Electrical Documentation Package
CTL Line Electrical — Unified Master Report
Houston Reinstallation & Tulsa New Line Integration — Rev 4.0 — Photo-Evidence Updated
Executive Overview
Unified master reference — 7 documents cross-verified, 25 contradictions resolved, photo-evidence updated. CompactLogix L32E confirmed as sole controller.
110
Circuits
13
Houston Panels
2
Tulsa Panels
9
Field Devices
19 / 24
Confirmed Equip.
2
Conflicts
9
Critical Risks
20
Field Verify Items
1216
Install Hours (est.)
15
Hold Points
937
Evidence Photos
25
Contradictions Fixed
Digital Twin — Matterport 3D Walkthrough61 Scans
Tulsa — New Line Integration (Permanent)
P-01 (Main Electrical Panel) and P-06 (Operator Console) are permanently retained at LEI in Tulsa, Oklahoma. These panels will be integrated into a new CTL line at the Tulsa facility. They are NOT shipping to Houston. This is an independent project.
2
Panels (permanent)
8
Blockers
Houston — Reinstallation Package
All remaining equipment ships from Catoosa, Oklahoma to Houston, Texas. This includes 13 panels, 9 field devices, all drives, and all motors. All original cable is scrap — new cable throughout.
Houston has no control panel and no operator console. P-01 and P-06 stay in Tulsa. What replaces them has NOT been defined.
13
Panels
9
Field Devices
Key Corrections (Rev 4.0)
1TULSA SCOPE: P-01 and P-06 are PERMANENTLY retained in Tulsa for a new CTL line. They do NOT ship to Houston.
2CONFIDENCE LEVELS: Aligned to Excel photographic evidence. Components identified via secondary visual cross-reference + catalog match are marked HIGH PROBABILITY, not CONFIRMED.
3P-01 DESIGNATION: Reclassified from MCC to Main Electrical Panel. P-01 integrates PLCs, safety, and control — not motor starters on a common bus.
4SOLE CONTROLLER: CompactLogix L32E confirmed as sole PLC. ControlLogix 5561, CompactLogix L24ER, DirectLogic 205 DISCARDED — not found in 70+ photos. Inventory error from generic Braner docs.
5MISSING RISKS ADDED: Solenoid voltage mismatch (Rexroth 110V vs Parker 120V), ABB disconnect discrepancy, PowerFlex 20P firmware gap.
6CIRCUIT COUNT: Corrected to 110 total (was shown as 70 in earlier dashboard).
7CUT CABLES CORRECTED: Cables at DISC-01/DISC-06 were cut WITH labels preserved. Cross-reference needed, not tone-test.
8BANNER ES-UA-5A CONFIRMED via Rev 4.0 field photography. Safety relay identity resolved.
9CERUS CMS-32H in EXIT-CONV panel, NOT P-01. AB 140M is in P-01.
Circuit Distribution110 Total
Power-AC
37
HIGH
Power-DC
14
HIGH
Control
16
HIGH
Ethernet/Network
10
MEDIUM
Field Device
10
MEDIUM
FireWire/Fiber
6
CRITICAL
Safety
4
CRITICAL
Signal/Instrumentation
6
MEDIUM
Mixed/Multipoint
7
MEDIUM
Matterport 3D Digital Twin
Navigate the CTL line in full 360°. Use the controls below or interact directly with the model. 61 scans across 7 zones.
Zone Navigation
Entry Zone
Leveler Zone
Control Zone
Drive Zone
Shear Zone
Operator Zone
Exit Zone
Model Info
Model ID: aFuCA21GbN3
Scans: 61
Zones: 7
Source: SPS Coil Processing, Catoosa OK
Polycam Scans
4 LiDAR/photogrammetry scans
High-density 3D mesh for dimensional verification
Tulsa — New Line Integration (Permanent)
P-01 and P-06 permanently retained at LEI, Tulsa. Independent project from Houston.
Permanent destination. These panels will NOT ship to Houston. All circuits scoped “Tulsa” belong exclusively to the new Tulsa line.
P-01 — Main Electrical PanelPermanent
Central controller and power distribution hub. NEMA 12 Hoffman 2-door, ~800 lbs. Sole controller: CompactLogix L32E (CONFIRMED). Previously called MCC but functions as control/distribution panel.
Key Components:
Discarded (not found in 70+ photos):
P-06 — Operator ConsolePermanent
Serial Mismatch: EH-14037 vs main line EH-13902.
Freestanding Braner USA console. 30+ pushbuttons/selectors. Flex I/O 1794-AENT (CONFIRMED). PanelView Plus 600 (HIGH PROB.).
Energization Blockers (8):
1ENC-C enclosure not documented in any drawing
2PowerFlex VFD model not legible in photos
3E-stop circuit trace incomplete
4PLC program not backed up — no recovery if damaged during integration
5SH terminal designation unclear
6K2D relay function ambiguous
7TB K30-K64 terminal mapping incomplete (60+ terminals)
8~100+ cut cables at DISC-01/DISC-06 — labels preserved, cross-reference needed
Missing Information — Tulsa7 Items
1ACME transformer tap position (110/115/120V)
2PLC program backup (L32E) — no recovery if lost
3HMI application backup — no recovery if lost
4Hirschmann port map — 8 ports unmapped
5ABB disconnect nameplate — actual rating unconfirmed
6New Tulsa line specifications — cannot design integration without this
7PowerFlex 20P firmware compatibility (V.5.006 vs V.7.002)
Houston Reinstallation Package
13 panels, 9 field devices, 110 circuits. No installation date communicated.
Houston has no control system. P-01 and P-06 stay in Tulsa. Houston needs a new PLC, HMI, console, switch, and safety relay. None defined.
What Houston Needs to OperateBLOCKING
| Need | Tulsa Has | Houston |
|---|---|---|
| PLC | CompactLogix L32E (stays in Tulsa) | NOT DEFINED |
| HMI | PanelView Plus 600 (stays in Tulsa) | NOT DEFINED |
| Operator Console | P-06 with 30+ buttons (stays in Tulsa) | NOT DEFINED |
| Network Switch | Hirschmann SPIDER II STX (stays in Tulsa) | NOT DEFINED |
| Safety Relay | Banner ES-UA-5A (stays in Tulsa) | NOT DEFINED |
| PLC Program | In CompactLogix L32E | NOT AVAILABLE |
| HMI Application | In PanelView | NOT AVAILABLE |
Installation — 12 Phases1216 Install Hrs (est.)
Phase 1
Receiving & Verification
Check every piece against its identity fingerprint (serial, nameplate, condition). Document damage. Confirm nothing is missing.
Phase 2
Facility Power & Grounding
Connect Houston utility service (480VAC 3PH, minimum 4000A). Install ground rod array (4/0 AWG copper, less than 5 ohms). Connect PNL-10.
Phase 3
Panel Positioning
Move and anchor every panel in its final position. Level to +/- 0.5 degrees. Secure mounting brackets.
Phase 4
Power Distribution
Run all 480V power cables from PNL-10 to every panel. Install and wire control transformers. Verify transformer taps.
Phase 5
DC Drive Connections
Cable the PowerFlex 20P drives to UNICO motors. Armature power: 4/0 AWG per motor. Field winding: #10 AWG shielded.
Phase 6
AC Drive Connections
Cable AC890PX to flattener motor (350 MCM). Cable AC890 rack to 6 roll motors. Restore FireWire fiber chain in exact sequence.
Phase 7
Exit Conveyor Drives
Connect 12 PowerFlex 525 drives to roller motors. Wire SIRCO disconnect. Configure network switch on 192.168.182.x.
Phase 8
Safety System
Wire safety relay STO outputs to all drive STO inputs. Connect E-stop stations. Test: all drives disable within 500ms.
Phase 9
Control Wiring
Connect all PLC I/O, Flex I/O nodes, and junction box terminals. Land every signal wire on its terminal.
Phase 10
Communication Network
Run Cat6 for both Ethernet subnets (84.x and 182.x). Run fiber for SynqNet. Verify three-subnet isolation. Ping-test every device.
Phase 11
Verification & Testing
Point-to-point continuity on every cable. Megger test all power cables (min 1 megohm at 500VDC). Ground resistance. Safety re-test.
Phase 12
Commissioning
Download PLC program. Restore HMI application. Load drive parameters. Run integrated test — start the line and verify every function.
Hold Points15
| ID | Ph | Description | Criteria | Sign-off |
|---|---|---|---|---|
| HP-001 | 1 | Equipment Condition Verified | All equipment inspected, condition report signed | PM + Inspector |
| HP-002 | 1 | Nameplate Data Confirmation | All nameplates match canonical registry | PM + Historian |
| HP-003 | 2 | Utility Service Confirmed | 480VAC 3PH available, >=4000A capacity | Licensed Electrician |
| HP-004 | 2 | Main Ground System Complete | 4/0 AWG main bond, 4-rod array, <=5 ohm | Licensed Electrician |
| HP-005 | 2 | Main Service Verified | Main disconnects located and confirmed | PM + Electrical Engineer |
| HP-006 | 2 | PNL-10 Connected & Tested | Main disconnect in place, no downstream voltage | Licensed Electrician |
| HP-007 | 3 | Panel Positioning Verified | All panels positioned, level +/-0.5 deg | PM + Supervisor |
| HP-008 | 4 | Power Cable Installation Complete | All cables per schedule, continuity verified | Licensed Electrician |
| HP-009 | 4 | Control Transformer Energization | Transformers powered, voltages +/-10% | Licensed Electrician |
| HP-010 | 5 | DC Drive Cable Routed | 4/0 AWG power and #10 AWG field cables in place | Licensed Electrician |
| HP-011 | 6 | AC Drive Cable Routed | 350 MCM flattener, roll motor cables, TCI connected | Licensed Electrician |
| HP-012 | 6 | FireWire Chain Restored | Daisy chain exact: PX-R1-R2-R3-R4-R5-R6 | Parker Support + PM |
| HP-013 | 8 | Safety Circuit Functional | E-stop test: all drives de-energize within 500ms | Safety Engineer |
| HP-014 | 10 | Network Topology Verified | All 3 subnets isolated, ping tests pass | Network Engineer |
| HP-015 | 11 | Megger Testing Complete | All power cables >=1M ohm @ 500VDC | Licensed Electrician |
Equipment Register
24 assets. Confidence aligned to photo evidence.
P-01
CONFIRMEDTULSA
Main Electrical Panel / Distribution + Control
Master Control Panel · Control
P-06
CONFIRMED (exterior) / MIXED (internals)TULSA
Main Operator Console
HMI / Local Control · Operator
P-03
CONFIRMEDHOUSTON
VFD Parker AC890 Coordinated Rack
Drive Enclosure · Drive
P-04-A
CONFIRMEDHOUSTON
AC890PX Flattener Drive Cabinet
Drive Enclosure · Drive
P-04-B
CONFLICT (label) / CONFIRMED (drives)HOUSTON
DC Drive Cabinet (PowerFlex 20P)
Drive Enclosure · Drive
P-05
CONFIRMEDHOUSTON
Shear Control Panel
Zone Control · Shear
P-07
MEDIUMHOUSTON
Auxiliary Cabinet (DL-205 not confirmed)
Zone Logic · Control
PNL-10
CONFIRMEDHOUSTON
Main Power Distribution Panel
Power Distribution · Power
PL-08
CONFIRMEDHOUSTON
Exit Conveyor Control Panel
Zone Control · Exit
EXIT-CONV
CONFIRMEDHOUSTON
Exit Conveyor Drive Enclosure
Drive Enclosure · Exit
ENC-A
CONFIRMEDHOUSTON
Entry Main Control Enclosure
Field Mounted · Entry
ENC-AA
CONFIRMEDHOUSTON
Leveler Field Enclosure
Field Mounted · Leveler
ENC-B
CONFIRMEDHOUSTON
Exit Section Enclosure
Field Mounted · Exit
ENC-D
CONFIRMEDHOUSTON
Leveler Motor Starter Enclosure
Field Mounted · Leveler
PNL-LV-01
CONFLICTHOUSTON
Exit Conveyor Control (Leveler)
Zone Control · Leveler
ENC-LV-01
CONFIRMEDFIELD
Leveler Local Station 1
Field Local · Leveler
ENC-LV-02
CONFIRMEDFIELD
Leveler Local Station 2
Field Local · Leveler
ENC-LV-03
CONFIRMEDFIELD
Leveler Local Station 3
Field Local · Leveler
JB12
CONFIRMEDFIELD
Junction Box 12
Wiring Junction · Entry/Leveler
JB-SH-01
CONFIRMEDFIELD
Junction Box Shear
Field Junction · Shear
JB-SH-04
CONFIRMEDFIELD
Junction Box Shear Zone 4
Field Junction · Exit
JB-LV01
PROBABLEFIELD
Junction Box Leveler Zone
Field Junction · Leveler
JB-SH-02
PROBABLEFIELD
Junction Box Shear Zone 2
Field Junction · Shear
JB-FIELD-01
PROBABLEFIELD
Field Junction Box 01
Field Junction · General
Point-to-Point Circuits
41 of 110 total. All terminal assignments FIELD VERIFY.
| Circuit | Type | Source | Destination | Voltage | Cable | Route | Conf. | Scope |
|---|---|---|---|---|---|---|---|---|
| P-AC-001 | Power-AC | Utility | P-01 Main | 480VAC 3PH | 4/0 AWG x3+GND | Underground duct | 95% |
Houston |
| P-AC-002 | Power-AC | P-01 | P-03 AC890 Rack | 480VAC 3PH | 2/0 AWG x3+GND | Cable tray 3A-3B | 95% |
Houston |
| P-AC-004 | Power-AC | P-01 | EXIT-CONV disconnect | 480VAC 3PH | 1/0 AWG x3+GND | Cable tray 5A-5B | 90% |
Houston |
| P-AC-006 | Power-AC | P-01 TB-70 | PL-08 input | 480VAC 3PH | 4 AWG x3+GND | Conduit 40ft | 85% |
Houston |
| P-AC-007 | Power-AC | P-03 drive | AC890 Roll #1 | 480VAC 3PH | 2 AWG x3+GND | Flex conduit 70ft | 90% |
Houston |
| P-AC-008 | Power-AC | P-03 drive | AC890 Roll #2 | 480VAC 3PH | 2 AWG x3+GND | Flex conduit 70ft | 90% |
Houston |
| P-AC-009 | Power-AC | P-03 drive | AC890 Roll #3 | 480VAC 3PH | 2 AWG x3+GND | Flex conduit 70ft | 90% |
Houston |
| P-AC-010 | Power-AC | P-03 drive | AC890 Roll #4 | 480VAC 3PH | 2 AWG x3+GND | Flex conduit 70ft | 90% |
Houston |
| P-AC-011 | Power-AC | P-03 drive | AC890 Roll #5 | 480VAC 3PH | 2 AWG x3+GND | Flex conduit 70ft | 90% |
Houston |
| P-AC-012 | Power-AC | P-03 drive | AC890 Roll #6 | 480VAC 3PH | 2 AWG x3+GND | Flex conduit 70ft | 90% |
Houston |
| P-AC-013 | Power-AC | PL-08 VFS4 | Leveler motor | 480VAC 3PH | 4 AWG x3+GND | Armored conduit | 88% |
Houston |
| P-AC-014 | Power-AC | PL-08 aux | ENC-AA motor | 480VAC 3PH | 6 AWG x3+GND | Conduit 30ft | 85% |
Houston |
| P-AC-016 | Power-AC | EXIT-CONV | PF525 #1-4 | 480VAC 3PH | 1/0 AWG x3+GND | Cable tray 5A | 88% |
Houston |
| P-AC-032 | Power-AC | Utility | P-05 main inlet | 480VAC 3PH | 4 AWG x3+GND | Conduit 30ft | 88% |
Houston |
| P-AC-034 | Power-AC | P-01 TB-70 | ENC-A disconnect | 480VAC 3PH | 8 AWG x3+GND | Flex duct 50ft | 80% |
Houston |
| P-AC-035 | Power-AC | P-01 TB-70 | ENC-B disconnect | 480VAC 3PH | 8 AWG x3+GND | Flex duct 50ft | 80% |
Houston |
| P-DC-003 | Power-DC | P-01 PSU | Banner ES-UA safety relay | 24VDC | #16 AWG x2 | Shielded 15ft | 94% |
Both |
| P-DC-004 | Power-DC | P-01 PSU | CompactLogix L32E | 24VDC | #14 AWG x2 | Shielded 10ft | 95% |
Tulsa |
| P-DC-008 | Power-DC | P-01 TB-61 | Hirschmann PoE | 24VDC | #12 AWG x2 | Cable 10ft | 93% |
Both |
| CTRL-006 | Control | P-01 L32E | AC890PX via X10 | 24VDC | Multiconductor 4C shielded | 70ft | 90% |
Houston |
| CTRL-011 | Control | P-01 ACME 120V | Rexroth 4WE10E33 #1 | 120VAC | #16 AWG 2C+GND | Armored 40ft | 85% |
Houston |
| CTRL-016 | Control | P-01 ACME 120V | Continental solenoid | 120VAC | #16 AWG 2C+GND | Armored 40ft | 70% |
Houston |
| ENET-001 | Ethernet | Hirschmann SPIDER II STX | CompactLogix L32E | Cat6 STP | Internal conduit | 95% |
Tulsa | |
| ENET-004 | Ethernet | Hirschmann | P-06 Flex I/O AENT | Cat6 STP | Conduit + trench | 88% |
Tulsa | |
| ENET-005 | Ethernet | Hirschmann | PL-08 VFS4-AENT | Cat6 STP | Flex conduit | 90% |
Houston | |
| FW-001 | FireWire | AC890PX Node 3 | AC890 Roll#1 Node 1 | Hybrid 4C fiber/copper | Flex conduit 70ft | 92% |
Houston | |
| FW-002 | FireWire | AC890 Node 1 | AC890 Node 4 | 2-fiber 62.5um | Armored 15ft | 94% |
Houston | |
| FW-003 | FireWire | AC890 Node 4 | AC890 Node 5 | 2-fiber 62.5um | Armored 20ft | 94% |
Houston | |
| FW-004 | FireWire | AC890 Node 5 | AC890 Node 6 | 2-fiber 62.5um | Armored 20ft | 94% |
Houston | |
| FW-005 | FireWire | AC890 Node 6 | AC890 Node 7 | 2-fiber 62.5um | Armored 20ft | 94% |
Houston | |
| FW-006 | FireWire | AC890 Node 7 | AC890 Node 8 + terminator | 2-fiber 62.5um | Armored 20ft | 94% |
Houston | |
| STO-001 | Safety | P-06 E-stop | P-01 Banner ES-UA-5A | 24VDC | #16 AWG 2C safety orange | 3/4 in orange conduit 80ft | 96% |
Both |
| STO-002 | Safety | Banner K1/K2 | 6x AC890 STO A/B at X11 | 24VDC | #16 AWG shielded x6 pairs | Safety conduit 70ft | 95% |
Houston |
| STO-003 | Safety | Banner K1/K2 | AC890PX STO A/B at X11 | 24VDC | #16 AWG shielded | Dedicated safety duct | 96% |
Houston |
| STO-004 | Safety | ENC-LV-02 E-stop | P-01 Banner aux | 24VDC | #16 AWG 2C | Safety conduit 25ft | 94% |
Houston |
| SIG-001 | Signal | FSI HDE-2221 50PPR | L32E HSC | 5VDC pulse | #20 AWG shielded quad | Dedicated conduit 20ft | 88% |
Houston |
| SIG-004 | Signal | MTR-01 thermocouple | PF20P #1 AI | mV DC | Type J TC cable | Dedicated conduit 30ft | 80% |
Houston |
| FIELD-001 | Field Device | JB12 | Entry zone hardwire | 24VDC | Multiconductor #18 AWG | Conduit 50ft | 80% |
Houston |
| FIELD-005 | Field Device | JB-SH-01 | Shear solenoid enable | 120VAC | 2C+GND #16 AWG | Armored 10ft | 90% |
Houston |
| MIX-001 | Mixed | P-06 pushbuttons (30) | P-01 terminal blocks | 24VDC/120VAC | Multiconductor #16 AWG ~60 cond | Armored conduit 80ft | 75% |
Tulsa |
| MIX-007 | Mixed | P-01 PLC output | P-06 stack light | 120VAC | 5-conductor #16 AWG | Armored conduit 80ft | 82% |
Both |
System Diagrams
Architecture, network topology, safety chain, and drive hierarchy. CAD-style reconstructions — NOT original drawings, NOT to scale.
Panel CAD Interior Layouts
CAD-style reconstructions from field photos. NOT original drawings, NOT to scale. Component positions approximate.
Risks & Field Verification
18 risks + 20 FV items.
C-001MCC Non-ExistenceCRITICAL
Houston lacks MCC. $180K+, 16+ weeks. Options: A (new), B (PNL-10 temp), C (rental). Recommended C+A parallel.
OpenHouston
C-002Terminal Block MappingCRITICAL
5-digit Weidmuller numbering not fully mapped across 200+ P-01 terminals.
In ProgressTulsa
C-003FireWire Node GapsCRITICAL
Node 2 unassigned by design. Node 3 = AC890PX (exists). Verify Node 2 position is physically empty.
OpenHouston
C-010Inter-Subnet GatewayCRITICAL
No gateway defined between 192.168.84.x and 192.168.182.x subnets. Must resolve before commissioning.
PendingHouston
C-014FireWire SequenceCRITICAL
Parker AC890 node sequence must be exact: PX→R1→R2→R3→R4→R5→R6. No alternatives. Parker connectors only (8-week lead).
PendingHouston
C-015Safety Design ReviewCRITICAL
Houston E-stop topology not finalized. Banner ES-UA-5A now CONFIRMED. Remaining: STO wiring verification and Houston-specific layout.
Open (Banner resolved)Both
C-004P-05 Password ExposedHIGH
Password '1234' handwritten on panel door. Security risk.
OpenHouston
C-005P-06 E-stop IncompleteHIGH
Button location and path to STO not fully traced from field evidence.
BlockedTulsa
C-006P-04 Designation ConflictHIGH
Two cabinets labeled P-04. Must verify AC890PX vs DC cabinet on site.
OpenHouston
C-008Exit Conv Motor AssignmentsHIGH
12x PF525 motor assignments not confirmed against physical motors.
OpenHouston
C-011Drive Parameters Not Backed UpHIGH
PF20P, AC890, AC890PX, PF525 parameters not backed up. Drive reconfiguration from scratch if lost.
In ProgressHouston
C-013HMI Application RestoreHIGH
PanelView Plus 600 backup not confirmed. Model itself unverified for P-06.
Not StartedBoth
NEW-1Solenoid Voltage MismatchHIGH
Rexroth solenoids 110V vs Parker solenoids 120V. Wrong transformer tap = damage on first energization.
OpenHouston
NEW-2ABB Disconnect Rating ClarifiedHIGH
PARTIALLY RESOLVED: 25A label is ACME transformer secondary breaker (IMG_2167), NOT the ABB disconnect. ABB is separate higher-capacity device (~90-100A). Excel OT60F3 still needs clean nameplate verification.
Partially ResolvedTulsa
NEW-4PowerFlex 20P Firmware GapHIGH
Drive #1 (2011): FW V.5.006. Drive #2 (2021): FW V.7.002. 10-year gap. May need alignment for synchronized DC motor operation.
OpenHouston
NEW-5ACME Transformer Tap UnverifiedMEDIUM
ACME TA-2-81219 confirmed with 110/115/120V taps. Current tap position NOT documented. Controls all solenoid and relay coil voltages.
OpenBoth
C-009DL-205 Integration MethodMEDIUM
EtherNet/IP vs serial integration not confirmed for P-07.
OpenHouston
C-012PLC Program BackupHIGH
CompactLogix L32E program backup pending. L32E is the sole controller — no backup exists. If program is lost, machine logic must be recreated from scratch.
Not StartedBoth
| FV# | Item | Description | Check | Priority | Status |
|---|---|---|---|---|---|
| FV-001 | P-06 Serial Identity | Confirm EH-14037 origin vs main line EH-13902. | Physical ID plate | CRITICAL | Open |
| FV-002 | P-01 OL-to-Motor Mapping | 12+ overload relay mappings. AB 140M is in P-01, Cerus CMS-32H is in EXIT-CONV. | Nameplate cross-reference | CRITICAL | Open |
| FV-003 | P-01 Fuse Mapping | Map all Ferraz Shawmut fuse blocks to circuits. | Trace fuse to device | CRITICAL | Open |
| FV-004 | AC890 FireWire Master ID | Confirm AC890PX node assignment in SynqNet chain. | SynqNet diagnostics | CRITICAL | Open |
| FV-005 | P-06 E-Stop Chain | Complete E-stop trace to Banner and all VFDs. Banner now CONFIRMED. | Ohm continuity, dual-channel | CRITICAL | UNBLOCKED |
| FV-006 | ControlLogix 5561 | DISCARDED: Not found in 70+ photos. Inventory error. L32E is sole controller. | CRITICAL | CLOSED | |
| FV-007 | CompactLogix L24ER | DISCARDED: Not found in any photo. Inventory error. | CRITICAL | CLOSED | |
| FV-008 | DirectLogic 205 | DISCARDED: Not found in any photo. Different form factor would be obvious. | CRITICAL | CLOSED | |
| FV-009 | Banner ES-UA-5A Model | RESOLVED Rev 4.0: Banner logo and safety terminal config confirmed in field photos. | CRITICAL | CLOSED | |
| FV-010 | P-01 Complete Wiring | Full internal wiring documentation for Tulsa new line integration. | CAD overlay + continuity | HIGH | Blocked |
| FV-011 | AC890 Parameter Backup | Capture all 6 AC890 parameter sets before any modifications. | SynqNet export | HIGH | Blocked |
| FV-012 | PLC Program Backups | CompactLogix L32E program backup. No recovery if lost. | RSLogix / Studio 5000 | HIGH | Open |
| FV-013 | HMI Application Backup | PanelView app file for restore. No recovery if lost. | FactoryTalk backup | HIGH | Open |
| FV-014 | Hirschmann Port Map | Map all 8 RJ45 ports to connected devices. | Network scan + MAC | HIGH | Open |
| FV-015 | ABB Disconnect Nameplate | 25A label is ACME breaker, not ABB switch. ABB is ~90-100A. Still need clean nameplate photo. | Clean ABB nameplate photo | HIGH | Open |
| FV-016 | Transformer Tap Setting | Verify ACME TA-2-81219 tap (110/115/120V). Determines all control voltage. | Photo + measurement | HIGH | Open |
| FV-017 | PF525 Motor Mapping | Map each PF525 to its conveyor motor. | Nameplate cross-ref | HIGH | Open |
| FV-018 | ~100+ Cut Cables | Cross-reference existing cable labels at DISC-01/DISC-06 against circuit documentation. Labels preserved. | Label-to-circuit cross-ref | HIGH | Open |
| FV-019 | ACME Transformer Tap Position | Verify current tap connection (110/115/120V). Controls solenoid voltage. | Photo of tap connection | HIGH | Open |
| FV-020 | PowerFlex 20P Firmware Alignment | Verify if V.5.006 and V.7.002 can coexist for synchronized operation. | Rockwell compatibility check | HIGH | Open |
Installation Phases
12 phases, 51 days, 1,216 hours. No date communicated.
Phase 1
Receiving & Verification
Check every piece against its identity fingerprint (serial, nameplate, condition). Document damage. Confirm nothing is missing.
Phase 2
Facility Power & Grounding
Connect Houston utility service (480VAC 3PH, minimum 4000A). Install ground rod array (4/0 AWG copper, less than 5 ohms). Connect PNL-10.
Phase 3
Panel Positioning
Move and anchor every panel in its final position. Level to +/- 0.5 degrees. Secure mounting brackets.
Phase 4
Power Distribution
Run all 480V power cables from PNL-10 to every panel. Install and wire control transformers. Verify transformer taps.
Phase 5
DC Drive Connections
Cable the PowerFlex 20P drives to UNICO motors. Armature power: 4/0 AWG per motor. Field winding: #10 AWG shielded.
Phase 6
AC Drive Connections
Cable AC890PX to flattener motor (350 MCM). Cable AC890 rack to 6 roll motors. Restore FireWire fiber chain in exact sequence.
Phase 7
Exit Conveyor Drives
Connect 12 PowerFlex 525 drives to roller motors. Wire SIRCO disconnect. Configure network switch on 192.168.182.x.
Phase 8
Safety System
Wire safety relay STO outputs to all drive STO inputs. Connect E-stop stations. Test: all drives disable within 500ms.
Phase 9
Control Wiring
Connect all PLC I/O, Flex I/O nodes, and junction box terminals. Land every signal wire on its terminal.
Phase 10
Communication Network
Run Cat6 for both Ethernet subnets (84.x and 182.x). Run fiber for SynqNet. Verify three-subnet isolation. Ping-test every device.
Phase 11
Verification & Testing
Point-to-point continuity on every cable. Megger test all power cables (min 1 megohm at 500VDC). Ground resistance. Safety re-test.
Phase 12
Commissioning
Download PLC program. Restore HMI application. Load drive parameters. Run integrated test — start the line and verify every function.
Evidence Methodology
Two-tier identification: direct nameplate reading (CONFIRMED) + catalog-assisted visual cross-reference (HIGH PROBABILITY).
01
Photographic Documentation
937+ field photographs capturing nameplates, interiors, wiring, drives, and equipment condition.
02
Matterport 3D Spatial Scanning
61 scans creating navigable 360° virtual model for spatial verification and cable routing.
03
Polycam LiDAR / Photogrammetry
High-density 3D mesh scan for dimensional verification and geometric documentation.
04
Direct Nameplate Reading
Tier 1 — CONFIRMED: Legible nameplates read directly from field photos. Highest evidence weight.
05
Catalog-Assisted Visual Identification
Tier 2 — HIGH PROBABILITY: Secondary visual cross-reference from partial markings and form factor, verified against manufacturer catalogs and specification sheets.
06
Cross-Document Verification
7 source documents merged and audited. 25 contradictions identified and resolved.
07
Multi-Source Consistency Review
Internal cross-check of all 7 source documents. 25 contradictions identified and resolved. Methodology documented.
Confidence Classification
| Level | Meaning |
|---|---|
| CONFIRMED | Manufacturer, model, and key specs read directly from nameplate in field photo. |
| HIGH PROBABILITY | Identified via secondary visual cross-reference + catalog match from partial markings, form factor, or serial fragments. Cross-verified against manufacturer databases. |
| MIXED | Enclosure CONFIRMED but internal components span multiple confidence levels. |
| MEDIUM | Existence inferred from system architecture, partial evidence, or single indirect source. |
| CONFLICT | Two or more sources provide contradictory identification for the same physical asset. |
| FIELD VERIFY | Insufficient evidence; requires physical on-site inspection. |
Multi-Source Consistency Review
Evidence IntegrityValidated — two-tier identification method documented
Document Consistency25 contradictions found and resolved across 7 sources
Risk Coverage20 original risks + 5 identified during cross-check
Normative ComplianceReferences NFPA 79, UL 508A, NEC 250, ISO 13849
Construction ReadinessProvides baseline for licensed engineer to produce final construction documents
Document Library & Forensic Archive
Complete project deliverable inventory. 60 documents across 7 categories, plus 58 forensic evidence files.
60
Project Documents
58
Forensic Files
937
Field Photos
61
3D Scans
Final & Unified Reports
8 files
CTL_UNIFIED_MASTER_REPORT_v4_FINAL
DOCX
PDF
P01_FORENSIC_SURVEY
DOCX
PDF
Reporte_Completo_Levantamiento_Panel
PDF
Reporte_Planos_Ingenieria_CTL_BRANER
PDF
AS BUILT JALM Braner Delta Tulsa 2026
PDF
COMPREHENSIVE_ELECTRICAL_REPORT_BRANER_DELTA_CTL_50pp
PDF
Technical & Reconnection Documentation
10 files
ELECTRICAL_RECONNECTION_PACKAGE_BRANER_DELTA
DOCX
PDF
ELECTRICAL_RECONNECTION_PACKAGE_V2
PDF
BRANER_DELTA_ELECTRICAL_REINSTALLATION_PACKAGE
PDF
Braner_Delta_CTL_Line-Electrical_Reinstallation_Package
PDF
DELIVERABLE_4_RECONNECTION_PROCEDURE
XLSX
Procedimiento Desconexion Electrica SPS Catoosa
PDF
PANEL_IDENTIFICATION_RECONNECTION_GUIDE
PDF
POINT_TO_POINT_RECONNECTION_SCHEDULE
XLSX
Forensic Analysis & Audit
8 files
Analisis Forense Electrico Tulsa
DOCX
Auditoria Forense Electrica Braner CTL
PDF
MASTER Forensic Analysis Braner USA
PDF
MASTER Forensic P03 P04 Parker AC890
DOCX
MASTER_FORENSIC_REPORT_COMPLETE
PDF
AUDIT_REPORT_DELIVERABLES_BRANER_DELTA
PDF
CAD Layouts & Engineering Drawings
14 files
P01_Interior_CAD_Layout
PDF
P03_Interior_CAD_Layout_DARK_R01
PDF
P04_Interior_CAD_Layout_DARK_R01
PDF
P06_Interior_CAD_Layout
PDF
P07_Interior_CAD_Layout_DARK_R01
PDF
P08_Interior_CAD_Layout_DARK_R01
PDF
CTL_LINE_COMPLETE_LAYOUT
PDF
PLANO_ELECTRICO_BRANER_CTL
HTML
Diagrama de Cables CTL Braner USA
PDF
HTML
ENCA/B/C/D_Interior_CAD_Layout_DARK_R01
PDF
Junction Box layouts JB-LV/SH series
PDF
HTML Dashboards & Interfaces
8 files
BRANER_DELTA_3D_COMMAND_CENTER
HTML
BRANER_DELTA_3D_NAVIGATION_DASHBOARD
HTML
BRANER_DELTA_RECONNECTION_COMMAND_CENTER
HTML
LEVANTAMIENTO_PANEL_P01
HTML
LEVANTAMIENTO_PANEL_P06_OPERATOR
HTML
LEVANTAMIENTO_PANEL_P07
HTML
LEVANTAMIENTO_PANEL_P08
HTML
CTL_FIELD_CONSTRUCTION_PACKAGE
HTML
Inventories & Matrices
7 files
MASTER_EQUIPMENT_REGISTER_BRANER_DELTA
XLSX
INVENTARIO_MAESTRO_BRANER_DELTA_v1
XLSX
MATTERPORT_PANEL_DOCUMENTATION_MATRIX
XLSX
DELIVERABLE_V2_TRANSFER_STATUS_MATRIX
XLSX
Desconexion_Electrica_SPS_Catoosa
XLSX
Equipment Register_EXPORTED
CSV
P01_P06_Tulsa_Retained_Panels_Final_Tables
XLSX
Administrative & Project Support
5 files
ADDENDUM LOTE3 Panel Braner USA
DOCX
Checklist_Info_Requerida_SPS
XLSX
EXECUTIVE_SUMMARY_BRANER_DELTA
PDF
HOUSTON_REINSTALLATION_READINESS_REPORT
PDF
TULSA_PANEL_INTEGRATION_CHECKLIST
PDF
The forensic archive contains detailed component-level analysis, nameplate identification, junction box documentation, and panel-specific technical evidence reports. Each file is cross-referenced to field photographs.
Panel & Enclosure Analysis
22 files
Junction Boxes & Components
12 files
Nameplate Analysis
3 files
Specific Reports / Technical Nomenclature
20 files
Manifests
1 files
Documentation Scope & Workflow
Overview of the technical documentation process. Origin site: SPS Coil Processing, Catoosa, Oklahoma.
Scope Summary
The project combined on-site field investigation with technical office work to produce a complete electrical documentation package. Field activities included panel inspection, cable routing documentation, junction box review, and photographic evidence collection. Office activities included evidence organization, circuit reconstruction, technical report preparation, CAD-style layout development, and final package consolidation. The resulting documentation supports reinstallation planning, retained-panel integration, and field verification.
01
Planning & Scope Definition
Defined project objective, electrical-only scope, dual-track requirements, and deliverable structure.
02
Field Documentation
Site walkthroughs, panel inspection, cable routing, terminal blocks, drives, breakers, junction boxes, and field cable evidence.
03
Evidence Organization
Downloaded and organized all photos, scans, and files by panel, enclosure, section, and document type.
04
Technical Review
Reviewed photographs individually. Identified devices, matched cable paths, cross-referenced labels, separated power/control/communication paths.
05
Circuit Reconstruction
Reconstructed point-to-point relationships from field evidence. Documented reinstallation risks where traceability was incomplete.
06
Report Development
Individual cable reports, junction box reports, panel reports, forensic analyses. Multi-format deliverables.
07
CAD Layouts & Diagrams
Panel interior layouts, cable routing diagrams, visual technical summaries for reconnection support.
08
Registers & Matrices
Equipment registers, transfer status matrices, point-to-point schedules, retained panel tables.
09
Dashboard Development
HTML-based technical interfaces for structured navigation of the documentation package.
10
Package Integration
Consolidated individual reports into unified packages and reinstallation-focused deliverables.
11
Final Review & Delivery
Formatting, consistency review, technical wording revision, and final export of professional deliverables.
Technical Summary & Practical Utility
Purpose and practical applications of this documentation package.
This package consolidates field evidence, circuit reconstruction, panel documentation, and routing analysis into a structured technical reference. Its primary purpose is to support reinstallation planning, retained-panel integration, and field verification by organizing dispersed evidence into a traceable, actionable format.
Field Risk Reduction
Documented cable routes, panel relationships, and circuit traceability reduce the probability of reconnection errors, misidentified junctions, and undocumented assumptions during reinstallation.
Practical Applications
Supports material planning, missing-item identification, pre-energization verification, and field troubleshooting. Provides a starting point for reinstallation rather than a zero-knowledge condition.
Key Benefits
1Preserves critical technical knowledge that is normally lost when a line is dismantled
2Reduces reconnection errors by documenting routes, destinations, electrical hierarchies, and validation points
3Accelerates the Houston reinstallation by avoiding a zero-start condition
4Supports retained-panel integration in Tulsa by preserving relationships between retained and transferred systems
5Reduces human error during high-stakes electrical reconnection
6Improves safety and traceability across both project tracks
7Provides a modern visual technical foundation for future intervention, audit, expansion, or troubleshooting
Documentation Approach
Rather than producing isolated reports, this package cross-references visual evidence, circuit reconstruction, layouts, schedules, and field observations into a consistent technical structure. The documentation covers not only what existed at the time of the survey, but also what to verify before reinstallation, what components are missing or unconfirmed, and where the critical risk points are. This approach supports field decision-making and reduces the likelihood of reconnection errors during reinstallation.