Past Projects

Explore some of our proven solutions and successful projects across Engineering, Power, and Automation.

Solar Site SCADA System Development

Saginaw Power and Automation designed, fabricated, and factory-tested a custom SCADA system to support the operation of a solar site. Our team developed and implemented a PLC and HMI program, providing real-time monitoring and control of critical site data. The project also included system delivery, startup, and commissioning, ensuring seamless integration and optimal performance.

Manufacture of Remote Densitometer Skids

Saginaw Power and Automation was responsible for procuring equipment and materials, assembling, and testing six densitometer cabinets for an oil pipeline. The project included internal factory acceptance testing (FAT) to verify system functionality, followed by an independent inspection and testing process to ensure compliance with industry standards and client specifications.

Wound Rotor Motor Secondary Controls

Saginaw Power and Automation designed a custom replacement system for the secondary controls of a dual 500HP wound rotor motor. The PLC-based system receives a start signal from the primary controller, sequentially staging contactors to reduce rotor resistance as each motor accelerates. The new secondary controller is fully interlocked with the primary controller, ensuring seamless operation. Additionally, each contactor is monitored for faults, triggering alarms upon failure. A built-in test sequence allows for contactor cycling, simulating a motor start to assist with troubleshooting and system diagnostics.

Heat Trace Monitoring Panel

Saginaw Power and Automation designed, built, and commissioned a heat trace monitoring panel to protect critical city water and wastewater lines. The PLC and HMI-based system continuously monitors utility power availability and heat trace functionality, ensuring reliable operation. The system also transmits real-time data to the city’s wastewater facility, allowing operators to proactively address any issues and maintain uninterrupted service.

Grain Facility HazMon Integration

Saginaw Power and Automation provided PLC and HMI programming to integrate HazMon (hazard monitoring) sensors into the facility’s control system. The project included PLC programming to connect the sensors to a HazMon Webserver, enabling real-time data collection and monitoring. Additionally, we implemented HMI (Ignition) programming to display sensor status and alarms, ensuring enhanced safety, visibility, and proactive hazard detection.

Manufacture of Remote Valve Control Building

Saginaw Power and Automation oversaw the assembly of multiple control panels and interconnecting wiring for a Remote Valve Control Building. Each completed building underwent a comprehensive Factory Acceptance Test (FAT) to ensure full functionality and compliance with project specifications before delivery.

Pipeline Control System Upgrade

Saginaw Power and Automation upgraded the control system for eight oil pump stations, replacing outdated ControlNet & DeviceNet controls with hardwired and Ethernet connections to enhance reliability and performance. SPA also upgraded the existing Modicon control system to an Allen Bradley system, standardizing the stations and terminals across two pipelines. This included the addition of new HMIs, Allen Bradley PLCs, and the removal of old networking devices, replacing them with modern equipment. SPA handled the design, programming, installation, and commissioning for the project. Upgrades also included new communications equipment, MCC overloads, and motor protection relays, ensuring improved system efficiency and long-term operational stability.

Portable Skid-Mounted Substation

SPA successfully completed the procurement, fabrication, and installation of a Sub skid-mounted electrical system for our Mining Client site. The project included building and delivering enclosures, integrating a Maddox 1000KVA transformer, and installing HV and LV cubicles with Versarupter switches, SEL751 relays, and feeder breakers. Additional scope covered arc flash labeling, relay programming, commissioning, and comprehensive testing, ensuring full compliance with our Client’s specifications.

Relay Retrofit

SPA successfully completed a relay retrofit project at a Pulp & Paper Mill, replacing legacy GE relays with an SEL-751 system at the PGW switchgear location G13. The project included designing and fabricating a replacement relay protection door, integrating new I/O between G5 and G13 relays, and modifying trip settings for improved coordination. SPA provided engineering, fabrication, testing, and startup support, ensuring enhanced system reliability and performance.

Before and After (Left to Right)

FAQ

Yes, we offer comprehensive power system services, including the design, installation, commissioning, testing, and maintenance of electrical systems. Our team can upgrade outdated systems to improve reliability and compliance with current codes and regulations, ensuring optimal performance of your power infrastructure.

Absolutely. Our staff has served in key engineering and project management roles on numerous large capital projects, such as pulp mill expansions, pipeline additions, and new facility control systems. We offer support from project scoping and control system design to commissioning and startup, ensuring successful project execution.

We have extensive experience in designing, building, and testing custom control panels, MCCs, and electrical houses in-house at our fabrication shop. This approach allows us to maintain high-quality standards and provide tailored solutions that meet the specific requirements of our clients across various industries.

Saginaw Power and Automation provides SCADA system integration, programming, and upgrades to enhance process monitoring and control. Our team works with utilities, industrial plants, and energy providers to design and implement custom SCADA solutions, ensuring real-time data acquisition, improved system reliability, and remote access capabilities. We have successfully executed SCADA upgrades for clients requiring legacy system modernization and enhanced automation features.

We have completed Arc Flash Analysis and remediation projects across multiple industries, ensuring compliance with NFPA 70E and OSHA safety standards. Our team conducts onsite electrical system evaluations, short circuit analysis, and coordination studies to identify hazards and recommend protective measures such as proper labeling, PPE requirements, and system modifications. One of our key projects involved conducting a full-facility Arc Flash study for a major industrial plant, mitigating electrical risks, and enhancing overall workplace safety.

Yes! Our engineers specialize in power system analysis, testing, and troubleshooting to help industrial facilities identify and resolve issues related to voltage stability, harmonic distortion, and equipment failures. We have conducted power quality assessments, relay coordination studies, and system performance optimization projects for clients facing unexpected shutdowns and power distribution inefficiencies. Our team provides onsite evaluations and tailored solutions to improve long-term system reliability.

Saginaw Power and Automation specializes in equipment retrofits and system upgrades to modernize aging infrastructure and improve operational efficiency. Our team has experience retrofitting legacy control systems, upgrading power distribution equipment, and integrating new automation technologies without causing major disruptions to production. One of our past projects involved replacing outdated motor control centers (MCCs) and reprogramming PLCs for a manufacturing facility, significantly enhancing system reliability and performance.

Saginaw Power and Automation provides comprehensive commissioning and startup support to ensure new or upgraded systems operate efficiently from day one. Our team collaborates closely with project managers, contractors, and facility personnel to conduct system testing, verify control logic, and troubleshoot any operational issues before full deployment. In a recent project, we assisted with the commissioning of a newly installed power distribution system for a manufacturing plant, ensuring seamless integration and compliance with industry standards.

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