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Airbus - Case Study

Case Study: MCS Integrated Control System for Airbus fuel systems test facility

MCS Control Systems were contracted by Airbus as 1st tier supplier to design, build, install and commission a comprehensive system to  control aviation-fuel supply and conditioning for testing of fuel behaviour in it’s current range of in-service passenger aircraft, development aircraft and future projects.

The process calls for aviation-fuel to be delivered to aircraft test rigs after being optionally heated to +50°C, chilled to -47°C, with vacuum to simulate altitude.  The process also supplies the rigs with Nitrogen, Dowtherm and Hydraulics; for dynamic rig movements.  The control system can respond to manual commands, or to an imported flight profile to simulate a typical flight plan. All events, data and fault conditions are monitored, displayed and logged for operators located in the control room, remote from the Zoned plant areas.

MCS were responsible for:

  • Design and manufacture of the MCC and ICA panels
  • Design and production of Siemens Step 7 PLC logic
  • Design and configuration of the Lab View application used for SCADA
  • Supply of all valves and instrumentation connected by an intrinsically safe Profibus network
  • Cable and interface installation across the facility, including hazardous areas
  • Process commissioning of the heating, chilling, vacuum and pumping sequences
  • Tuning all flow, temperature and pressure control loops
  • Commissioning the control system to achieve acceptance under DSEAR regulations
  • Production of all documentation and calculations to prove ATEX compliance
  • Onsite customer training and support
  • Design and configuration of simulator to enable training without effecting the plant

MCS are continuing to work with Airbus to enhance facility operations to meet future requirements. The facility was opened by HRH The Duke of York on the 28th of February 2006.


The facility was opened by HRH The Duke of York in February 2006

Photo & Logo© Airbus UK 2006




I would like to say how well MCS have performed at Cropwell Bishop, following a sucessful FAT test we have completed the SAT sign off on site in 15 days which included 3 days E2E testing over Modbus. Having a fully operational ASP circulating flows...

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