August 15, 2008: The scope of this project was to upgrade the two control systems associated with an 8-zone rotary furnace. Both the existing TDC 2000 DCS for the regulatory controls and the existing Modicon 484 PLC for the BMS were replaced with two new Allen Bradley ControlLogix based PLC systems. There was also field equipment upgrades for the regulatory control system including the installation of new replacement gas flow control valves, gas and air flow control valve actuators, the upgrade of existing and installation of new flow and pressure measuring instrumentation and the installation of new zone air flow temperature elements. KMH supplied the PLC cabinets, including TSSA requirements for BMS. Both systems were FAT tested with the customer at KMH’s facilities. KMH provided commissioning and startup support, including fuel-air curve development and rotary furnace control loop tuning.