Clayton Control Systems was contacted by a Petrochemical Company with a plant located in the South American country of Chile that manufactures and supplies the majority of chlorine used for the country's water supply system. The chlorine manufacturing plant was severely damaged by a magnitude 8.1 earthquake and it was urgent that repairs be made to restore the plant to operating status. The Main Rectifier Control Panel at the facility had suffered severe damage and it was determined that replacement of the damaged equipment was necessary. The manufacturing facility had a reserve supply of chlorine for only a few months and it became most urgent that the Control Panel be replaced as quickly as possible. Due to the extent of the destruction, the client was challenged with the difficulty of recovering drawings and other documentation for the Control Panel. Minimal information was available, limited to photographs they were able to take of the existing Control Panel and some drawings that were over 30 years old and in the German language. Clayton Control Systems' Engineering team reviewed the photographs and performed some translation of the German instructions, after which we discussed the operation sequence with the client. The result was that we successfully created new drawings and programming that allowed the client to install the new Control Panel with great ease.

The Control Panel produced by Clayton Control Systems was a very complex structure that reduced floor space from seven sections to three sections and updated the client's technology to current state-of-the-art. The new Control Panel contained three (3) Programmable Logic Controller (PLC) Chassis, a Touch Screen Operator Interface Panel, Protective Relaying and Power Monitoring, Selector Switches, and Indicating Lights. The front of the assembly was furnished with a Mimic Bus on the compartment doors to help identify the control operators and correctly identify/execute the correct operating sequence. The Control Panels contained approximately 3.5 miles of control wiring.

Clayton Control Systems designed, manufactured, tested, and shipped this project in less than six weeks.