If you attended a Mariners game during the 2018 season on a rainy Seattle day, you were likely thankful for the closed stadium roof overhead that kept you dry. What you may not have known, however, is that the control system operating the roof was recently overhauled with a new, modern control system produced by a partnership between Process Solutions and SASCO.

The Problem

The existing roof control system, which had been in place since the stadium opened in 1999, was using obsolete VFD’s, as well as an antiquated PLC system that was introduced to the market over 30 years ago. Furthermore, both the drives and PLC controllers were no longer supported by suppliers or commercially available.

With the obsolete control system components beginning to fail, the stadium was forced to either pay for costly repairs or search for replacements on the used market. With the Seattle Mariners opening day only five months away, it was decided that the best solution was to build a new, modern control system to have the roof operable in time for the start of the 2018 Baseball season.

The Solution

Process Solutions and SASCO partnered together to design and build a modern control system to operate the 22-million-pound roof. The new control system consists of eight drive panels, each housing a 200HP DC drive, a redundant PLC panel, an operator control station panel, remote I/O racks, and a dedicated PLC panel for manual control of the system. Additionally, to enable the roof to open and close, the roof structure is built on wheelsets that travel back and forth along rail tracks. Process Solutions designed and built control panels to control the wheelset’s braking mechanisms and hydraulic units for raising and lowering spuds. The spuds are essentially large pins for locking the wheelsets in place once the roof’s desired position has been reached. Furthermore, the wheelset panels monitor the travel truck assemblies and provide continuous diagnostics of the roof’s operation. Process Solutions also improved upon the system’s skew control technology, which mitigates the stress induced on the mechanical structures of the roof during transit.

Altogether, the new system is comprised of eighteen new back panels and one controls cabinet combining for eleven PLC’s with 1200 total I/O points, 1600HP worth of drives, and over 55,000 feet of wire. The system also includes more safety features and added redundancy for more reliable roof operation.

Part of what made this project successful was Process Solutions’ partnership with SASCO. While Process Solutions was responsible for the design and build of the new control system, SASCO worked on the demolition and removal of the old system. SASCO was also responsible for installing the new control system at Safeco Field, wiring the panels to the equipment, conducting system power-up, and providing troubleshooting assistance.

SASCO has been involved in numerous projects at Safeco Field with past projects including the installation of the 11,425 square-foot jumbotron, which is the largest in the MLB, as well as the installation of security camera conduit, lighting in the Mariner Moose Den, power for kitchen equipment and various kiosks, the ribbon display boards around the field, and power for the security metal detectors.

Why Process Solutions was Chosen for the Project

Process Solutions’ and SASCO’s staff flexibility and work capacities played an important role in securing the Safeco Field Roof Controls project. With only 5 months before the start of the 2018 MLB season, Process Solutions and SASCO were able to rapidly mobilize a team of engineers, shop technicians, and electricians to work on the project without having to delay or impact the progress of other ongoing projects.

To further save time, Process Solutions built pre-assembled wiring harnesses, along with pre-fabricated back panels, creating a plug-and-play style assembly process.

Finally, Process Solutions’ and SASCO’s demonstrable expertise and knowledge of the existing Safeco Field roof control system, as well as comparable systems from the same era also helped secure the project.

The Challenges we Faced

The Safeco Field project presented Process Solutions and SASCO with unique challenges that needed to be overcome. The main challenge, however, was complying with a tight schedule to meet the needs of the Seattle Mariners opening night and the Stadium maintenance crews.

Another challenge faced during the project was maintaining as much internal infrastructure at the stadium as possible. This included existing field wiring and equipment placement, which meant Process Solutions needed to lay out the new control system’s back panels in a specific way to mesh with the internal structures.

In the end, Process Solutions and SASCO were able to meet all deadlines and overcome each of the challenges faced during the project. This resulted in the delivery of a turnkey control system to Safeco Field that will be supported for many years to come.

About Process Solutions, Inc.

Located near Seattle Washington, Process Solutions is the Northwest’s largest control systems integrator. With 30+ years in business and over 100 engineers and technicians on staff, Process Solutions has the knowledge, experience, and capacity to take on almost any automation project. Process Solutions provides a wide range of automation services, including electrical control panels, PLC and HMI programming, Industrial and collaborative robots, energy management and refrigeration systems, and SCADA and IIOT software. For more information, please visit www.processsolutions.com.  

For more information about SASCO and the products and services they offer, please visit www.sasco.com.

Vaclav Mydlil
Sr. Director of Advanced Automation
Vaclav leads the dynamic Energy Management and Refrigeration Division at Process Solutions. With an impressive 20 years of experience in power demand management and refrigeration control systems, Vaclav is the driving force behind one of the company’s most innovative systems.

His expertise extends to PLC and cloud-based systems, ensuring seamless integration and optimal performance. Vaclav’s commitment to excellence is underscored by his Master of Science degree, specializing in control systems and electrical engineering, which he earned from the University of Life Sciences in Prague, Czech Republic.

Beyond the office, Vaclav’s passions include kayaking, snow skiing, and woodworking. Most of all, he enjoys moments spent with his wife and three kids.
Steve Pelton
Vice President of Sales
With over 20 years at Process Solutions, Steve Pelton has held various roles, including Sales Engineer, Sales Director, and his current position as Vice President of Sales.

In addition, Steve oversees Process Solutions’ Energy Management and Refrigeration Division — ensuring the company remains at the forefront of energy-efficient solutions that cater to diverse food production applications. Steve also spearheads the strategic development of the company’s machine monitoring solutions, aligning them with client needs and market trends.

Steve’s background includes mechanical engineering, but his career trajectory has mainly focused on control systems marketing and management. His ability to bridge technical expertise with business acumen has been instrumental in Process Solutions’ growth.

Outside the office, Steve passions include conquering rugged trails on his mountain bike, perfecting his golf swing, and exploring new destinations with his family.
Matt Barnes
Chief Financial Officer
Matt, with 28 years of financial strategy and accounting experience, plays a pivotal role at Process Solutions. As the Chief Financial Officer (CFO), he spearheads the company’s growth strategy, ensuring financial stability and health.

Beyond traditional financial management, Matt also oversees strategic initiatives aimed at optimizing Process Solutions’ on-hand inventory costs and availability. By fine-tuning inventory management, Matt ensures the company can meet client needs efficiently and maintain a healthy bottom line.

Matt graduated with a degree in accounting from Western Washington University and previously served as a financial executive at a large retail corporation. Outside of work, Matt enjoys traveling, soccer and spending time with his family.
Kevin Orr
Executive Vice President
Kevin boasts an impressive tenure of over 25 years at Process Solutions. His position in the company has been multifaceted, spanning roles as a project engineer, engineering manager, and Process Solutions’ first Executive Vice President.

Under Kevin’s leadership, the food processing division has flourished, earning its reputation as of the most respected in the industry. Today, Kevin closely collaborates with executives from leading food processors and food processing equipment manufacturers across the country.

Kevin is a devoted husband and father with a passion for international travel.
Todd Busby
Chief Executive Officer
Todd has dedicated over 30 years to Process Solutions, where he has worn multiple hats—from panel builder to project engineer and sales representative.

As the CEO of Process Solutions, Todd has spearheaded significant transformations. Under his leadership, the company has diversified into new industries, acquired a world-class facility, and more than doubled its size.

Todd, a native of the Puget Sound region, is a devoted husband, father, and avid outdoorsman. When he’s not at work, you’ll find him supporting his three kids in all their pursuits or hunting and fishing in Eastern Washington.
David Crumpley
David has dedicated over 15 years to Process Solutions, where he has served as a Senior Engineer, Vice President, and now Chief Operating Officer. His multifaceted experience spans technical expertise, strategic leadership, and operational efficiency.

As the head of Process Solutions’ Water/Wastewater division, David orchestrated the modernization of the company’s internal systems and boosted operational efficiency across the organization.

In his current role as President, David continues to drive innovative initiatives aimed at expanding the company’s reach and further streamlining internal processes.

Outside of work, David enjoys spending quality time with his family and pursuing his passions as an avid outdoorsman.

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We provide numerous remote and on-site services to our customers, including software upgrades, troubleshooting, hardware replacement, and feature additions. Our staff size provides us flexibility to quickly respond to standard time frames and emergency service.


Process Solutions provides commissioning services, as well as system start-ups. Our staff will travel anywhere in the world to help you get your system up and running. We start up hundreds of systems per year, and our licensed electricians on staff can pull permits as needed.


Our Engineering and CAD department can create a wide range of documents, including functional specifications, software design documents, test manuals, O&M manuals, P&ID, system drawings, and network drawings. Drawings for FDA level documents are a particular specialty.


Process Solutions software designers are equipped to handle any size job. We structure our program code to be easily read by both customers and engineers, making support and system upgrades fast and easy.


Process Solutions builds over 3,000 panels per year. Our high-volume model makes our technicians experts in the field and provides our customers with an industry leading experience. Efficient manufacturing practices, mixed with automated manufacturing equipment, allows for quick and consistent job completion.


Creation of custom designs for new and legacy systems. All drawings are template based using automatic CAD macros. Our techniques create an efficient design process with recognizable and easy to understand drawings.

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