Project Name: Secure Facility Control Panel Upgrade

Facility:
Federal / Government Aerospace Facility
United States

Scope:
Control Engineering, Inc. was selected by Johnson Controls Federal Systems to upgrade and modernize an existing control panel supporting a secure aerospace test environment.
The project focused on replacing aging control components, improving system reliability, and ensuring continued compliance within a federal facility environment.

Work included:

• Replacement of legacy control hardware
• Design and fabrication of upgraded control panel
• Integration of updated PLC platform
• Re-termination and validation of field wiring
• I/O verification and signal testing
• Safety interlock validation
• System documentation and as-built drawings
• On-site commissioning within secure facility constraints

All work was executed under federal access controls and coordination requirements, requiring strict adherence to security protocols and documentation standards.

System:
The upgraded panel architecture was engineered to improve long-term maintainability while maintaining compatibility with existing facility infrastructure.

Core elements included:

• Modern PLC-based control platform
• Updated power distribution and protection components
• Improved I/O organization and labeling
• Industrial-grade enclosure design
• Enhanced serviceability and troubleshooting access

The system was tested and validated to ensure proper interlock sequencing, safe operation, and seamless integration into the existing building or test control system.

Benefit:
The modernization improved reliability and reduced risk associated with aging control hardware.

Key outcomes include:

• Improved system uptime
• Enhanced maintainability
• Clearer wiring and documentation structure
• Compliance with federal facility standards
• Reduced long-term service risk

This project demonstrates CEI's ability to execute control system upgrades within highly secure federal environments while maintaining strict operational and documentation requirements.