Our Work With DuPont

DuPont Dowtherm Boiler Controls, Chattanooga, TN

FeedForward completed a control system upgrade for DuPont-Chattanooga to control the Dowtherm system boilers and condensate collection tanks. Our scope of supply included Foxboro I/A control system hardware and software, application engineering, factory testing and startup support. The total system includes 200 I/O points, 4 main graphic displays, 100 overlays and 40 controller outputs for various boiler controls. The system has been installed and FeedForward provided the characterization and tuning during startup. The system is now operational in the automatic mode.

DuPont Liquid Crystal Polymer, Reactors, Evaporators and Tank Controls

FeedForward completed a Foxboro I/A Control System for a complex batching process for DuPont’s Specialty Polymers Area in Chattanooga. The system included 4 operator workstations, two I/A controllers and approximately 500 I/O points. The control configuration included recipe management and a unique sequence control strategy. FeedForward’s scope of supply included hardware and software procurement, software and graphics configuration, factory testing and on-site startup support.

DuPont Nylon Flake Handling Controls

This nylon flake handling system modernization used an existing Allen-Bradley PLC network and layered a RSView 32 MMI as a replacement for TCP Smart Screens. There are eight PLC’s, two data server PC’s (one of these runs the RSWorks development software), and eight client PC operator stations. The PC’s and PLC’s communicate on an Ethernet LAN. The system has a hot cutover requirement to substitute bus communication from DH and DH+ to Ethernet. The system has approximately 8000 tags; the system configuration is shown on the attached diagram.

DuPont Engineered Polymer Autoclave Controls

FeedForward has completed a project to convert an existing Autoclave Reactor Process from Modicon 984 PLC’s to ControlLogix with a Wonderware HMI. FeedForward has responsible for implementing a new process description into ControlLogix for regulatory, discrete, interlock and sequence control requirements. The ControlLogix Sequential Function Chart (SFC) method is being used as a master scheduler for the phase step logic for the polymerization process.

FeedForward’s scope of supply includes an upgrade to the existing Wonderware HMI, developing of an overall control system configuration for four reactors, ControlLogix configuration and factory staging and testing. Onsite installation and startup support was also included.