A leading wallboard manufacturer operates one of the largest wallboard production facilities in the United States, serving high-growth markets in Texas and the South. As production demands increased, the facility faced mounting challenges. The calcining operation, which converts raw gypsum rock into slurry before it becomes wallboard, relied on outdated electrical infrastructure and aging automation systems. This led to persistent issues with reliability, process variability, and unexpected shutdowns, increasing costs and threatening efficiency.
To address these challenges, the manufacturer turned to Revere Control Systems for a full-scale modernization of its electrical infrastructure, automation controls, and instrumentation. The goal was to increase reliability, improve process control, and execute the entire project without unplanned downtime.
The FEED Study: Laying the Foundation
Long before execution began, Revere conducted a Front-End Engineering and Design (FEED) study—an essential first step that set the stage for a smooth and successful project.
The FEED study, which began in 2018, allowed Revere to:
- Validate the existing infrastructure by assessing all I/O points, network systems, and electrical equipment.
- Develop a detailed execution plan, ensuring that upgrades could be completed without disrupting production.
- Identify critical resilience improvements, including reengineering the system so that failures in one section would not compromise the entire process.
- Provide cost and feasibility assessments, enabling the manufacturer to secure project funding in March 2020.
Despite the COVID-19 pandemic causing delays, engineering work progressed throughout 2020 and full project execution began in 2021, wrapping up in early 2023.
The Challenge: Aging Infrastructure and Production Risks
Two major operational challenges were central to the plant’s issues:
- Process Variability: The plant’s legacy systems struggled to maintain precise control over temperature and material inputs. Operators were forced to overcompensate with raw materials and energy, leading to unnecessary costs.
- Runability and Reliability Issues: A failing PROFIBUS network caused recurring “phantom shutdowns” where equipment would suddenly stop running with no clear reason. Troubleshooting these failures was time-consuming and inefficient.
Additionally, the plant’s electrical infrastructure was outdated, with unreliable motor control systems, insufficient network redundancy, and limited operator visibility. Addressing these issues required a comprehensive modernization effort spanning power distribution, controls, and instrumentation.
The Solution: A Full Electrical and Automation Overhaul
Revere designed and executed a phased upgrade strategy, ensuring that every aspect of the system was modernized without unplanned downtime.
| Electrical Infrastructure and Power Distribution | Revere completely rebuilt the plant’s power distribution system, replacing all outdated components with modern, high-reliability infrastructure. This included: – Upgraded seven new motor control centers (MCCs) with 480V AC switchgear. – Replaced all power and control wiring, including cable raceways and instrumentation cabling. |
| Control System and Network Upgrades | To eliminate reliability issues and enhance control, Revere upgraded the plant’s automation and network systems: – Replaced all PLCs with Allen-Bradley ControlLogix systems. – Eliminated the unreliable PROFIBUS network and transitioned to a Rockwell Automation-based Ethernet/IP network. – Integrated Allen-Bradley Stratix switches to ensure seamless communication between automation components. |
| Enhanced Operator Visibility and Process Control | A major improvement came from the implementation of Inductive Automation’s Ignition HMI system, which: – Replaced the outdated operator interface with a modern, intuitive system. – Provided a real-time historian, allowing operators to analyze process data for better decision-making. – Displayed all interlocks and permissives, so operators could instantly diagnose why a system was not running—eliminating the need to call maintenance for troubleshooting. |
| Instrumentation and Safety Improvements | Revere overhauled the plant’s instrumentation systems, ensuring precise control and enhanced safety: – Revamped burner management systems on the kettles, improving safety and fuel efficiency. – Installed new instrumentation for temperature, pressure, and material flow control, reducing process variability and increasing efficiency. – Conducted extensive factory acceptance testing (FAT) and software validation before installation, ensuring error-free commissioning. |
| Process Monitoring with New Camera System | To further improve operator oversight, Revere installed a comprehensive vision system throughout the plant. Previously, there were only a few cameras, making it difficult to monitor processes. The new system provided: – Expanded camera coverage, giving operators full visibility into critical operations. – Higher-resolution video feeds, improving real-time monitoring and troubleshooting. |
The Results: Increased Efficiency, Reliability, and Cost Savings
- Zero Unplanned Downtime: All work was completed without further impacting production.
- Eliminated Phantom Shutdowns – Replacing the PROFIBUS communications resolved chronic reliability issues.
- Optimized Process Control: Reduced process variability led to significant cost savings on raw materials and energy.
- Improved Operator Control: The Ignition HMI system provided enhanced visibility and troubleshooting capabilities.
- Stronger Electrical Resilience: The redesigned infrastructure ensured long-term reliability.
One of the most significant accomplishments of this project was completing all upgrades without unplanned downtime. Throughout the execution phase, Revere worked in close coordination with the manufacturer to ensure that every aspect of the project was aligned with the plant’s production schedule. Cutovers were carefully planned and strategically timed to prevent disruptions, allowing operations to continue uninterrupted.
As the project progressed, Revere remained flexible, modifying timelines and adjusting work sequences in real time to accommodate shifts in the plant’s operational needs. When unexpected constraints arose, Revere adapted its approach to maintain the plant’s full production capacity while still delivering the necessary system upgrades. A detailed status tracker methodology was employed to manage each transition, ensuring that every cutover and system integration was executed with precision.
This project marked just one of several successful collaborations between Revere and a manufacturing partner. Following the calcining modernization, Revere also completed a PLC 113 common PLC replacement project, further enhancing plant-wide automation. With a proven track record of delivering complex upgrades with zero unplanned downtime, Revere remains a trusted partner in this client’s ongoing modernization and expansion efforts.