96″ × 0.160″ steel processing line · S/N EH-13902 · Tulsa area, OK → Houston, TX. Full relocation methodology: document → de-energize → move → reinstall → prove. Built on the digital twin you are browsing.
This plan governs the deinstallation, transport and reinstallation of a BRANER U.S.A. Cut-To-Length line — serial EH-13902, 96″ wide × 0.160″ gauge — from Tulsa area, Oklahoma to Houston, Texas (~510 highway miles). The operating machine is captured as a digital twin before the first wire is lifted; that twin then becomes the verifiable blueprint for reassembly.
| Field | Data |
|---|---|
| OEM / Type | BRANER U.S.A. — Cut-To-Length steel processing line |
| Line serial | EH-13902 · machine plates MC-13960 / MC-13961 · electrical plate ET-J39542 |
| Capacity | 96″ (2,438 mm) width × 0.160″ (4.06 mm) gauge |
| Power | 480V · 3φ · 60 Hz + 110V control · ≈1,333 HP installed (909 AC + 424 DC) |
| Process train | Coil Car → Decoiler → Leveler → Servo Feeder → Shear → Exit Conveyor → Stacker |
| Control | Allen-Bradley CompactLogix (sole controller) + Yaskawa MP3300iec motion + PanelView Plus HMI |
| Origin | Tulsa area, OK |
| Destination | Client plant — Houston, TX |
The running machine is the only source of truth for its interconnections, parameters and configuration. Stage 01 freezes that truth.
| Type | Description | Circuits | Share |
|---|---|---|---|
| PWR-AC | AC Power 480V | 37 | |
| CTRL | Control 110/120VAC · 24VDC | 16 | |
| PWR-DC | DC Power 500V | 14 | |
| ENET | EtherNet/IP network | 10 | |
| FIELD | Field instrumentation | 10 | |
| MIXED | Mixed power+control | 7 | |
| SIG | Signal (encoder/thermocouple) | 6 | |
| FW | FireWire IEEE-1394 (Parker drives) | 6 | |
| SAFETY | Safety / STO (#16 twisted pair) | 4 |
Evidence status at stage close: 54 CONFIRMED · 27 PARTIAL · 28 TO BE VERIFIED · 1 WARNING. Anything not CONFIRMED becomes an open item (Stage 06).
| TAG | Equipment | Manufacturer / Model | Serial | Ratings |
|---|---|---|---|---|
| MTR-300 | Flattener main motor | UNICO / Reliance RPM AC Inverter Duty | 61812I | 300 HP · 460V 3φ · 355A · 84 Hz base · 2500/4000 RPM |
| MTR-DC-A | Decoiler mandrel DC motor #1 | UNICO DC Mill-Duty Frame 5080 | 35748 | 212 HP · 500VDC · 360A · 1150/1250 RPM · 1,450 lb |
| MTR-DC-B | Coiler mandrel DC motor #2 | UNICO DC Mill-Duty Frame 5080 | 35749 | 212 HP · 500VDC · 360A · blower-cooled |
| MTR-DC-01 | Decoiler/Coiler DC motor ~300 kW | UNICO / Reliance mill-duty | 61921 | 300/224 kW · 460V · 2500 RPM (max 4000) |
| MTR-100 | Exit conveyor motor | Marathon BLUE MAX NVC 445THFS18093AA | WAAA090440 | 100 HP · 460V 3φ · 125A · frame 444TC · PWM VFD only |
| MTR-WEG-125 | Roll motor | WEG NEMA Premium Inverter Duty | — | 125 HP · 460V 3φ · PWM VFD only |
| MTR-LV-60 | Leveler roll motor | Marathon BLUE MAX NVC 405THFS18089A | WAAA090800 | 60 HP · 460V 3φ · 73A · 1178 RPM 6-pole |
| MTR-WEG-10 | Hydraulic pump motor | WEG 01018ET3E0S215TC | 1023389xx | 10 HP · 208-230/460V 3φ · 1760 RPM |
| MTR-BALDOR | Auxiliary motor | Baldor-Reliance XEX Severe Duty (Marine) | — | 1.5 HP · 460V 3φ · 3450 RPM · frame 56C |
| Gearboxes | Detail |
|---|---|
| OCG SA183-7LV | 300 HP · ratio 34.506:1 · S/N 264724 — main leveler/decoiler drivetrain |
| Sumitomo Cyclo CHVJ (×2) | 80.1 HP ratio 11:1 + 26.4 HP cycloidal — rolls/auxiliaries |
| Flender SDN 320 | S/N 304405 · 750 RPM input |
| From | To | Type | Circuits | Critical note |
|---|---|---|---|---|
| P-02 (MCC) | P-01 (Main Panel) | PWR-AC | 1 circuit (L1/L2/L3+GND) | MCC NOT DESIGNED. Entire line blocked until utility service and MCC engineering completed. |
| P-02 (MCC) | P-04 (DC Drives) | PWR-AC | 3 circuits (3× L1/L2/L3) | Dedicated breakers ~400A each (pending MCC design). DC-PWR-03 (Decoiler) motor HP completely unknown. |
| P-02 (MCC) | P-03 (AC890 Rack) | PWR-AC | 1 circuit through TCI reactors | Rack input breaker PENDING. FLA input for rack not calculated. |
| P-02 (MCC) | AC890PX | PWR-AC | 1 circuit | Dedicated breaker size PENDING Parker manual. |
| P-01 (Main Panel) | P-04 (DC Drives) | PWR-AC | 2 circuits (pass-through from MCC bus) | Input: 460V/336.6A 3PH each. Output: 500VDC/412A REGEN. |
| P-01 (Main Panel) | P-03 (AC890 Rack) | SAFETY + CTRL | STO: 6 runs #16 AWG + I/O bundle | STO FIRST function test before any motor. I/O individual conductors NOT mapped. |
| P-01 (Main Panel) | AC890PX | SAFETY | 1 run STO A/STO B | Critical for 300HP flattener motor. |
| P-01 (Main Panel) | P-05 (Console) | SAFETY + ENET | 1 E-stop circuit + 1 Ethernet cable | E-stop field wiring path not individually documented. PanelView IP unknown. |
| P-01 (Main Panel) | DL-205 | ENET | 1 Ethernet cable (CB-0178/CB-1920) | IP 192.168.84.101 CONFIRMED. Only device with documented IP. |
| P-01 (Main Panel) | PF525 #1/#2 | ENET | 2 Ethernet cables | IPs 192.168.182.180 and .118 documented. Machine assignment UNKNOWN. |
| P-04 (DC Drives) | MTR-01 (UNICO S/N 35748) | PWR-DC + SIG | 4 circuits: armature + field + encoder + thermocouple | DO NOT invert polarity A1/A2. Measure field resistance 11.3 ohm. |
| P-04 (DC Drives) | MTR-02 (UNICO S/N 35749) | PWR-DC + SIG | 3 circuits: armature + field + encoder | Parallel field mode: 150V/5.5A. |
| P-03 (AC890 Rack) | Roll Motors #1-#6 | PWR-AC | 6 motor circuits | Motor nameplates PENDING. HP from drive tags only. Cable sizes estimated. |
| AC890PX | MTR-300 (Flattener 300HP) | PWR-AC | 1 motor circuit (U/V/W) | BASE FREQ = 84Hz NOT 60Hz. DPFV blower MANDATORY. |
| P-03 (AC890 Rack) | Internal FireWire Chain | FW | 6 daisy-chain segments | Node sequence MANDATORY: PX(3)→1→4→5→6→7→8. DO NOT modify. |
| P-01 (Main Panel) | JBOX-01 to JBOX-08 | FIELD + CTRL | 10+ field circuits | JBOX-05 = ground distribution (FIRST). JBOX-06 = DANGER label. JBOX-03 high-density. |
| P-01 (Main Panel) | Solenoid Valves | CTRL | 6 solenoid circuits (110/120VAC) | E33 ≠ J33 (open vs closed center). Parker requires 120V not 110V. Continental voltage UNKNOWN. |
| Energy source | Isolation point | Verification |
|---|---|---|
| Electrical 480V 3φ | LS Susol TS800NU 800A main breaker + Eaton RGH 1600A — lock & tag per worker | Absence of voltage verified with CAT III meter at MCC bus and every downstream panel |
| DC bus 500V (drives) | ABB EHDB 360 contactors open + Gould A70P semiconductor fuses pulled | DC bus discharge: wait and measure <50V before touching |
| Hydraulic (Rexroth HPU) | Pump locked out + isolation valves closed | Trapped pressure bled at 4WE/Parker manifolds; gauge at 0 |
| Pneumatic | Lockable shut-off valve | Line purged; gauge at 0 |
| Mechanical / gravity | Decoiler mandrel and leveler head physically blocked | Visual inspection + pull test |
| Control 110/120V | ACME / HEVI-DUTY control transformers de-energized | Measured at secondary |
Click a phase. The work does not advance past a hold point without a signature.
| HP | Phase | Gate | Acceptance criterion | Sign-off |
|---|---|---|---|---|
| HP-001 | F1 | Equipment condition verified | Everything inspected, receiving report signed | PM + Inspector |
| HP-002 | F1 | Nameplate data confirmed | Nameplates match the canonical registry | PM + Historian |
| HP-003 | F2 | Utility service confirmed | 480VAC 3PH available, ≥4,000 A | Licensed electrician |
| HP-004 | F2 | Main grounding system | 4/0 AWG bond, 4 rods, ≤5 Ω measured | Licensed electrician |
| HP-005 | F2 | Main service verified | Main disconnects located and labeled | PM + Electrical Eng. |
| HP-006 | F2 | PNL-10 connected & tested | Disconnect in place, no downstream voltage | Licensed electrician |
| HP-007 | F3 | Panel placement | All panels positioned, level ±0.5° | PM + Supervisor |
| HP-008 | F4 | Power cable installation | All cables per schedule D1, continuity OK | Licensed electrician |
| HP-009 | F4 | Control transformer energization | Transformers energized, voltages within ±10% | Licensed electrician |
| HP-010 | F5 | DC drive cable pulled | 4/0 AWG power + #10 AWG field in place | Licensed electrician |
| HP-011 | F6 | AC drive cable pulled | 350 MCM flattener, roll cables, TCI connected | Licensed electrician |
| HP-012 | F6 | FireWire chain restored | Exact daisy chain: PX–R1–R2–R3–R4–R5–R6 | Parker support + PM |
| HP-013 | F8 | Safety circuit functional | E-stop test: drives de-energize <500 ms | Safety Engineer |
| HP-014 | F10 | Network topology verified | 3 isolated subnets, all pings OK | Network Engineer |
| HP-015 | F11 | Megger complete | All cables ≥1 MΩ @ 500VDC | Licensed electrician |
| ID | Priority | Category | Description | Required action |
|---|---|---|---|---|
| OI-001 | P1 | MCC ENGINEERING | MCC does not exist. No breaker schedule, no bus rating, no utility service data for Houston facility. | Engage licensed PE. Define Houston utility service kVA. Design MCC with full breaker schedule. Verify protection coordin |
| OI-002 | P1 | BREAKER SIZING | CB-001 (ABB D30) confirmed at only 30A. Grossly undersized for 1,335HP system. May be isolation breaker only. | Verify CB-001 function (isolation vs protection). Size proper main breaker for P-01 feed from MCC. |
| OI-003 | P1 | DECOILER MOTOR | Motor HP/V/FLA/Frame completely unknown. Nameplate not readable in any photo. | Photograph decoiler motor nameplate at Houston receiving. Record HP, V, FLA, Frame, RPM, S/N. |
| OI-004 | P1 | HPU MOTORS | HPU Motor #1 (M-10) and #2 (M-11) nameplates unreadable. No circuit info. | Photograph both HPU motor nameplates. Trace circuits back to panel/starter. LOTO before any work. |
| OI-005 | P1 | 12 UNASSIGNED MOTORS | 12 motors confirmed by nameplate but NO panel/drive/starter/cable/route documented: Marathon 100HP, 60HP, 4HP; WEG 125HP, 10HP; TECO 10HP ×2; Baldor 1.5HP; Deco | Resolve via schematic #13951 OR trace each motor back to panel/drive/starter at Houston. |
| OI-006 | P1 | CUT CABLE GROUPS | 8 disconnected cable groups (DISC-01 to DISC-08) with unknown destinations. Includes cut ends, bare copper, contaminated JBs, possible thermal damage. | IMMEDIATE: Insulate all bare copper before transport. At Houston: tone-test EVERY conductor. Label and map. Replace dama |
| OI-007 | P1 | FIRMWARE MISMATCH | PowerFlex 20P #1 runs FW V7.002, #2 runs FW V5.005. Different firmware on identical drives controlling parallel motors. | Contact Rockwell. Determine target firmware version. Update both drives to same FW before commissioning. |
| OI-008 | P1 | ETHERNET IP PLAN | 6 of 9 networked devices have NO documented IP address. Only DL-205 (192.168.84.101) and PF525s (192.168.182.x) confirmed. | Create Houston IP addressing plan for ALL EtherNet/IP devices. Document Hirschmann port assignments. |
| OI-009 | P1 | HIRSCHMANN PORT MAP | Hirschmann SPIDER STX port-to-device mapping not documented. 7+ devices connected but no port assignment table. | Document physical port assignment at Hirschmann switch. Create network topology diagram. |
| OI-010 | P1 | P-01 WIRE DESTINATIONS | Terminal block wire numbers confirmed by audit (01xxx, 5xx/7xx, ICO, Bxxxx series) but field destinations NOT closed. | Obtain schematic #13951 OR tone-test all outgoing conductors from P-01. Priority: ICO series first (safety). |
| OI-011 | P2 | AC890 I/O BUNDLE | P-01 to P-03 I/O multiconductor bundle mapped at bundle level only. Individual conductor-to-terminal mapping missing. | Tone-test each conductor in bundle. Map to specific AC890 I/O board terminals and pins. |
| OI-012 | P1 | TRANSFORMER TAP SETTING | Control transformer ACME supplies 110VAC (Rexroth) and 120VAC (Parker). Houston voltage may differ from Tulsa area. | Verify transformer primary/secondary tap configuration for Houston voltage. Confirm separate taps for 110V and 120V circ |
| OI-013 | P2 | CONTINENTAL SOLENOID | HV-CONT-01 Continental EBA 1CN4-AC — solenoid voltage completely unknown. | Identify valve physically. Measure coil resistance. Confirm supply voltage. |
| OI-014 | P1 | AC890 DC BUS ARCHITECTURE | Parker AC890 rack DC bus architecture (shared vs individual per drive) NOT confirmed. | Obtain Parker documentation for AC890 rack. Confirm DC bus sharing mode. |
| OI-015 | P2 | BLOWER MOTOR SOURCING | Blower motors P/N 303-063 (1HP each, on MTR-01 and MTR-02) — exact panel source (P-01 vs P-04) not confirmed. | Trace blower power cables to source panel. Confirm branch breaker rating. |
| OI-016 | P2 | LIMIT SWITCH CIRCUITS | 4+ Allen-Bradley 802T-AP limit switches confirmed on machine but circuit connections NOT documented. | Map each limit switch to PLC DI input. Document tag, function, and wire route. |
| OI-017 | P2 | THERMOCOUPLE DESTINATION | MTR-01 thermocouple P1/P2 (N.C./N.O.) — destination terminal (PLC input or drive input?) not documented. | Verify thermocouple destination: PLC DI or drive analog input. Confirm N.C./N.O. configuration. |
| OI-018 | P1 | ROLL MOTOR NAMEPLATES | 6 roll motor nameplates NOT photographed. HP values come from drive tags only (75/100/75/25/25/25). FLA not confirmed. | Photograph all 6 roll motor nameplates at Houston. Record HP, V, FLA, RPM, S/N. |
| OI-019 | P1 | SCHEMATIC #13951 | Braner/Delta schematic drawing #13951 referenced but not available. Would resolve majority of unknown wire destinations. | Contact Braner/Delta for schematic package #13951. If unavailable, plan full tone-test campaign at Houston. |
| OI-020 | P1 | FIREWIRE CABLE INSPECTION | 6 IEEE 1394a FireWire cables are IRREPLACEABLE (discontinued standard). No spares available. | Inspect ALL 6 FireWire connectors immediately at Houston receiving. Photograph connector condition. Handle with extreme |
| Step | Phase | Task | Verification | HP | Responsible |
|---|
Progress is saved locally in your browser — use it as a live punch list during the install.