From emergency callouts to complex commissioning with no existing documentation, here’s the real work Tri-Sphyre does for clients across the country.
A selection of current and past engagements across the industries we serve. Every project is different — these represent the range of our work in scope, industry, and the specific problems we were brought in to solve.
Marine Dredging
Currently developing a custom dredge operator training simulator replicating the full HMI and control environment of a cutter suction dredge. Operators will train in realistic scenarios — normal operations, fault conditions, and emergency procedures — with zero risk to the vessel or ongoing production.
Scope: Full simulator development with milestone-based delivery.
Metals & Steel
Full DC-to-AC conversion on a vertical strand caster at a flat-rolled steel facility — replacing legacy DC drives with Siemens S120 drives across two pinch rolls and the dummy bar, along with a new Siemens S7 PLC, ET200SP remote I/O, Wonderware HMI updates, full EPLAN drawings, and a drop-in back panel replacement. Two commissioning engineers on-site for startup.
Scope: Full engineering, panel fabrication, and on-site commissioning. Fixed-price delivery.
Metals & Steel
Relay, contactor, and softstarter upgrade for the caster shear motor controls at a flat-rolled steel facility, including PLC code updates on the existing Siemens PLC and Wonderware HMI updates. Scope designed to eliminate mechanical shock on motor startup, reduce wear on shear components, and improve reliability on the caster line.
Scope: Full upgrade with PLC and HMI updates, one commissioning engineer on-site for 5 days.
Marine Dredging
Ongoing maintenance plans and remote support across two active dredge operations, with field response for drives, controls, and electrical systems as needed. Currently developing a custom HMI system for the site to give operators improved visibility and control over the dredge operation.
Scope: Ongoing maintenance agreements with remote monitoring and priority field dispatch. Custom HMI development currently in progress.
Manufacturing
A critical production drive failed unexpectedly at this manufacturing facility, threatening extended downtime. Tri-Sphyre responded to the emergency callout, dispatched an engineer to site, diagnosed the failure, sourced a replacement drive, and completed installation and commissioning — getting the line back up the same day.
Scope: Emergency callout, same-day diagnosis, drive sourcing, installation, and commissioning. Line back up the same day.
Converting & Nonwovens
Commissioned a new production line for a nonwovens manufacturer that had no electrical documentation on site. Beyond completing the full commissioning, Tri-Sphyre created a complete set of electrical drawings from scratch — giving the client accurate as-builts for the first time and a real foundation for safe maintenance and future upgrades.
Scope: Full commissioning plus a complete electrical drawing package created from zero. No prior documentation existed on site.
Aggregates & Mining
Complete automation overhaul of a lake-based sand dredge in partnership with a leading dredge equipment manufacturer. Tri-Sphyre replaced legacy AutomationDirect controls with Allen-Bradley, upgraded the HMI from AutomationDirect to Ignition, integrated GPS for automated positioning, added winch tension and vibration sensors, ladder angle monitoring, and established remote connectivity for off-site operation capability. New EPLAN electrical drawings delivered for the full system.
Scope: Full electrical engineering, controls programming, systems integration, and commissioning. Delivered in partnership with a leading dredge equipment manufacturer.
Automotive
Multiple service calls to an automotive manufacturing facility in Tennessee for emergency controls response, PLC troubleshooting, and downtime support. Tri-Sphyre has served as the on-call engineering resource for this plant, providing fast response when production is down and building an ongoing service relationship over several years.
Scope: Multiple on-call service engagements for emergency and planned controls support. Active ongoing relationship.
Energy & Utilities
Full electrical design and shop fabrication of control panels for a major energy technology company’s demonstration laboratory. Scope included Siemens S7 redundant PLCs, EPLAN drawings developed to client standards, panel assembly at Tri-Sphyre’s facility, and on-site installation and commissioning at the client’s Alpharetta location.
Scope: Electrical design, panel shop fabrication, and on-site commissioning at client facility.
Energy & Utilities
Developed a custom inventory tracking and management software system for the operations team of a major energy technology company. The application was built to their specific workflow and reporting requirements, giving the team real-time visibility into parts, equipment, and materials without relying on generic off-the-shelf tools.
Scope: Full custom software development built to client’s operational requirements and workflow.
Tell us what you’re working on. We’ll come back with a clear scope, timeline, and budget — no runaround.