Client Challenge
A major textile manufacturer in South Carolina needed ongoing automation support and system upgrades to enhance the reliability, efficiency, and performance of its polyester manufacturing operations.
The facility relied on complex automation systems, including Rockwell PlantPAx, MES systems, and various process control elements, and power plant/boiler room controls.
In addition to daily automation support, the plant required a significant control system upgrade for four polyester manufacturing lines (Drawframe 13-16) and the successful startup of Drawframe 10. The key challenges included:
- Maintaining and troubleshooting critical automation systems to minimize downtime.
- Designing and implementing control system upgrades for medium-voltage switchgear, MCCs, and high-power AC motors.
- Ensuring precise control and calibration of instrumentation and drives for optimal machine performance.
- Upgrading legacy control panels and integrating new PLC/SCADA systems to handle complex automation needs.
Our Solution
DSI provided a multi-faceted automation support and upgrade solution, ensuring both daily operational reliability and long-term system enhancements. Our approach included:
- Ongoing Plant Automation Support:
- Assisted plant maintenance and automation teams with troubleshooting and system optimizations.
- Supported Rockwell PlantPAx DCS, MES systems, safety systems, and process controls to maintain seamless operations.
- Monitored and maintained power plant/boiler room controls and oil quality monitoring systems.
- Drawframe 13-16 Upgrade:
- Designed and implemented control system upgrades for four polyester manufacturing lines.
- Provided electrical design for medium-voltage switchgear, low-voltage MCCs, and AC motors up to 400HP.
- Designed PLC/SCADA and control panels, overseeing the installation of 10 control panels per machine.
- Integrated approximately 800 I/O points and 25 drives per machine, ensuring enhanced control and performance.
- Drawframe 10 Startup:
- Performed I/O checkout and verification against electrical prints and P&IDs before machine startup.
- Ensured accurate mapping of all I/O points in the ControlLogix PLC program.
- Set up and calibrated VFDs, PID loops, AC/DC motors, and instrumentation for optimal machine operation.
- Verified and fine-tuned HART and analog feedback systems to ensure precise process control.
The Results
DSI’s expertise and hands-on approach provided:
- Increased Operational Reliability: Continuous automation support reduced downtime and optimized system performance.
- Seamless System Upgrades: The Drawframe 13-16 upgrade improved manufacturing efficiency and machine control capabilities.
- Successful Machine Startup: Drawframe 10 was commissioned with properly configured motors, drives, and control loops, ensuring smooth production.
- Future-Ready Infrastructure: The facility now operates with upgraded controls, modernized PLC/SCADA integration, and improved process instrumentation, positioning it for future expansions and efficiency gains.
By combining technical expertise with proactive problem-solving, DSI has helped this textile manufacturer maintain high production standards while modernizing its automation systems. The ongoing success of these projects further solidifies DSI’s reputation as a trusted partner in industrial automation.
