Wunderlich-Malec is an engineering and systems integration firm founded in 1982 with headquarters in Minnesota. They have 22 offices in the US and an international presence, are 100% employee owned, and serve a diverse set of industries. They specialize in automation projects using Rockwell software including PlantPAx, FactoryTalk, and RSLogix. They emphasize simulation, collaboration, continuous education, and maintaining a diverse client base to ensure stability and growth.

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WUNDERLICH – MALEC
ENGINEERING l SYSTEMS l SERVICES

2. COMPANY OVERVIEW
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Who is Wunderlich-Malec?
•Founded in 1982
•Headquarters in Minnetonka, Minnesota
•Full Service Engineering and Systems
Integration
•Professional Registration in 42 states
•Stability due to:
• Diverse Vertical Markets/Client Base
• 100% Employee Owned Corporation
•22 Offices in the US
•International Presence – LATAM, China

3. APACS to PlantPax
Selection Process
• Moore APACS DCS to PlantPax conversion 2011-2012
• Dissatisfaction with Siemens due to product withdrawal
• Many subsystems with Rockwell PLC 5,SLC,Micro
• Maintenance comfortable with Rockwell
• Close relationship with the local distributor
• WM had previously implemented BOP systems
• Former employees worked at WM client site
• WM/RA Demonstrated reduced life cycle cost vs Siemens
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4. APACS to PlantPax
Project Background
• 5 LM6000 48MW gas turbines
• 1 Three drum Heat Recovery Steam Generator (HRSG) with steam turbine
• 4 Once Through Steam Generator (OTSG) HRSGs with 2 steam turbines
• 3 redundant L75 CLXs with approximately 2500 I/O
• Redundant Factory Talk, Redundant OPC, PDC, BDC, & Asset Centre Servers
• Asset Centre implemented to meet NERC/FERC compliance
• Servers in two locations for disaster recovery
• Narrow conversion window with rewiring to IFMs
• PlantPax objects matched up well with APACS objects simplifying conversion
and significantly reducing implementation time
• Through the use of PlantPax steam tables and energy balance models
provided by OTSG vendor the client was able to reduce the time to bring the
OTSGs on line
• Installed fiber ring around the plant replacing APACS coax

5. APACS to Plant Pax
Network Overview

6. OTSG Steam Table Logic

7. HP Feedwater FB Logic
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8. Sample Screens
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9. LBSM Project
• Fast Track specialty chemical batch project
• Transition from manual pilot to production plant due to high product
demand
• Good relationship with local distributor
• WM demonstrated process and electrical solution expertise
• 4 reactors with associated front end and back end equipment
• Expanded Rockwell content beyond PLC
• H/W included CLX, Versaview HMIs, Rockwell VFDs and MCC
• A proprietary interface to an analytical system critical to the end
point detection of the batch was provided
• PlantPax and LBSM utilizing Phase Manager were implemented
• Approximately 200 I/O

10. System Overview

11. Simulation
• WM builds simulation into every PlantPax project
• Significantly reduces site start up time and cost
• AOIs created for different objects
• VFDs, Motors, Valves
• P_AIN analog inputs
• Psychometric data for air handler models (based on steam tables)
• PID loops based in parametric model (lead, lag, gain, bias)
• Rapid implementation of AOIs
• Extensive fault insertion testing that could not be tested on a
live plant
• Fail to start / stop, Fail to open / close, PV alarms
• Analog simulation runs faster than real time to reduce testing
time
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12. Ladder Simulation
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13. Rockwell Technology
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 Design
 FactoryTalk AssetCentre
 RSLogix 5000/500/5
 HMI
 FactoryTalk View Site Edition (SE) / Machine Edition (ME) /ViewPoint
 PlantPAx
 Logix Batch and Sequence Manager
 Manufacturing Intelligence
 FactoryTalk VantagePoint / Historian
 RSNetWorx for DeviceNet / ControlNet.
 Connected Components Workbench and Drive Explorer for VFD and MCC
configuration.
 GuardLogix

14. INDUSTRIES SERVED
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WME’s stability can be attributed to diverse client base
and industry markets:
• Aviation/Aerospace • Mining
• Building Automation • Medical Device Manufacturing
• Brewery • Oil and Gas – Compressor Stations
• Chemical • Pharmaceutical
• Data Centers • Pulp and Paper
• Ethanol • Semiconductor
• Food Processing • Utilities
• Grain Storage/Export • Warehousing
• Material Handling • Water/Wastewater Treatment

15. Company Culture
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Resources
 Hire the best (industry subject matter experts)
 Retain
 Continuous education (technical universities, vendor training and
industry certifications (CSIA Audit, PMP, TUV, UL)
Collaboration
 Share knowledge and project resources within the company
 Vendor Channel management (invest with channel partners to be
current with new products, steering committee, user groups/forums,
beta testing, etc.)
Growth
 Organic via new business unit locations and products
 Acquisitions

16. COMPANY OVERVIEW
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• Financially Strong
• Revenue Growth +250% since 2009
• Tracking 8% ahead of 2015 goals through 3rd Quarter
• Goal is maintained >5% Growth/Year (rolling average)
• Current Backlog is 55+M. Very Strong.
• Opportunities in Pipeline >100M. Good Diversity.
• Customer Focused
• Over 80% of project work is repeat business, long term customers
• We succeed together. On-time, on-budget solutions set up our
customers to be competitive and grow, which results in the next
project. Long term vision even in small projects.

17. OPERATIONS
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18. Certifications / Organizations
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19.  19Thank You!
WUNDERLICH – MALEC
ENGINEERING l SYSTEMS l SERVICES