Fliteway TechnologiesFlitewayTechnologies

Automation & Monitoring

Controls & Instrumentation

Fliteway designs and fabricates custom control systems, motor control centers, and instrumentation packages for environmental remediation equipment. With 271+ controls projects completed, our controls engineering team delivers reliable automation, remote monitoring, and UL 508A listed panel assemblies that keep your remediation systems running safely and efficiently.

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Custom PLC-Based Control Systems

Every Fliteway remediation system can be equipped with a programmable logic controller (PLC) based control system for automated operation, safety protection, and performance optimization. PLC control is essential for systems that operate unattended, require precise process control, or must comply with regulatory monitoring and reporting requirements.

Our controls engineers work closely with the mechanical and process design team to develop control strategies that match the specific operational requirements of each project. From simple motor start/stop sequences to complex multi-loop process control with cascading setpoints, we design control logic that maximizes system performance while maintaining safe operating conditions.

Allen-Bradley (Rockwell Automation)

CompactLogix and ControlLogix PLC platforms with Ethernet/IP communication, PanelView Plus and PanelView 5000 HMI touchscreens, PowerFlex variable frequency drives, and Point I/O distributed I/O modules. Programmed using Studio 5000 Logix Designer with structured text, function block diagram, and ladder logic programming.

Siemens

S7-1200 and S7-1500 PLC platforms with PROFINET communication, Comfort Panel and Unified Comfort Panel HMI touchscreens, SINAMICS variable frequency drives, and ET 200SP distributed I/O modules. Programmed using TIA Portal with ladder diagram, function block diagram, and structured control language.

Motor Control Centers and Variable Frequency Drives

Environmental remediation systems rely on motors to drive blowers, pumps, mixers, and other rotating equipment. Fliteway designs motor control solutions that provide reliable starting, speed control, protection, and energy efficiency.

Motor Control Centers (MCC)

Motor control centers consolidate motor starters, disconnect switches, overcurrent protection, and control wiring in a single NEMA-rated enclosure. MCCs simplify installation, reduce field wiring, and provide a central point for motor management and troubleshooting.

  • •Full-voltage non-reversing (FVNR) and full-voltage reversing (FVR) starters
  • •Combination motor starters with integral disconnect and overload protection
  • •Soft starters for reduced inrush current on large motors
  • •Power monitoring (voltage, current, power factor, kWh)

Variable Frequency Drives (VFDs)

Variable frequency drives provide precise speed control for motors driving blowers and pumps. VFD speed control enables process optimization (matching blower speed to extraction demand), energy savings (reducing motor speed reduces power consumption by the cube of the speed ratio), and soft starting without mechanical stress.

  • •Allen-Bradley PowerFlex 525 and PowerFlex 755 drives
  • •Siemens SINAMICS G120 and G120X drives
  • •Sizes from fractional HP to 500+ HP
  • •Line reactors, output filters, and EMI/RFI filtering

Process Instrumentation

Accurate process measurement is essential for system performance monitoring, regulatory compliance, and automated control. Fliteway selects and installs industrial-grade instrumentation appropriate for each measurement application.

Flow Measurement

Magnetic flow meters (for liquid), thermal mass flow meters (for air and gas), vortex flow meters, paddlewheel flow sensors, and ultrasonic flow meters. Totalizing capability for cumulative volume tracking and regulatory reporting.

Pressure Measurement

Pressure transducers and transmitters for system vacuum, discharge pressure, and differential pressure across filters, carbon beds, and other process equipment. Analog (4-20mA) and digital communication output options.

Level Measurement

Float switches, ultrasonic level sensors, capacitance probes, and submersible pressure transducers for liquid level monitoring in tanks, vessels, knock-out pots, and wells. High and low level alarms for overflow prevention and dry-run protection.

Water Quality Analyzers

pH probes and transmitters, oxidation-reduction potential (ORP) sensors, dissolved oxygen (DO) meters, turbidity analyzers, and conductivity meters for monitoring water treatment performance and discharge compliance.

Temperature Measurement

Thermocouples (Type J, K, T), RTDs (Pt100, Pt1000), and temperature transmitters for process temperature monitoring. Critical for thermal remediation systems, blower discharge temperature protection, and catalytic/thermal oxidizer control.

Gas Detection

Photoionization detectors (PID), flame ionization detectors (FID), lower explosive limit (LEL) monitors, and fixed gas detection systems for personnel safety and process monitoring in vapor extraction and treatment applications.

SCADA and Remote Monitoring

Environmental remediation systems often operate at remote locations with limited site access. Fliteway provides SCADA (Supervisory Control and Data Acquisition) and remote monitoring solutions that give operators real-time visibility and control from any location.

Cloud-Based SCADA Platforms

Industrial cellular gateways connect the PLC to cloud-based SCADA platforms via 4G LTE or 5G cellular networks. Operators access system dashboards, real-time data, historical trends, and alarm management through a web browser or mobile application. No on-site network infrastructure or IT support required.

Alarm Notification

Automated alarm notifications via SMS text message and email alert operators to fault conditions, setpoint deviations, and maintenance requirements. Configurable alarm priorities, escalation rules, and acknowledgment tracking ensure timely response to critical events.

Data Logging and Reporting

Continuous data logging captures operating parameters (flow rates, pressures, temperatures, run hours, chemical usage) at configurable intervals. Historical data can be exported for regulatory reporting, performance analysis, and trend tracking. Automated report generation reduces the manual effort required for periodic reporting.

Cybersecurity

All remote monitoring solutions include cybersecurity measures appropriate for industrial control systems. Encrypted cellular communications, VPN tunnels, role-based access control, multi-factor authentication, and regular security updates protect against unauthorized access.

UL 508A Listed Panel Fabrication

Fliteway fabricates control panels in-house at our Cudahy, Wisconsin facility. Our panel shop builds UL 508A listed industrial control panels to exacting standards for quality, safety, and reliability.

  • •NEMA-rated enclosures: NEMA 1 (indoor), NEMA 4/4X (outdoor, watertight), NEMA 7/9 (hazardous locations). Stainless steel, painted steel, and fiberglass options.
  • •UL 508A listing: All panels are designed and built to UL 508A requirements including proper short circuit current ratings (SCCR), overcurrent protection coordination, wire sizing and termination, and labeling.
  • •Quality workmanship: Organized wire routing in wire duct, consistent wire labeling, clear component identification, and professional panel layout. Every panel is inspected and tested before shipment.
  • •Documentation: Complete panel documentation including electrical schematics, wiring diagrams, bill of materials, I/O lists, and UL 508A listing report.
  • •Factory acceptance testing (FAT): Full functional testing with simulated I/O to verify PLC programming, HMI screens, alarm logic, and communication interfaces before the panel leaves our facility.

Frequently Asked Questions

What PLC platforms does Fliteway use?
Fliteway designs control systems using industry-leading PLC platforms including Allen-Bradley (Rockwell Automation) and Siemens. Allen-Bradley platforms include the CompactLogix and ControlLogix families, programmed using Studio 5000 Logix Designer. Siemens platforms include the S7-1200 and S7-1500 series, programmed using TIA Portal. Platform selection is typically driven by client preference, existing facility standardization, or project specifications. Our controls engineers are proficient in both platforms and can provide programming, configuration, and commissioning support regardless of the selected hardware.
Do you provide UL-listed control panels?
Yes, Fliteway fabricates UL 508A listed industrial control panels. UL 508A is the standard for industrial control panels and covers the safety of the panel assembly including proper wire sizing, short circuit current ratings (SCCR), overcurrent protection, and enclosure ratings. Our panel shop builds panels to UL 508A requirements and applies UL listing labels to compliant assemblies. We also build panels to meet additional standards as required by the project, including NEC (National Electrical Code) compliance, NFPA 79 (industrial machinery), and client-specific electrical standards.
What remote monitoring options are available?
Fliteway offers multiple remote monitoring solutions for environmental remediation systems. Cellular-based remote monitoring uses industrial cellular gateways (4G LTE / 5G) to connect the PLC to a cloud-based SCADA platform, allowing operators to view system status, operating data, trends, and alarms from any web browser or mobile device. Modbus TCP/IP and OPC UA communication protocols enable integration with existing plant SCADA systems. Alarm notification via SMS text message and email alerts operators to fault conditions, high/low setpoints, and maintenance requirements. Data logging captures operating parameters at configurable intervals for regulatory reporting and performance optimization. All remote monitoring solutions include cybersecurity measures including encrypted communications, role-based access control, and VPN tunnels.
Can Fliteway integrate controls with existing site systems?
Yes, Fliteway designs control systems that integrate with existing site infrastructure. We support a wide range of communication protocols including Modbus RTU (serial), Modbus TCP/IP (Ethernet), EtherNet/IP, PROFINET, OPC UA, and BACnet. Our controls engineers work with the site owner, general contractor, and other system integrators to define communication requirements, I/O mapping, and interface points. We provide detailed submittals, network architecture drawings, and point-to-point wiring diagrams to ensure seamless integration.
What types of enclosures does Fliteway use for control panels?
Fliteway selects panel enclosures based on the installation environment and applicable electrical codes. NEMA 1 enclosures are used for indoor installations where protection from dust and accidental contact is sufficient. NEMA 4 and NEMA 4X (stainless steel) enclosures provide watertight and dust-tight protection for outdoor installations and washdown environments. NEMA 7 and NEMA 9 enclosures are available for hazardous (classified) locations where flammable vapors or combustible dusts may be present. Enclosure sizing accounts for heat dissipation, component spacing, wire bending radius, and future expansion. Climate control (heaters, fans, air conditioners) is added as needed for temperature-sensitive components.

Discuss Your Controls & Instrumentation Project

Contact our controls engineering team to discuss your automation requirements, PLC platform preferences, instrumentation needs, and remote monitoring objectives. We will design a control system that delivers reliable, safe, and efficient operation for your remediation equipment.

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