The following are some past projects undertaken categorised in reverse chronological order. For the most recent projects and those still underway please look at our News page. Follow the links to jump to sections grouped by company.
Egbert Systems Ltd___ DNC Electronics Ltd___ Schneider Electric___ Simon Engineering Group
Projects with Egbert Systems Ltd [Job title - Software Project Engineer] (next)
We travelled to West Meath in the republic of Ireland for Atkins Fulford Hydro to investigate a problem with the microfiltration system. The system is controlled with three micro PL7 PLCs, one for each of the two filters and one that acts as a master control. The problem turned out to be that both feed pumps were kept running should one of the filters fail. This was modified and tested.Moulding Cell at Proseat (Woodbridge)
Over the summer of 2007 we assisted Daval Controls Ltd. at Proseat (Woodbridge) with an upgrade to their moulding line 2. The control system we modified is the existing Rockwell 5/05 which has a RSView32 SCADA connected to it over Ethernet. The plant was being increased in size (22 to 35 moulds) with other equipment being controlled from a Schneider PLC as well as the Fanuc robot control.IWSS
We have completed the development and commissioning of an IWSS (Isokinetic Wellhead Sampling System) rig used to increase the accuracy of the Vx flowrate measurements in wet gas conditions for Schlumberger in Aberdeen. The system uses TwinCAT with a C# (.NET) control engine and includes Profibus and Modbus networks. It is intrinsically safe and EX certified. This was an protracted project that required travelling to Aberdeen for a week at a time to suit the project mechanical/electrical status as well as financial allocation and the re-assessment of overall design after the project was let down by the original software designer.Robot Cell Control with Kuka
We have now completed commissioning of two Kuka robot cells with Daval Controls Ltd. Both controls use Siemens S7-300 PLCs and HMIs on a profibus network. One is to control and schedule the loading and cleaning of bolsters and die holders for an extrusion press in Hereford. The other is to manage and control the hemming of automobile boots and bonnets. Modifications to the original design were requested to the press loader robot sequences to improve cycle time and encorporate operational changes the following year.Layah
We designed, coded and FAT tested an SLC system for water channel cleaning with bandscreens in Layah.Electron Beam Welding at Rolls Royce
We supported Fusion Technologies Ltd in Bristol with their installation of an electron beam welder at Rolls Royce, Hucknall. The CNC and operator front end are bespoke software and the machine interface is a Siemens step 7 with Profibus network and distributed I/O.Motney Hill Inlet Works
We have re-written the inlet works control software to include a second washwater channel that included re-sequencing the screens and subsequently the addition of isolation penstocks. This is an SLC500 system.Overall Marking Machine
We have completed the development of a PC controlled industrial printing machine for Aluminium slab at ALCOA Kitts Green. The control is achieved using the TwinCAT I/O system and programs written in .NET framework and C#.Aggregate Industries
We have modified the block bar coder machines for specific feed rates and counts due to the unreliability of the current gap detection system at Aggregate Industries, in Calne. The controller is an SLC 5/01.West Ham & Inverasdale Water Filtration
We have completed the West Ham six filter Micro Filtration project (an SLC 500 system with a Panelview+ HMI) and a single filter installation at Inverasdale (an SLC 500 system with no HMI).Mater Dei Hospital
We have completed an order for the design and delivery of a BMS system for Block C of the new hospital at Mater Dei, Malta with ESI. We have submitted panels C01_CC1/CP1_CC1, C02_CC1, C03_CC1, C04_CC1, C05_CC1, C06_CC1, C07_CC1, C07_CC2 C08_CC1 & CP2_CC1. Each panel had a Siemens 300 PLC and an HMI using WinCC. Masterdrive (pump control) and Simocode (fan control) units were linked over Profibus and an ethernet network connected all the PLCs from all the blocks for SCADA control and monitoring. The commissioning was undertaken by ESI engineers on site.Elmstead Market
A retrofit was carried out for Switchgear International of the control system for the pumps that are used to maintain flow from Elmstead market pumping station. An SLC 500 with a PanelView+ mimic were used to sequence the pumps generating a required flow.Beenhams Heath Water Filtration
We have just completed the Beenhams Heath Micro Filtration project. This site, near Reading, will filter supply water to the area including the micro-filtration for Crypto-sporidia. This is an SLC 500 system with a Panelview HMI.
Becton Dickinson - Air Lock Control System
Becton Dickinson serves industrial laboratories and institutions with products for biopharmaceutical production, environmental monitoring, drug discovery, and high throughput screening (HTS) to enhance clinical and diagnostic research. BD offers refillable serynges and other parenteral drug delivery devices to pharmeceutical companies and manufactures precision glass tubing and ampoules for a variety of applications. We were called in by Wilkinson Electrical (Plymouth) to design and install two air lock systems at Becton Dickinson in Swindon as part of internal improvements. An air lock room is used to maintain integrety of controlled atmosphere of production rooms with respect to changing and tool transfer rooms. A request to enter using a pushbutton or footswitch will allow entry and dissable entry from any other door as long as another door is open.
Electron Beam Welding
We have started supporting Fusion Technologies Ltd in Bristol with their software requirements. Fusion are specialists in electron beam welding and supply and support CNC machines for all applications.
Horsley Cross Pumping Station
Working for Switchgear International, we designed & implemented the PLC and HMI software for a retrofit control system at Horsley Cross pumping station. Pump sets are used to maintain the water tower level according to a demand look up table. An SLC500 with a PanelView touchscreen was used.
HHT inverter replacement
Working with Harland Simon ICS Limited to design and implement the replacement of the existing Siemens inverters with new ones. Control of synchronization panel is with Allan Bradley SLC-500 and interface to existing SY/MAX PLCs with Modbus+ network. All the inverters have now been installed along with the Interface panel. The old synchronisation panel is still in situ, though isolated and off.
Robot Welding Cells at Wagon
Working with Daval Controls Ltd the software for three robot welding cells was written and commissioned for Wagon in Wantage. The cells weld chasis members for the new Rover 75 cars. Siemens S7 PLCs were used with OP (TP170B) HMIs to control and monitor the clamp and door sequences and interface with the robots as they run the appropriate weld program. Kuka robots were used.
Mallaig, Bonar Bridge & Banff (Gallow Hill)
Working with Atkins Fulford Ltd, the PLC software was written and commissioned on site in the Highlands. The systems consist of either single or two fiters with an SLC500 PLC. At Mallaig manual control is acheived locally and the system interfaces via I/O with another SLC500 which controls the rest of the plant and is linked to a PanelView 1400. Bonar Bridge interfaces via I/O to a telemetry system as does Banff.
MLC Stotfold Pig Development Unit
Working for the Meat & Livestock Commission to modify the control system used to automatically feed pigs at Stotfold pig development unit, Hertfordshire. This was a second trial into the production of pig feed made from a blend of products (some by-products) to find a cheap and nutritious substitute to traditional swill (now banned under tighter controls). Both dry, liquid & fermented feeds are tried. A re-calibration of the PH and temperature sensors was undertaken as well as correcting the dial-out control box.
Bray Water Filtration
Working with Atkins Fulford Ltd, the PLC software was written and commissioned on site at Bray near Windsor. The system consists of five fiters each with an SLC500 PLC with a main SLC500 to control ancillary plant equipment. A DH+ network links all the PLCs and a Modbus link over telephony is used to connect to a central control station and is used for telemetry, control interlocks and SCADA data.
Heathrow Airport Terminal 3 FLINK
Assisted ASE with developement and on site testing of Factory Link SCADA for baggage handling systems at Heathrow Airport Terminal 3.
Denge Water Filtration
Working with Atkins Fulford Ltd, the PLC software was written and commissioned on site at Denge in South East Kent. The system consists of two fiters each with a ControlLogix 5000 PLC. A ControlNet I/O network was used to interface the filters with the main plant control PLC. Ancillary control was performed by the main PLC.
Dublin Airport FLINK
Assisted ASE with developement and on site testing of Factory Link SCADA for baggage handling systems at Dublin Airport.
Ballysallagh Water Filtration
Working with Atkins Fulford Ltd, the PLC software was written and commissioned at Ballysallagh, near Bangor, Northern Ireland. The system consists of two fiters with an SLC500 PLC per filter and a main PLC (also SLC500) linked on DH+. Manual control is acheived locally with a PanelView 1000 also on the DH+ network. The system interfaces via I/O to a Siemens PLC which sits on a site wide Profibus network. Some digital I/O is used to synchronise the feed pumps.
Allen Process Systems Salalah Project
Working for Allen Process Systems in London to write the PLC program for a water separation system for the petrogas industry at Salalah. A Rockwell SLC500 PLC with RSView32 SCADA was used in a dual redundant hot standby configuration.
Woodgreen & Matchams
Working with Atkins Fulford Ltd, the PLC software was written and commissioned at Woodgreen & Matchams, in the New Forrest, Hampshire. The systems consist of either four or five fiters with an SLC500 PLC per filter and a main PLC (also SLC500) linked on DH+. Manual control is acheived locally with a PanelView 1000 also on the DH+ network. At Woodgreen the system interfaces via RS485 to the site SCADA (InTouch), to telemetry and with digital I/O to synchronise the feed pumps. At Matchams the system interfaces to telemetry and feed pumps via I/O.
BAe Systems Retrofits
Working with DNC Machine Tools Ltd, a retrofit for BAe Systems of two lathes to be used in the shaping of misile charge. Fanuc 18i controls were used.
Network Support at CEC Marketing
We re-instated and enlarged a PC network during relocation of CeC Marketing in Swindon. Further assistance was supplied with network management.
Puma line ATI
Working with ASE, the software for the Puma engine block heat treatment ATI line was re-written to correct sequence response to hardware faults. The operator interface (Monitor 77) was expanded to include QA product tracking and implemented on the SCADA (InTouch). The PLC is a Telemecanique TSX 47 with an ASI fieldbus.
Holland Haven Lime Dosing
Working for Switchgear International Limited, a Rockwell RSLogix PLC and a PanelView operator interface were used to control a lime dosing system on a new sewage processing plant near Clacton-on-Sea, Essex.
BAe Systems kevlar overwind retrofit
Working with DNC Machine Tools Ltd, a retrofit for BAe Systems of a Kevlar overwind machine was achieved using a TwinCAT soft-control solution and a VBasic OCX MMI.
Diaper & sons chicken slaughter house
Working for Switchgear International Limited, a Telemecanique Micro TSX37 and Magelis XBT operator interface were used to control a chicken slaughter line near Bury-St-Edmunds.
Columbier Paper Mill Retrofit
We assisted in the commissioning of a Masson Scott Thrissell paper mill at Colombier in Sittingbourne. A Siemens 318 was used to replace the original control.
Direct Wines bar code scanning system
Assisted ASE with software application for networked PC and handheld scanners for bar code reading at Direct Wines, Reading. The applications were written in C/C++.
Newcastle Airport FLINK
Assisted ASE with developement and on site testing of Factory Link SCADA for baggage handling systems at Newcastle Airport.
Peugeot Primer 1
Standby for retrofit TSX system (replacing GEM 80 system) in primer 1 booth at Peugeot, Coventry.
HHT system manual & improvements
Generate system manual and implement various modifications to improve throughput and monitoring.
Extrusiuon Form Tools
Several small CNC jobs which included a memory upgrade on a Fanuc 6 and a serial link implementation on another Fanuc 6. The upgrade of their DNC link system using Camtek NCCOMs software. The installation of the new DNC link for part program distribution system, included linking in with a factory wide ethernet network supplying the shopfloor PCs with the TAP format part programs.
HHT additional PLC (HHT-C) for expansion purposes
The PLC network is expanded to include a third PLC to load share and give extra capacity for further logic to be implemented (in particular the cooling fan control) at ALCOA, Birmingham.
Marley Fine Screens
Logic modifications and implementation for fine screens. Work issued by ASE.
Working for ASE, the rewriting of the software to control a hopper measuring and distribution system controlled by a TSX 47/30 processor and including an XBT (for operator control) and 6 Altivar drives on a Unitelway network. This was required as the memory had been corrupted by power spikes.
Monitor 77 & Factory Link
Working for ASE, the upgrading of several SCADA systems to modern PCs for Y2K compliance. DOS Monitor 77 version 5.0 and Windows NT FLINK version 6.6 from OS/2.
Projects with DNC Electronics Ltd [Job title - Software Project Engineer] (next) (top)
Matrix Churchill series 2, 3, 3/15 and 302 with GE Fanuc and Control Techniques CNCs.
Industrial PC, axis and I/O cards, programmed in C. Control Techniques drive.
PC based communications and file management software and multiple serial port access.
Board replacement, parameter verification and memory upgrade.
Written with Foxpro.
Written with Easy PC.
Two 205 series Direct Logic PLCs.
Various GE Fanuc CNCs.
Netware 4, MS-DOS and Windows 3.1 with ISDN connection and web pages.
Projects with Schneider Electric [Job titles - Applications Engineer, Project Engineer] (next) (top)
3 Symax 400 PLCs with Dexterity SCADA.
1 Symax 400 with PCIM SCADA and menu written in C.
Inlet, storage and incinerator feed at Calder valley incineration plant. 2 Symax 600 PLCs working in hot standby with TCS SCADA.
Smelting oxygen lance system at Llanwern British Stee. 3 Symax 400 PLCs with Access 4000 I/O systems.
Commissioning of Italian cylinder cutter and implementation of SCADA monitoring of air and water supply at Chesterfield Cylinders. 1 Symax 400 PLC, 1 Altivar 45 2 drive and PCIM SCADA.
Quotation software for systems and TSX products written with Foxpro.
2 Symax 600 PLCs, 2 Symax 400 PLCs and Factory Link SCADA running on HP Unix workstation.
Projects with Simon Engineering Group [Job title - Software Engineer] (top)
Petit Beurre biscuit forming, cooking and cooling line at LU (General Biscuits), Nantes, France. Two Siemens 155U PLCs with WF470 SCADA linked to an HP1000 line and product monitoring system.
Oseberg B drilling platform bulk handling, chemical dosing and air compressor systems. 1 Siemens 135U PLC with WF470 SCADA.
Ritz cracker forming, cooking and seasoning line at Christie Brown, Montreal, Canada. 2 Allen Bradley PLC-5s with AFE SCADA and Newport displays.
Gyda drilling platform chemical dosing system. 1 Siemens 135U PLC with Newport displays and fixed mimic.