rev ere revere - amazon s3 · port of miami tunnel project. 3 conveyor-control e-houses. in 2014,...

REVERECONTROL SYSTEMS



2240 ROCKY RIDGE ROAD BIRMINGHAM, ALABAMA 35216

T 800.536.2525T 205.824.0004WWW.REVERECONTROL.COM

Utility Plant Raw Water IntakeRake and Screen Control E-HouseRevere was commissioned to design and furnish an E-House to control the raw water intake of a major public utility. The controls are designed to meet EPA 316B to protect aquatic life.

Control System SpecificationsGeneral Controls

• HMIs

• Ethernet Switch Fiber Center

• Three NEMA 4X Remote I/O Control Panels including PLC, Ethernet Switch and Ancillaries

• Three NEMA 4X Wash water combination FVNR starters (300HP, 480V)

• Five NEMA 4X Variable Frequency Drives

Fiber Optics and Cables

• 4000 foot, 6-Conductor Fiber Optic Cable

• Connectors, Testing and Terminations as required

Field Instrumentation

• 25 Ultrasonic Level Sensors

• 28 Pressure Guages

• 15 Pressure Transmitters

• 4 Orifice plates with taps

• 1 Flow Transmitter dP transmitter

E-House SpecificationsThe utility expressed aesthetic concerns about the E-House, so Revere utilized a Stainless Steel housing to ensure that final product would meet the customer’s needs, both functional and visual. Equipment in the E-House includes:

• 8’ deep by 18’ wide building enclosure

• Uninterruptible Power Supply

• Uninterruptible Power Supply Batteries/Ancillaries

Internal view of Rake and Screen control E-House

provided by Revere.

To address aesthetic concerns, Revere utilized a Stainless

Steel housing.






Mining Crusher ProjectCrusher Control E-HouseA multinational oilfield services cvorporation needed an electrical control system for a Crusher machine at a mine in Kazakhstan. Revere designed, furnished, and commissioned an E-House containing the full scope of controls required, as well as capable of withstanding the harsh Kazakh weather.

The E-House was designed to withstand temperatures as

low as -40°C and remain operational.

An internal view of the Kazakhstan Crusher Control

E-House

Control System SpecificationsMajor control elements included in the E-House:

• Siemens IEC-style 380VAC, 3-phase, 4-wire, 50Hz Motor Control Center

• Siemens S7 PLC control panel

• Siemens S7 PLC control panel (Crusher OEM provided)

• Siemens mill drive VFD control panel (Crusher OEM provided)

• Siemens mill primary and secondary fan VFD control panels (Crusher OEM provided)

• Siemens mill separator VFD control panel (Crusher OEM provided)

Field equipment included in control system:

• Two non-fused motor disconnects

• Two “Auto-Off-Jog” control stations

• Three continuous level transmitters

• Three point level switches

• One mill separator motor plug/receptacle box

E-House SpecificationsDue to the remote nature of the final location, the entire E-House assembly and control system was set up and tested in North Alabama, then broken down and shipped to Kazakhstan. The E-House included some of the following features:

• Interior lighting

• Emergency interior lighting

• Exit signs

• Interior outlets

• HVAC able to handle temperatures down to -40°C

FL_GBPP_1215




Barite is a mineral needed to make drilling mud used in oil and gas drilling operations. The plant in Kazakhstan will serve the vital drilling activity in that part of the world. The processing operation involves multiple steps of crushing, grinding, separating, washing, concentrating, and drying to produce a powder that is ready to be bagged and shipped.

Because of the challenges of performing construction in this remote region, the entire plant was constructed in the US. It was then disassembled and shipped is segments to the mine site for re-assembly.

Our automation deliverables for the project included

• FEED study

• Siemens S7 with WinCC

• Network architecture

• Motor Control Centers

• Integration of third-party systems (controls provided by crusher manufacturer)

• Instrumentation package

• Commissioning

• FAT

• 3D graphics

Packaged E-House for Installation in Kazakhstan


Greenfield Barite Processing Plant


Packaged E-House included MCC, controls, and network server, tested in USA prior to shipment to end user.

Deliverables for the E-House included

• Layout and design

• Engineering work station

• Air conditioning

• Equipment integration plan






Port of Miami Tunnel Project3 Conveyor-Control E-HousesIn 2014, Miami, FL, officially opened the PortMiami Tunnel, a 4,200-foot underwater tunnel connecting the Port of Miami with the rest of the city. The tunnel took nearly 3 years to bore.

During the project, three distinct conveyor systems were used to remove tunnel-boring debris from the drill site. Revere Control Systems designed, assembled, and commissioned three E-Houses to control the systems.

E-House Deliverables• Detailed designs and drawings for control/electrical

containers and electrical switchboards

• Detailed schematics for electrical and lighting networks, PLC/sensors/communication network, video, control and electrical containers, electrical switchboard and relay boxes

• Control System Operator Station (for Tunnel Boring Machine control cabin)

• Conveyor Local Control Stations

• Conveyor control containers complete with power and control equipment

• Tunnel Boring Machine-located conveyor system operator panel

Conveyor Control SystemsRevere built three similar but distinct E-Houses to control the three conveyor systems: East Tunnel, West Tunnel, Overland Surface.

Features Unique to East and West Tunnel E-Houses:

• One Dual 200HP Control Container with HVAC

• Two 200HP constant torque variable frequency drives

• 480-240/120VAC transformer

• 240/120VAC, single-phase distribution panelboard

Features Unique to West Tunnel E-House:

• One 50HP constant torque variable speed drive

Features Common Among All E-Houses:

• HVAC

• Interior lighting

• 120VAC convenience outlets

• NEMA 1 PLC cabinet with Ethernet communications

• 6” PanelView Plus touchscreen operator interface

One of Revere’s three E-Houses responsible for

controlling the debris removal conveyor systems at the

Port of Miami TunnelAn internal

view of

the Port

of Miami

Tunnel

Project

E-House






Automobile Shredder ProjectShredder Control E-HouseRevere was commissioned to design and furnish an E-House containing the Motor Control Center, PLC, and electrical/programming equipment needed for a new automobile shredding machine, as well as an external operator control chair.

E-House SpecificationsThis project was particularly unique, the customer asked Revere to re-purpose an 9’6” high by 8’ wide by 40’ long shipping container to serve as the E-House. Revere modified the container to meet the customer’s needs, including:

• Two-inch insulated interior wall panels

• HVAC

• One equipment double door

• Two personnel doors

• Work table

• Interior lighting and emergency lighting

• Interior 120VAC outlets

Control System SpecificationsNEMA 1 Gasketed PLC Motor Control Center:

• Allen-Bradley 10” PanelView Plus operator interface

• “E-Stop” pushbutton

• PLC I/O system including processor, power supply, Ethernet communications, and I/O pre-wired to terminal blocks to interface with various equipment, including FVNR starters, contactors, and Variable Frequency Drives

• Approximately 750 total “connected” horsepower






Textile Production Line Upgrade ProjectPrep Range and Tenter Control E-HouseA major textile producer contracted Revere to do a large-scale automation upgrade of their production line, and desired an E-House be used to centralize control operations. We designed, installed, and commissioned the E-House, as well as performing the entire cutover for the line’s automation within the 14-day window requested by the customer.

Control System SpecificationsTo accomplish the quick cutover desired, Revere assembled and tested all control system components (including E-House setup) at our facility before shipping.

Major control elements included in the E-House:

• ABB ACS880 Drive System for Prep Range and Tenter Ranges Nos. 1 & 2

• Allen-Bradley ControlLogix controllers; one primary controller per line with local and remote I/O designed to facilitate optimized installation and future support

• E-Stop safety circuits with annunciation of an E-Stop condition by location

• WonderWare HMI with one engineering workstation inside the E-House (6 additional operator work stations around the facility)

• Dell Industrial Data Server that supports all HMI and Control System software on all three lines

• Schneider IEC across-the-line motor starters and Manual Start protectors

E-House SpecificationsThe project required a two-piece modular design for the E-House to allow for easy assembly and setup on site. Other factors considered in E-House design included:

• The customer planned to mount the E-House on a frame atop Tenter No. 1, so weight, size, and mounting considerations were paramount.

• An Arc-Flash rating of 0 or 1 with open construction was necessary.

• Cable trays were required to handle the significant wiring I/O demands of the E-House.

Due to the number of control system components involved,

space within the E-House was at a premium; functional

and efficient design was crucial.

Revere consolidated multiple equipment controls into

this central E-House for easier line management.

rev ere revere - amazon s3 · port of miami tunnel project. 3 conveyor-control e-houses. in 2014,...

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