An International Silicon Metals Producer Upgrades Controls for Mix System #5

Objective:    To modernize, a large silicon metals producer upgraded their Mix System #5 control platform to include Rockwell ControlLogix controllers, Factory Talk platform-based visualization, recipe and batching systems, data acquisition and reporting. In addition, modern, efficient, VFD-based electromagnetic raw materials feeders were needed to replace existing outdated feeders.   Description of Services Provided: Designed, manufactured,…

Large Scale DLC Modernization in 8 Weeks

Objective:    A large 40-year-old mid-Western foundry was experiencing significant downtime and prolonged mean time to repair control system elements due to obsolescence and uncoordinated HMI strategy.  They invited Revere to participate in a lean event using Revere subject matter expertise to advise on production risks related to automation.  A major production risk was identified and…

Major Building Products Firm Increases Capacity and Yield

Objective:    The project included recommissioning and modernizing controls for (2) 300’ long production lines that had been idle for several years. It was necessary to upgrade the 1200 I/O PLC controls from a TI 555 platform to ControlLogix on each line. In addition, the system would require safety enhancements and new servo motion control to…

A leading N. American Diversified Wood Products Company Upgrades Boiler and Control Panels

Objective:    Revere served as the primary contractor on this boiler upgrade job. With controls at end-of-life and replacement parts no longer available, obsolescence put the client at critical risk for a production and safety-critical facility area.  The project included bringing the boiler system up to a level of full-compliance using individual ControlLogix and GuardLogix processors.…

Leading Global Textile Provider Prep Range and Tenter Frames Automation Upgrade

Objective:    This leading global textile provider needed a highly reliable control and drive system platform that could be supported well into the future.  Due to existing power and control system unreliability which limited production by as much as 40%, they were required to run their lines 24×7 to meet customer demand and had no capacity…

A Global Full-Service Firm Constructs Barite Grinding Mill in US and Ships Overseas

Objective:    A big challenge for this global O&G company was getting materials to market faster from remote regions of the world. Often, the raw material is readily available, but to properly leverage their competitive advantage, the firm must keep a tight handle on the operational costs associated with accessing and transporting the material.  They needed…

Lime Plant Power Upgrade

Objective: This electrical upgrade project was critical for an aging Tennessee limestone plant to both stabilize crushing processes and meet modern electrical safety standards.  Updating their plant power feed and equipment would be instrumental in gaining efficiencies and productivity.  In addition, the aging plant was at risk for accidents and regulatory challenges from governmental agencies.…

Large Mineral and Aggregate Company Upgrades Truck Scales Requiring New Ethernet Interface and PLC Upgrade

Objective:       A large crushed stone quarry had antiquated truck scales that no longer met Department of Transportation requirements.  This project to upgrade large truck scales included new Ethernet interface upgrading, converting from PLC ControlLogix L55 processor to ControlLogix L73 processor, converting (1) RSView32 install, (1) older RSViewSE Distributed and (1) FTViewSE Station installations in three…

N. American Leader in Wallboard and Joint Compound Materials Expands Outside Sources for Gypsum

Objective:       A large gypsum wallboard plant’s only resource for gypsum was a nearby power plant, creating a significant cost risk and bottleneck.  They needed a way to bring in more gypsum from outside sources by railcars to expand their volume.  The project included building and delivering an E-house with PLC Panels, Distribution Transformers…

Major Aluminum Sheet and Plate Producer Developing New Micro Mill Technology to Scale Production of Aluminum Sheets

Objective: This aluminum sheet producer developed new mill technology to scale up the production of aluminum sheets so that it could be deployed to multiple user sites. This technology would result in reduced transportation costs, decreased supply chain delays and optimize energy costs. They were looking for a lean, flexible, responsive engineering team for construction,…