The lead systems resource at BRiAR-LLC is David A. Knighten (BSEET), who has over 28 years of experience working with electronic
control systems and operator displays. He's also a Navy veteran with two Desert Storm deployments. He's currently pursuing a Master
of Engineering Degree in Systems Engineering at Old Dominion University.
Provided day-to-day electrical and instrumentation systems reliability support in an OSB plant for various nuisance issues and backlog projects.
Migrated the Main PLC's existing, outdated ControlLogix L61 processor to L83E, dramatically expanding system capabilities and improving scan times.
Overhauled the alarm triggers and descriptions on the Main HMI for the ControlLogix PLC as well as the DC Drives PLC-5 to enable a more cohesive strategy for operator alarm management. Under the previous design, all alarms were ignored and no history was provided or maintained.
Developed an interlock, first-out history and status detail HMI page for all motor circuits on the PLC. Previously, the operators had little if any
indication as to what tripped a motor off line or was keeping it from starting.
Instituted a startup routine in the PLC for the Broke Chest Transfer Pump to compensate for the flow transmitter being over 100 feet downstream of the
flow control valve. This alleviated a major upset in the Machine and Stock Chest levels that occurred every time the pump was started.
Completed a construction scope of work and supervised installation of analog speed references to the oscillating wire and felt showers, which previously
had to be manually adjusted at the field panels after every grade change.
Traced out the full topology to update documentation for the Ethernet Process Controls Network and the ControlNet Flex Drives Network.
Completed a construction scope of work and configured the runtime program for a new Panelview HMI screen to be installed at the Size Press.
Overhauled the runtime programs in the FactoryTalk View ME Station PCs (Pulper Area and Main Control Room) and Panelview Plus touch screens (Reel and Winder)
to reconcile obsolete references that had accumulated over the previous ten to fifteen years and were the root cause of slow, fault-prone displays.
Completed a construction scope of work for combining two existing pushbutton stations into one and adding two large LED displays for draw and tension at the calender.
Assisted in troubleshooting various drive-related faults and problems in the Webco Winder. Reviewed, resolved conflicts, and documented the entire Webco Winder PLC program to assist the
mill E/I with troubleshooting future issues.
Provided the electrical scope of work in a mill expansion bid package that included the addition of a new blend chest, a new pulper, and an upgraded switchgear.
Initiated an effort to document all the mill's electrical circuits into CAD drawings, which required the development of new drawing
standards for elementary and loop drawings.
Provided a construction Scope of Work and supervised the electrical installation of a starch supply system
to the tissue machine size press. The construction package included:
Configured and installed a locally networked database using Apache HTTP Server 2.4, PHP 7.1 and MySQL 5.7 on a
64-Bit Windows 10 machine. Developed a custom CMMS (Computerized Maintenance Management System) to provide
the mill with a critically needed server-based reliability tool.
Provided a construction scope of work for the connection of Walchem pH and Hach Turbidity sensors to the
ControlLogix PLC's Flex I/O, as well as specification and installation of an Allen-Bradley alarm station to
annunciate possible environmental compliance issues at the No. 2 Saveall. The scope included
a tasks narrative, new loop drawings, revised I/O drawings, a cable schedule and an I/O commissioning list.
Served as the lead on-site automation engineering resource at a specialty papers tissue mill that appeared to be suffering from years of unconstrained entropy.
Mill equipment included a Yankee dryer, pulpers, DAF savealls, Webco winder, boiler, Measurex MxOpen QCS, and a Parsytec WIS.
Specific tasks included:
Provided TDC configuration night coverage for startup of a Lundberg upgrade to the #7 Evaporator
including instrument commissioning, loop tuning, and general startup support. TDC 3000
configuration duties included graphics development using Display Builder with Native Window as
well as entity builds and edits of regulatory control, digital composite and logic points.
2017: Graphic Packaging International, Inc., Louisiana Mill - West Monroe, LA
Provided a construction Scope of Work to support the replacement of a relay-based Forney burner
control system and gas train on a Foster-Wheeler Power Boiler with new John Zink Hamworthy
burners, Skotch and Jamesbury block valves, and Coen BMS. The construction package included:
Provided night coverage as the redundant ControlLogix BMS resource in support of a Recovery
Boiler startup following a DCS upgrade from TDC 3000 to Delta V, involving assistance with
loop commissioning and development of peer-to-peer communications as needed.
Provided TDC configuration to support the installation of a new starch cooker as well as
modifications to existing equipment during a routine maintenance outage. TDC 3000
configuration included graphics development with Picture Editor; numerous entity builds and
edits for regulatory control, digital composite, device control and logic points; and
edits of various History Module entries. A checklist procedure for regular system backups
was also provided to assist mill personnel whenever qualified TDC support is unavailable.
2017: Graphic Packaging International, Inc., Louisiana Mill - West Monroe, LA
Provided an electrical construction Scope of Work for installation of a natural gas Legacy
Technology IR Heater on the #6PM 2nd Rod. The construction package included:
Georgia Pacific Crossett Paper Operations - Crossett, AR
Provided instrument specification for a new Weak Black Liquor Heat Exchanger.
Weyerhaeuser - Port Wentworth, GA
Provided Process Controls support to include TDC configuration and CAD logic drawings of existing power house, pulp mill, and pulp machine interlock bypass logic.
Big River Rice and Grain - Mer Rouge, LA
Provided a PanelView replacement upgrade for the dryer.
Domtar - Ashdown, AR
Provided design and configuration of a temporary PanelView operator station for the No. 2 Recaust BMS, an Allen-Bradley PLC-5, during a control room rebuild.
WestRock - Hodge, LA
Provided design and calibration procedure for a new load cell tension controller on paper Machine No. 5 Winder.
WestRock - Hodge, LA
Provided design of a Power Relay Modbus TCP network as well as a scope of work to move an existing ControlLogix PLC to a new enclosure along with the supportive communications hardware for both the existing process controls network and the new power relay network.
Enable Midstream Unionville Compressor Station - Lincoln Parish, LA
Provided instrument specification and CAD drawings to update an existing horizontal blowdown level control during a compressor upgrade.
Clearwater Paper Corp - McGehee, AR
Converted TDC 3000 graphics to Experion PKS format for the planned upgrade on the Paper Machine No. 1 Wet End.
Armstrong Flooring - Warren, AR
Provided ControlLogix PLC and PanelView configuration to support a complete sawmill conveyor system redesign.
Domtar - Ashdown, AR
Provided electrical Scope of Work including CAD drawings, cable schedule and narrative description for a hydraulic skid replacement in No. 3 Wood Yard.
Georgia Pacific Crossett Paper Operations - Crossett, AR
Provided CAD documentation of an industrial radio communications project for the clarifier and other remote locations.
Georgia Pacific Crossett Paper Operations - Crossett, AR
Provided instrument specification and design for a new dryer can in the Paper Machine C3 Rebuild Implementation project.
Graphic Packaging International - West Monroe, LA
Provided CAD drawings and Experion configuration for a new Rod Coater at the 1st Rod on Paper Machine No. 7, including peer-to-peer with a new ControlLogix. Also included was a new Dry End I/O cabinet and network switch for the Experion.
Clearwater Paper Corp - McGehee, AR
Provided peer-to-peer interfaces between the Utilities Experion PKS and a new ControlLogix Recovery Boiler BMS, and between the Experion and a new ControlLogix for Turbine Generator No. 5, to include new Experion graphics and control modules for each.
NRG - Sterlington, LA
Assisted with general troubleshooting and configuration of a GE Fanuc PLC with WonderWare HMI for an eight-unit Gas Turbine Generator station.
Tennessee Gas Pipeline Co. - Herkimer, NY
Assisted with development of Station Control Panel design with CAD drawings and Bill of Materials as part of the Station 245 Compressor Replacement.
GP Chemical, LLC - Crossett, AR
Provided electrical contractor Scope of Work to include CAD drawings, I/O list, cable schedule and narrative description for a new Fike Dust Conflagration system.
Graphic Packaging International - West Monroe, LA
Provided CAD drawings and Experion PKS graphics and controls configuration, including the development of a new Modbus TCP interface, for a new Hydrogen Controller being installed on Turbine Generator No. 5.
Domtar - Ashdown, AR
Assisted with development of Functional Specifications for all loops and equipment affected by the planned No. 3 Recaust DCS Upgrade.
Georgia Pacific Crossett Paper Operations - Crossett, AR
Assisted with drawing review for 10A Boiler DCS Upgrade Detailed Design.
Graphic Flexible Packaging - Pine Bluff, AR
Evaluated the existing Lime Kiln Burner Management System, an Allen-Bradley SLC-5/05 PLC, for conformance to existing code and minimum requirements for a proposed upgrade to Rockwell ControlLogix.
Clearwater Paper Corp - McGehee, AR
Provided programming modifications required for the Paper Machine No. 1 Wet End Logic Manager in a plan to split one overloaded LM into two smaller ones.
Graphic Packaging International - West Monroe, LA
Provided Experion PKS controls and graphics configuration as well as startup support for a new Base Cleaner System on Paper Machine No. 6.
Koch Nitrogen - Sterlington, LA
Assisted plant electrical and instrumentation personnel with general troubleshooting of system faults related to the Modicon PLCs and HMIs for the Shipping and Pipeline areas, and configured new changes required by various MOC documents.
Certainteed Meridian Ceiling Plant - Meridian, MS
Assisted with CAD loop drawings and instrument specifications for plant overhaul.
Georgia Pacific - Crossett, AR
Assisted mill with configuration on the No. 1 Mill Coater Kitchen Upgrade. The upgrade consisted of installing a GAW coating system. The configuration was done on a DeltaV platform.
Graphic Packaging International - West Monroe, LA
Assisted mill with electrical design and Experion DCS configuration with multiple ControlLogix PLC peer-to-peer interfaces for a paper machine coater overhaul and upgrade.
Graphic Packaging International - West Monroe, LA
Assisted mill with CAD loop drawings and instrument specification for modifying existing pH loops on a paper machine.
Graphic Packaging International - West Monroe, LA
Assisted mill with Experion DCS configuration of a SCADA MODBUS interface to new air compressors with vendor-supplied controllers.
Graphic Packaging International - West Monroe, LA
Assisted mill with Experion DCS configuration of a SCADA MODBUS interface to new hydrogen controls with vendor-supplied controllers on No. 5 and No. 6 Turbine Generators.
Domtar - Ashdown, AR
Provided review of existing No. 2 and No. 3 Kiln Burner Management Systems to address deficiencies against current code requirements.
Graphic Packaging International - West Monroe, LA
Provided electrical design and scope of work for a new broke surge tower.
Graphic Packaging International - West Monroe, LA
Led the migration of Recovery Boiler No. 5 DCS from TDC 3000 to Experion PKS r410.
- Created construction drawings and scope of work for electrical contractors.
- Installed/Configured Operating Systems and EPKS software on stations and servers.
- Configured C300 controllers, FTE network switches, multiple PLC Peer-to-Peer connections.
- Translated points, program routines, controller interfaces from "TDC World" to "EPKS World".
- Assisted the team with converting TDC schematics to Experion graphics for the operator HMI.
- Configured existing TDC HPM I/O for direct integration to Experion PKS.
- Performed checkout, provided startup support, developed "As Built" documentation.
Graphic Packaging International - West Monroe, LA
Assisted mill with meeting new safety and operational requirements as specified by FM Global.
Graphic Packaging International - West Monroe, LA
Provided controls upgrade on Honeywell TDC 3000 for a lime kiln air flow and pressure control.
Graphic Packaging International - West Monroe, LA
Provided controls upgrade for the High Pressure Power Boiler (HPB).
- Provided graphics and control module configuration on Honeywell Experion PKS for the addition of HPB damper controls, moving numerous pneumatic single-loop controllers to DCS.
- Provided design and configuration of the HPB BMS upgrade on a Rockwell ControlLogix platform including peer-to-peer connection to the Experion for HMI.
Graphic Packaging International - West Monroe, LA
Configured Allen-Bradley ControlLogix PLC for controls upgrade of an Anion/Cation system.
Tubbs Rice Dryers, Inc. - Mer Rouge, LA
Configured Allen-Bradley SLC-5/03 PLC and PanelView 900 HMI for a new continuous dryer addition, to include conveyors, bucket elevators, gates, augers, airlocks and fans.
GP Chemical, LLC - Crossett, AR
Provided design, specification, drawings and electrical scope of work for a new hot water injection system on a process kettle.
Tubbs Rice Dryers, Inc. - Mer Rouge, LA
Configured Allen-Bradley SLC-5/03 PLC and PanelView 1000 HMI for changes to a large conveyor and storage system.
Graphic Packaging International - West Monroe, LA
Provided short-term full time on-site support as a Process Controls Engineer for the Recovery, Power House, and Caustic/Lime Kiln Areas.
Graphic Packaging International - West Monroe, LA
Configured Honeywell Experion PKS graphics, instrumentation and control modules for installation of a heating system on a demineralized water supply.
Graphic Packaging International - West Monroe, LA
Configured Honeywell Experion PKS to communicate via SCADA to a Recovery Boiler Rapper Control MODBUS interface.
Koch Nitrogen - Sterlington, LA
Provided specification, design, and drawings of a Motor Control Center replacement.
Graphic Packaging International - West Monroe, LA
Configured Honeywell Experion PKS for SCADA interface to a new DaVinci paper machine dry end scanner control system.
Graphic Packaging International - West Monroe, LA
Configured Honeywell Experion PKS graphics and SCADA interface for display of First Outs in a Recovery Boiler Flame Supervisory and Safety System.
Orange County Container Group - Forney, TX
Assisted with DCS replacement from MeasureX MXOpen to Honeywell Experion PKS, configuring graphics and converting a textual export of the existing control modules to a format legible for duplication in Experion.
Graphic Packaging International - West Monroe, LA
Configured graphics, instrumentation and control modules in Honeywell Experion PKS for DCS upgrade of a multiple-effect evaporator and concentrator, and led the concurrent upgrade and expansion of the existing Recovery Area DCS.
Graphic Packaging International - West Monroe, LA
Configured Current First Out and First Out History for multiple NCG headers in an Allen-Bradley PLC-5, and configured SCADA interface to Honeywell Experion PKS to display trips, first outs, and other related alarms and information to NCG Incinerator operators.
Graphic Packaging International - West Monroe, LA
Made customer-requested revisions to Master Fuel Trip interlocks in a Recovery Boiler Burner Management System, updating Instrument Loop and Logic Drawings as required to reflect the changes.
Tennessee Gas Pipeline - El Paso, TX
Designed electrical interface wiring between multiple compressor control panels and vendor PLC from separate vendors for natural gas compressor stations in New Jersey and Pennsylvania, to include maintaining interconnect wiring diagrams through numerous design changes and field updates.
Southeast Supply Header, LLC - Shreveport, LA
Assisted with design and configuration of natural gas compressor station PLC programs in Louisiana and Mississippi.
ISP Polymer - Paducah, KY
Configured Sequential Control Modules and graphics in Honeywell Experion PKS to allow batch process automation, trained on-site personnel for maintaining existing sequences and configuring any new ones that plant operations may require.
Southeast Supply Header, LLC - Shreveport, LA
Designed electrical interface wiring between multiple compressor control panels and vendor PLC from separate vendors for a natural gas compressor station in Louisiana, to include maintaining interconnect wiring diagrams through numerous design changes and field updates.
Spectra Energy - Houston, TX
Designed electrical interface wiring between multiple compressor control panels and vendor PLC from separate vendors for a natural gas compressor station in Mississippi, to include maintaining interconnect wiring diagrams through numerous design changes and field updates.
Solvay Advanced Polymers - Port Bienville, MS
Configured Sequential Control Modules and graphics in Honeywell Experion PKS to allow batch process automation, trained on-site personnel for maintaining existing sequences and configuring any new ones that plant operations may require.
Graphic Packaging International - West Monroe, LA
Provided Honeywell Experion PKS graphics and control module configuration and revision for changeover of Paper Machine Wet End controls, including refiner configuration, from a conventional hardwood and pine mix to a pine-only stock supply system.
CenterPoint Energy - Shreveport, LA
Proofed Cause and Effect Documents, designed electrical interface wiring between multiple compressor control panels and vendor PLC from separate vendors for multiple natural gas compressor stations in Oklahoma, Louisiana and Arkansas, to include maintaining interconnect wiring diagrams through numerous design changes and field updates.
Graphic Packaging, International - West Monroe, LA
Led the creation of a Black Liquor Recovery Boiler Burner Management System:
- Developed Logic Drawings and programmed a new Allen-Bradley ControlLogix redundant processor system to serve as a BMS using BLRBAC, NFPA and FMGLOBAL guidelines and requirements.
- Configured a SCADA interface to the existing Honeywell Experion PKS Control System and constructed a graphic interface allowing the Experion to serve as the BMS HMI.
Graphic Packaging International - West Monroe, LA
Provided graphics and control module configuration for upgrade of PM1 controls from pushbuttons, relays and single loop controllers to Honeywell Experion PKS.
NRG Energy Corporation - Sterlington, LA
Specified, built and installed upgraded computer hardware for replacing an existing WonderWare HMI platform integrated with GE Fanuc PLC’s at a secondary power turbine generator facility, upgraded a WonderWare version 7 system to version 10.
Domtar - Ashdown, AR
Provided programming modifications to an existing Allen-Bradley PLC-5 with PanelView HMI for installation of a new Roll Doctor on 64PM Top Calender Roll.
Corrugated Systems Incorporated - Forney, TX
Led the creation of a DCS for a new boiler.
- Configured redundant Servers, Stations and Fault Tolerant Ethernet for a new Honeywell Experion PKS Control System on a new wood-fired Boiler.
- Built Control Modules in the Control Execution Environment, designed graphics, implemented a SCADA interface to an Allen-Bradley CompactLogix BMS with PanelView HMI.
Potlatch Corporation - McGehee, AR
Provided design and implementation of a replacement control system for the Lime Kiln Burner Management System, allowing the addition of Petcoke as a fuel source. Programmed ControlLogix PLC, assembled cabinet.
Guide Corporation - Monroe, LA
Provided on-site support as a senior manufacturing engineer.
- Provided troubleshooting and repair support as well as design improvements for multiple headlamp assembly lines and a UV lens spray coater which incorporated Adept and Fanuc 4-Axis and 6-Axis Robots, Keyence and Banner Camera Vision Systems, Allen-Bradley PLC-5 and SLC-500 PLCs with PanelView interfaces utilizing Data Highway and Data Highway Plus communications.
- Developed Rockwell RSView alarm monitoring applications with Allen-Bradley InView message displays.
- Interfaced Bar Code scanners and label printers to PLCs utilizing Allen-Bradley "BASIC" modules.
- Supported programming and maintenance on Weber automated screwdrivers, Nordson hot melt systems, and Bosch conveyors.
Graphic Packaging, International - West Monroe, LA
Provided on-site support for multiple projects:
- Configured Control Modules and HMI graphics for the No. 4 Recovery Boiler DCS migration from TDC 3000 to Experion PKS.
- Added configuration for new refiners on the paper machine TDC 3000.
- Provided a complete overhaul of all Experion PKS graphics in the Power House area.
Green Bay Packaging - Morrilton, AR
Configured and designed graphics on an Allen-Bradley PanelView 1000 Plus to serve as HMI for a SLC-5/04 in a Black Liquor Safety System.
ANGUS Chemical - Sterlington, LA
Provided programming and configuration for new product development utilizing existing Allen-Bradley SLC-5/04 and PLC-5 platforms, including several Allen-Bradley PanelView 1000 Plus HMIs.
Domtar - Ashdown, AR
Provided logic design and Allen-Bradley PLC-2 programming of the Burner Management System and electrical system design support for adding fuel oil to the No. 3 Lime Kiln.
KOCH Nitrogen Sterlington, LA
Provided control system design and construction drawings for a new nitrogen storage and delivery terminal involving a new Modicon PLC with Magellan HMI, including fiber-optics and wireless communications media.
CenterPoint Energy - Shreveport, LA
Assisted with selection, design and assembly of control system hardware for multiple natural gas compressor stations in Oklahoma, Arkansas and Louisiana.
Mississippi Polymer Technologies - Port Bienville, MS
Provided long-term design and configuration services:
- Designed, specified materials, built control system cabinets, modified elementaries and wiring diagrams, estimated plant electrical loads, configured Honeywell Experion C200 controllers and completed installation for new and existing industrial control systems.
- Provided extensive on-site support to repair and restart the facility following Hurricane Katrina in 2005.
- Gained extensive introductory experience to Honeywell Experion PKS r210 configuration, noted for expertise in building Sequential Control Modules and associated explanatory HMI graphics.
May 1999 to Nov. 2004: Potlatch Corporation - McGehee, Arkansas
Employed as a Direct-Hire Engineering Resource:
- Began as Electrical Engineering Technician, supporting Senior Project Engineers on large power and instrumentation work orders, serving as project manager for selected capital projects;
- Promoted to E/I Reliability Engineer for the Paper Machine and Extruder, providing design support for repair- and upgrade-related work orders not requiring capital expenditure approval;
- Promoted to E/I Reliability Planner for the Pulp Mill and Power House, developing repair work order packages with kitted parts; designated as the backup Power House E/I Supervisor.
Sep. 1989 to Sep. 1995: U. S. Navy - Norfolk, VA
Enlisted as a Control System Technician:
- Operated, maintained, and repaired a dual-radar Gun Fire Control System in the Navy's Advanced Electronics Field during two Middle East deployments in support of Desert Storm;
- Successfully served in various collateral duties including Combat Systems Department Administrative Assistant, Work Center Repair Parts Administrator, Work Center Supervisor, Gun Division Training Coordinator, Gun Division Lead Petty Officer, and Ship's Duty Master-At-Arms;
- Volunteered for armed boarding teams during Gulf War I in the Red Sea and Persian Gulf, inspecting merchant vessel cargo to enforce U.N. sanctions against Iraq.
