
naming scheme that closely resembles the legacy address registers the electricians and engineers were used to. We provided
modifications to the CiTect HMI. |
- ControlLogix
- PLC-3
- CiTect SCADA
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- ControlNet
- EthernetIP
- Data Highway Plus
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|
Request |
| Coal Handling |
ECS has completely redone a number of large coal handling systems including BREC D.B. Wilson station and Duke Zimmer.
The Wilson system was originally all wireless.
We have also redone a number of smaller systems and have worked on improvements to parts of systems, such as trippers. |
- ControlLogix
- PLC-5
- Square D
- Modicon
- Other PLCs1
- Emerson Ovation
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- Wireless I/O
- Wireless cameras
- PanelView
- Vijeo
- PC based HMI2
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Request |
| Stacker/Reclaimers |
ECS automated the stacker at AEP Rockport station. Cameras were added for monitoring in the main control room.
The stacker at D.B. Wilson station utilized Rockwell Ethernet I/O. |
- ControlLogix
- Modicon
- Wireless I/O
- Wireless cameras
|
- Vijeo Citect
- Intellution
- RSView32
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|
Request |
| Barge Unloading |
ECS has provided complete barge unload controls including drives, controllers, HMI and chairs. Types include
clamshell and continuous haul. |
- ControlLogix
- Other PLCs1
- AC & DC Drives
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Request |
| Boiler Control |
ECS retrofitted complete boiler controls for a 100MW unit at KU Green station. We have also provided controls for
coal-fired university steam generators. |
- ControlLogix
- ProcessLogix (RA Branded Honeywell)
- FactoryTalk View SE
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Request |
| Burner Management |
ECS has provided and worked on several burner managment systems. We modified a Rockwell BMS designed for coal
burners to manage combined coal and gas firing. |
- ControlLogix
- Modicon
- RSView32
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|
Request |
| Sootblowing |
ECS provides a completely compatible, drop-in replacement for your Diamond, Clyde Bergeman or other soot blower
control system. Our package interfaces directly to
Neuco SootOpt® if an intelligent management system is required. |
|
Request |
| SCRs |
ECS has provided SCR controls for several units including two at Hoosier Energy's Merom Station and one at
Big Rivers' D.B. Wilson Station. |
- ControlLogix
- Modicon
- RSView32, FactoryTalk View SE
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Request |
| Scrubbers (FGD), Limestone handling |
One scrubber system ECS designed has run for over 20 years without causing a unit trip. A recent system was moved in phases
from a Net90 DCS into several PLCs. |
- ControlLogix
- PLC-5
- Modicon
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- RSView32
- FactoryTalk View SE
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|
Request |
| Wet Ash, Dry Ash and precipitators |
ECS has provided a number of complete ash system retrofits. |
|
Request |
| Water Systems—Demineralizers, Condensate Polishers, and RO plants |
ECS has provided a number of complete water system retrofits. |
|
Request |
| Instrumentation |
Temperatures, airflow, O2, pressure and level are common applications for which we have specified instrumentation. |
- Endress & Hauser
- Emerson / Rosemount
- Honeywell
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Request |
| Water and Wastewater plant systems |
ECS has provided complete control systems for various water treatment facilities including dedicated water
treatment at power plants and municipal water and wastewater plants. ECS provided the hardware design, software development,
installation, and commissioning. Systems included full SCADA with data historian and reporting tools. |
- ControlLogix
- Historian
- Visual Basic
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Request |
| Lift and Pumping Stations |
ECS has provided complete control and monitoring system for remote well and lift stations.
Communications to remote stations utilized wireless Ethernet across spread spectrum 90MHz radio modems. |
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- PanleView
- MTE Radio Modems
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Request |
| SCADA systems |
ECS has provided full SCADA systems for water/wastewater treatment facilities with data historian and reporting tools. |
- ControlLogix
- FactoryTalk View
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Request |
| Instrumentation |
Mass flows, levels, pressures, temperatures, viscosity, and weights are common applications for which we have specified instrumentation. |
- Endress & Hauser
- Emerson / Rosemount
- Honeywell
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|
Request |
| Assembly systems |
ECS has provided complete control solutions for automated assembly machines, conveyor lines,
dial tables, walking beams, and lean work cells. We have integrated custom stations with OEM supplied stations. |
- Pick and Place
- Press Stations
- Assembly Stations
- Laser Etching
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- Machine Vision
- Bar Code Tracking
- RFID Tracking
- Product Data Management
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Request |
| Tire mounting and Wheel Balancing |
ECS has provided complete control solutions for several tire mounting and wheel balancing systems. |
- ControlLogix
- PLC-5
- RSView32
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- Machine Vision
- Tire Pressure monitoring transmitters
- JIT production
- Legacy database interface
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Request |
| Painting/Finishing |
ECS has provided software development services for the control of painting and finishing lines. |
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Request |
| Curing ovens |
ECS has provided complete control solutions for different types of curing and drying ovens. |
- ControlLogix
- PLC-5
- Mitsubishi Q and A series
- Siemens S7
- PowerFlex drives
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- Flame Safety
- Burner Control
- PanelView
- CiTect SCADA
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Request |
| Inventory tracking |
ECS has developed custom software applications to track inventory. |
|
Request |
| Testing and Inspection |
ECS can provide full stations or additions to existing stations. |
|
Request |
| Cut-to-length |
ECS provided a complete upgrade of a control system on a cut-to-length machine.
ECS upgraded an Allen Bradley PLC5/40 with a ControlLogix. We utilzed Powerflex 753 drives to replace the 1336 drives for the
Stacker Blower, Prime Stacker Lift Table, Prime Stacker Chain Conveyor, Reject Stacker Lift Table, and Reject Stacker Chain Conveyor.
We utilized PF755 drives for servo applications to replace the IMC Motion Controller on the Shear, Feeder, Leveler, and Uncoiler. |
- PowerFlex 755
- PowerFlex 753
- A-B 1336
- A-B IMC S Class Motion
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Request |
| Stamping/Forming |
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- FactoryTalk View
- PanelView
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Request |
| Extrusion |
ECS has worked on many extruders including multi-layer sheet extruders. |
|
Request |
| Thermoforming |
ECS has provided complete control system retrofits for thermoforming machines, including direct heater control. |
|
Request |
| Inventory systems |
ECS has provided various inventory tracking systems based on bar codes and RFID. |
- Fork Truck terminals
- Shipping dock stations
- Control System Integrated
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- Stand-alone SQL Server
- Interfaced to your ERP system
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Request |
| Data Visualization, Key Performance Indicators and Dashboards |
Data visualization systems give a wider population of less technical users access to production information,
allowing more informed decision making. |
- Factory Talk Metrics
- Factory Talk Vantage Point
- Proficy Portal
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- Microsoft SQL Reporting Services
- Custom .NET applications
- Plant information displays
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Request |
| Workflow management |
Workflow systems improve quality and consistency of manual operations by packaging appropriate operator instructions
with each work release or batch of product released to manufacturing. These products are also excellent tools for documenting
standard operating procedures. |
- Factory Talk eProcedure
- Proficy Workflow
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Request |
| Data Collection and Historians |
Collecting data from your plant floor, either for process improvement or compliance purposes, is a given
in today's competitive world. ECS has provided a wide variety of time based and event based collection systems, with and without
reporting systems, to help our customers compete effectively. |
- Factory Talk Historian
- Factory Talk Transaction Manager
- Proficy Historian
- Various HMI products2
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- ECS Historian for Microsoft SQL Server
- Third Party and custom OPC servers
- Microsoft SQL Server Reporting Services
- Custom ActiveX tools for embeded systems
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Request |
| Time Collection |
ECS has two products for time collection. One is an add-in for Microsoft Outlook. The other is a web based product that
collects time tickets against downtime codes for breakdowns or product changeovers. Both return data to Microsoft SQL Server. |
|
Request |
| Reporting |
ECS has provided a wide variety of client and server based reporting solutions. |
- Microsoft SQL Server Reporting Services
- Microsoft Excel
- Various HMI products2
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Request |
| Network Upgrades |
|
- ControlNet, DeviceNet
- EthernetIP
- Fieldbus
- Modbus, Modbus TCP
- Profibus
- Hart
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- Domain Controllers
- Security
- Threat Protection
- Routers
- Switches
- VPNs
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Request |
| Reliability and Recovery |
ECS can help you increase the reliability of your plant systems and help you decrease the time to recover from
a catastrophic failure with virtualization and backup technologies. |
- Microsoft HyperV
- Microsoft Virtual PC
- VMWare Workstation
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- Microsoft Data Protection Manager
- Acronis True Image
- FactoryTalk AssetCentre
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|
Request |
