Greenway Electric
 





Serving clients throughout
the United States.
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Greenway Electric Inc.
1424 North Mosley
Wichita, Kansas 67214
Office: (316) 263-6189
Fax: (316) 263-4075
 

CEMENT HANDLING AND PROCESSING PROJECTS

Holcim
Holcim (US) Inc. Truck load out facility
Electrical and Control Systems, Allen Bradley ControLogix
Design/Build
Holly Hill, South Carolina

Greenway Electric, Incorporated (GEI) worked with owners and contractors to design and build a cement terminal that had to incorporate new and old control technology. The entire facility control system was a Modicon system that needed to be expanded to handle the delivery of cement to the storage silos and communicate with the new Contrologix system that handled the loadout system, involving approximately 26 motors and 300 I/O points. GEI adopted the customer's standards for control documentation, naming and numbering scheme. GEI performed all the Supervisory Control and Data Acquisition (SCADA) programming using RSView32 as well as the PLC programming using RS Logix 5000 Software. Commissioning of the facility involved communication between the existing facility's control system and the new control system while not impeding daily production.

Titan America
Tarmac Cement Import Terminal Facility
Electrical and Control using Allen Bradley ControLogix
Design/Build
Tampa, Florida

Greenway Electric, Incorporated (GEI) worked in cooperation with the facility owners and contractors to design and build a cement terminal to operate 24 hours per day. The process included the design, assembly, and installation of all the components for lighting, HVAC, and motor and equipment control, involving approximately 28 motors and 320 I/O points with some I/O points distributed remotely. GEI participated and drove the functional description creation, using flow charts, tables and standardized documentation, which became the programmers guide and then transitioned into the Standard Operating Procedure (SOP) for the operators. GEI performed all the Supervisory Control and Data Acquisition (SCADA) programming using RSView32 as well as the PLC programming using RS Logix 5000 Software. GEI then performed the Factory Acceptance Testing (FAT) at our facility for all control panels that were constructed and then onsite with the owners for the program function and data acquisition. Successful commissioning of the entire facility required a ten day, combined effort of builders, programmers, engineers and operators.

Cemex
Cemex Terminal Upgrade
Electrical and Control using Allen Bradley ControLogix
Design/Build
Fort Worth, Texas

The project successfully upgraded a cement terminal. Greenway Electric, Incorporated (GEI) worked with the facility owners to design and build a cement terminal upgrade. A New Allen Bradley SLC 500 system handled the entire facility, involving approximately 21 motors and 280 I/O points. GEI adopted the customer's standards for control documentation, naming and numbering scheme. GEI performed all the Supervisory Control and Data Acquisition (SCADA) programming using Panelbuilder 32 as well as the PLC programming using RS Logix 500 Software. Commissioning of the facility involved communication between the existing facility's control system and the new control system while not impeding daily production.

GRAIN HANDLING AND PROCESSING PROJECTS

DeBruce
DeBruce Grain Elevator
Plant Renovation
Wichita, Kansas

Located in Wichita, Kansas, the DeBruce Grain Elevator is ranked in the Guinness Book of Records as the world's largest elevator under one head house, with a licensed capacity in excess of 29.7 million bushels. This facility has automated handling capabilities enabling one individual to direct grain to 5 million bushels within the facility. Wichita has the capacity to dump 1,000 trucks per day and can unload over 1 million bushels in a 24-hour period.

This location is served by the Kansas & Oklahoma, Union Pacific and Burlington Northern Santa Fe Railroads. The rail load out capacity allows for 100 or 110 cars in a single switch. Situated in South Central Kansas, Wichita originates both farmer owned and elevator owned grain throughout Kansas, Eastern Colorado, and Northern Oklahoma. Wichita provides grain to flour mills, processors, poultry users and ships unit trains to the Gulf and to end users in Mexico.

During a two year renovation period, Greenway Electric provided 13.8 kV Primary Service, 2500 kVA Transformer, Secondary Service, 3000A Switchgear, Motor Control Center, automated control system, facility wiring, lighting and a full plant paging system.

Purina
Land O'Lakes Purina Feed LLC
Control System Upgrade to Allen Bradley ControLogix
Design/Build
Portland, Oregon

This facility was entirely controlled by an obsolete Modicon PLC system with a Repete batching system integrated in the middle of the process. The project required that Greenway Electric, Incorporated (GEI) completely document the process flow and assign new equipment numbers to all existing process components. The project also required research and verification of all existing I/O points. The documentation of the I/O had to be precise so that a replacement plan could be formed that would not interfere with the production requirements of the plant. GEI obtained training and certification on the Modicon PLC platform so that the necessary program modification could be made during the changeover. GEI successfully installed approximately 930 I/O points, test the different sections of the process, perform the PLC programming modifications, then convert to the new platform with no interruption of the operation of the plant.

ADM
Archer Daniels Midland
ADM Milling Company - ADM Grain Company
Electrical and Control System Upgrades
Chicago, Illinois - Arkansas City, Kansas - Hutchinson, Kansas - Ama, Louisiana
Kansas City, Missouri - Enid, Oklahoma - Kingston, Jamaica

Founded in 1902 and incorporated in 1923, Archer Daniels Midland (ADM) is headquartered in Decatur, Illinois, and operates processing and manufacturing facilities across the United States and worldwide. Over the last ten years, Greenway Electric, Incorporated (GEI) has undertaken more than one hundred projects for multiple divisions of this client, including ADM Milling, Jamaica Flour Mills Limited, and ADM Grain. Projects have varied widely in scope and duration and include the rewiring of multiple, 1.0 million bushel Grain Storage Additions to existing elevators, the installation and testing of scale gates, elevators, and generators.

Mennel Milling
The Mennel Milling Company
New Buhler Flour Mill
Electrical Design/Build
Bucyrus, Ohio

The facility was entirely designed by Buhler and equipped with Buhler milling machines. The project required that Greenway Electric, Incorporated (GEI) completely understand the process flow and the functionality of the equipment being supplied. GEI prepared a Functional Description for the entire mill and reviewed with Buhler to meet their process requirements and Mennel's production requirements. GEI then proceeded to design and build the complete electrical control system. When the programming was complete, GEI connected the control system to simulation software and presented the control system to Mennel and Buhler for acceptance and operator training. GEI then successfully installed, tested, and commissioned the mill, meeting everyone's expectations of process control, productivity and safety.

logo anheuser busch
Anheuser Busch
Idaho Falls Malt Plant Expansion Project 3879
Design/Build
Idaho Falls, Idaho

This project maximized plant capacity by taking advantage of existing plant infrastructure and services to add 7.8 million bushels of malt per year. Greenway Electric, Incorporated (GEI), worked with owners and contractors to install the electrical service in the structure to minimize exposed conduits and raceways. The process included the design, assembly and installation of all the components for lighting, HVAC, and motor and equipment control, involving approximately 403 motors and 2200 I/O points. Our firm drove the Functional Description creation, using flow charts, tables and documentation, which became the programmers guide and then transitioned into the Standard Operating Procedure (SOP) for the operators. Greenway performed all the Supervisory Control and Data Acquisition (SCADA) programming using Wonderware as well as the PLC programming using RS Logix 5 Software. Factor Acceptance Testing (FAT) was completed at our facility for all control panels that were constructed and then onsite with the owners for the program function and data acquisition. Commissioning of the entire facility required a joint effort of Builders, Programmers, Engineers and Operators that took four months.