Synopsis of Stacker/Reclaimer Drives, PLC, and HMI Upgrade

Situation: A bucket-wheel-style stacker/reclaimer had been in operation at a provincial fossil-fuel-based power generation's facility for close to 15 years. Issue: Wear and tear-related issues limiting stacker/reclaimer performance. Major issues identtified as obsolete traverse, luff, and slew drives (obtaining replacement parts was both challenging and expensive); and limitations to how and when the stacker/reclaimer operations could be switched from "manual" mode to "auto" mode (caused delays to starting up the overall Coal Handling System in "auto" mode). Technology: ABB ACS 800 drives, GE PLC Series 90-70 controller, Modbus Ethernet, ABB PLC, Ethernet, iFIX.

Requirement: Drives, PLC, and HMI upgrade. Brock Solutions' Role: Perform the stacker/reclaimer drives, PLC, and HMI upgrade in two phases: Phase 1: Replace the existing traverse, luff, and slew drives with modernized drives Phase 2: Rewrite and modify the existing PLC code in a new Windows-based environment and add a HMI interface to the existing mechanical-based operator consoles

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