One circuit of work from drawing board to commissioned line.

Control Panel and Loop Design

This service begins with the process and instrumentation diagram and ends with a drawing set a panel workshop can build without interpretation. Our engineers define instrument ranges and signal types, allocate loop numbers, lay out marshalling and terminal blocks, size breakers and power supplies, and produce panel general arrangements, wiring schedules and loop sheets for every control function. We separate power and signal routing, mark every conductor, and leave documented spare capacity so that a future modification does not require a new panel. The loop sheet is the heart of the deliverable: it shows the sensor, the transmitter, the controller, the final element and the alarm and interlock paths in one view. Because we commission what we design, our loop sheets already anticipate the practical problems that appear when wiring meets field conditions.

SCADA and HMI Integration

We build the operator interface as a logical model of the plant, not a decorative picture. Screens are organised by process area and by task, with navigation that a new operator can learn in a single shift. We rationalise alarms so that every alarm demands an action, set trend groups that answer real diagnostic questions, and apply role-based access so that critical setpoints cannot be changed by accident. Historian integration, production reporting, and secure remote access are configured with network segmentation in mind, keeping control traffic apart from business traffic. Our HMI standards specify colour use, font sizes and state indication so that the interface stays readable and consistent across every screen we deliver.

Factory Acceptance Testing

Factory acceptance testing is where a design proves itself before it carries any risk on site. We prepare a test procedure that walks through every digital and analogue input, every output, every alarm, and every interlock, using simulators and signal injectors to reproduce realistic process conditions. The client is invited to witness the test, question the logic, and request changes while the panel is still on the bench. Results are recorded item by item, deviations are logged with owners and dates, and the signed test report becomes a formal project milestone. We never treat FAT as a formality; a defect found in the workshop costs a fraction of the same defect found during a shutdown.

System Commissioning and Handover

Commissioning converts tested hardware into a live, trusted system. Our engineers perform loop checks against field wiring, configure controllers and communication links, tune control loops for stability and response, and prove interlocks under real conditions in coordination with operations. We manage the punch list from first energisation to closure, document every field change, and progressively hand over subsystems so that operations gain confidence before the final acceptance. The handover package includes as-built drawings, I/O schedules, software backups, alarm lists, calibration certificates and operating notes. Training is delivered on the actual system, not on slides, so that knowledge stays with the people who run the plant.

Legacy System Migration

Older control systems hold valuable operational knowledge that is rarely fully documented. Our migration service starts with a survey: we photograph panels, trace wiring, capture existing logic, and interview the operators who know the plant best. From that survey we build a modern control model and a phased cutover plan. Where the risk justifies it, we run the old and new systems in parallel so that behaviour can be compared directly. Where a shutdown window is short, we pre-stage as much work as possible and rehearse the cutover. The outcome is a current platform that preserves the lessons of the old one instead of discarding them.

Support and Calibration Contracts

A support and calibration contract keeps a commissioned plant inside its design envelope. We maintain an asset register, schedule calibration and drift checks, verify instrument performance against traceable references, plan spare parts, and keep software backups current. Fault response follows a defined path with agreed priorities, so a control fault at an inconvenient hour is handled by an engineer who already knows the plant. Contract clients also receive priority for small modifications, drawing updates and troubleshooting, which lowers the cost of every future change. The contract is reviewed annually against actual plant performance so that the service stays matched to the asset.

Request a loop review

Send us your process description, existing drawings or a short summary of the problem. We will respond with a proposed scope, a rough programme and the information we need to firm up a quotation.

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