Case Studies

Case Studies
Federal Mogul

Federal Mogul - Case Study

Case Study: Valve Guide
Rotary Machines
(Mitsubishi PLC Upgrade)

Project Description: Federal Mogul, a leading manufacturer of engine components selected MCS Control Systems to replace 13 obsolete Mitsubishi PLC’s in their precision valve guide facility with minimum downtime and disruption.

Approach: It was assumed many of the machines had the same program. Software for all machines was examined and verified. Due to the configuration and available stoppage times, a phased approach was not possible, i.e. CPU transplant followed by an I/O transplant. For this project the “big bang” approach was adopted where the entire PLC complete with I/O and wiring was replaced in a single shutdown. Following the successful transplant of the first PLC, the second, third, and so on were done by adopting the same “big bang” strategy. At all stages the customer was kept informed to ease his concerns. MCS always had a back up plan in case any thing went wrong and to minimize risk. MCS provided standby cover in the event of any issues but this was not required as the system ran sweetly as before the transplant. In some cases the change over was so quick and smooth the operators did not realize that the machines had been upgraded.

Results: All 13 PLCs were successfully transplanted over a period of 6 months with minimum down time and loss of production.

Approach: On the initial site survey, the existing S5 PLC code was uploaded and the system functionality was verified and recorded. The software was then converted to S7 and internally tested using simulation software against an agreed set of testing requirements. The Bumper Spraying Line is critical to the plant operation and this transplant had to be approached with each phase planned in detail along with contingency plans in place to minimise any downtime. During commissioning, our first step on site was prove the Robot Interface. Rigorous functionality tests were carried out on “Ghost” jobs to validate the robustness of the PLC software prior to launching into production.

Results: Working closely with the End User the new S7 PLC systems were installed and commissioned over a 5 hour period with no down time and disruption to production.

TI Automotive

TI Automotive - Case Study

Case Study: 345 & Hybrid Tank Line
Move Location: TI Automotive, Deeside

Project Description: In July 2011 MCS Control Systems were contracted by TI Automotive to assist with PLC & HMI software modifications on Line 6 which manufactures and assembles fuel tanks for Toyota. The client wished to move all Toyota production onto Line 6 to free the currently used Line 7 for future work. Line 6 machinery includes Blow Moulding, Water Bath, Ageing , Cut and Weld, Pump Install & Test and Leak Test

Approach: MCS had worked previously with TI Automotive installing Data Traceability Systems on Line 6 and Line 7. We had also worked with TI on the introduction of a new model tank on line 6 in 2009. The 345 tank was previously manufactured on Line 7 but the Hybrid Tank is a new tank ready to launch late 2011. For this project MCS had to consider and implement tank “birth barcode” label printing for each variant of tank and Poka Yoke systems to prevent the Operator loading a wrong variant tank on the production run. New parameter sets also had to be implemented in the Pump Install & Test station and the Cut & Weld machine. Rigorous functionality tests were carried out on live jobs to validate the of the system for all existing and new variants.

Results: Working closely with the client the project were installed and commissioned over a 5 day period with no down time and disruption to production.

Unipart Jaguar X150

Unipart Jaguar - Case Study

Case Study: Jaguar X150 Fuel Tank Line

Project Description: Unipart Eberspächer Exhaust Systems needed an integrator who could install a Traceability System onto their Jaguar X150 Fuel Tank line. The Traceability System needed to track the installation of fuel pumps and sender units and also monitor test results from various stations such as a Helium Leak Tester and a Torque tool. In addition, all of the data needed to be stored in a format approved by Unipart’s IT department.

Approach: MCS Control Systems installed a series of Beckhoff PLCs to all of the stations that needed to be monitored, interfacing with the test tools and barcode scanners. Data received from the barcode scanners and test equipment were processed by bespoke C++ services and passed to an industry standard SQL Server database which was housed in Unipart’s Server room, remote from the factory floor. As well as recording and tracking, the Traceability System also performed some high level control by disallowing, for example, fuel tanks from being leak tested that had not already passed a torque operation. MCS Control Systems also created various screens that allowed the user to enquire on all data stored and change various configuration parameters.

Results: The project was completed successfully within a very tight schedule. It has been running for a number of years and has had various additions required by the client.

Results: Working closely with the client the new Cognex systems were installed and commissioned over a 3 day period with no down time and disruption to production.

Decoma Sybex PLC Transplant

Decoma Sybex - Case Study

Case Study: Siemens PLC Upgrade Location: Decoma Sybex, Banbury

Project Description: MCS Control Systems were contracted by Decoma Sybex to upgrade two of their Siemens PLC’s in the Primer Premix area from the S5 range to the current S7-300 range. These PLC’s control the paint mixing system that delivers mixed Primer to the Fanuc Robots on the Bumper Spraying Line. This functionality was to be exactly replicated in the new S7 PLC’s.

Approach: On the initial site survey, the existing S5 PLC code was uploaded and the system functionality was verified and recorded. The software was then converted to S7 and internally tested using simulation software against an agreed set of testing requirements.

The Bumper Spraying Line is critical to the plant operation and this transplant had to be approached with each phase planned in detail along with contingency plans in place to minimise any downtime. During commissioning, our first step on site was prove the Robot Interface. Rigorous functionality tests were carried out on “Ghost” jobs to validate the robustness of the PLC software prior to launching into production.

Results: Working closely with the End User the new S7 PLC systems were installed and commissioned over a 5 hour period with no down time and disruption to production.

Unipart Landrover T5

Unipart Landrover T5 - Case Study

Case Study: Landrover T5 Exhaust Downpipe Cell

Project Description: Unipart Eberspächer Exhaust Systems needed an integrator who could retro-fit a Traceability System onto their existing Landrover T5 Exhaust Downpipe cell. It was a matter of utmost importance that the system have no detrimental effect on a live cell.

Approach: MCS Control Systems installed upgraded the existing S7 PLCs to handle the additional functionality of the Traceability System. New HMIs were installed that allowed the operator to select the product that they were building and to view leak rates from the twin leak testers in the cell. Bespoke services written in C# were created that processed data from the PLCs and stored the information in an industry standard SQL Server database which was housed in Unipart’s Server room. End of Line ticket printing and exhaust etching were also re-written as part of the retro-fit. MCS Control Systems also created various screens that allowed the user to enquire on all data stored and change various configuration parameters.

Results: The project was successfully completed within a small shutdown window. The Traceability System had no detrimental impact on the functionality of the cell.

Magna Interior Solutions

Magna Interior Systems - Case Study

Case Study: X250 Assembly Machine Modifications Location: Magna Intier Automotive, Redditch

Project Description: MCS Control Systems were contracted by Magna Intier Automotive to design and install an automated air blow down system on their X250 machines which assemble door interiors for Jaguar. A quality issue on a some vehicles lead Unipart to review and improve the assembly system on machines.

Approach: The client reported that debris left in the assembly machines was causing the door interiors to be slightly marked and sometimes damaged, leading to costly re-works. Working with the client, MCS designed a concept that would stop the assembly cycle just prior to the welding operation and prompt the operator to blow down the “nest” part of the machine to clear debris. To ensure that this had been done, an pressure switch was installed on the air line. Rigorous functionality tests were carried out on live jobs to validate the robustness of the air blow system for all four machines. The Siemens S7 PLCs and HMIs that control the machines were modified and tested.

Perkins Engine Paint Plant

Perkins Engines - Case Study

Case Study: Perkins engine painting Plant (Siemens S7-300 PLC )

Project Description: Perkins engines company limited installed an engine paint shop plant during a major UK engine manufacturing plant overall in Peterborough. George Koch & Sons as the main contractor needed a systems integrator who could design the control systems, manufacture the control panels, and carry out the electrical site installation/site commissioning. The engine paint plant process main line and booth line consisted of the following:

  • RO plant
  • Manual spray booth
  • Oil separation plant
  • Cure oven with gas burners
  • Paint sludge removal plant
  • Dry off oven with gas burners
  • Paint mix area ( explosive atmosphere area)
  • Automatic engine spray booth containing four Fanuc spraying robots
  • 5 stage fiberglass reinforced plastic system for pre-treatment spray washing of the engines.

Approach: MCS Control Systems paint plant was divided into two separate control systems one the main line and one for the spray booths. Each control panel contained a S7-300 PLC and was interlocked with a site SCADA via an Ethernet network. The main control panels were installed on platforms above the dry off ovens and the cure ovens and all the site SWA cabling was installed on two main cable tray runs along each line.

Results: Working closely with our client the installation and commissioning was completed over a two month period and with the approval of the end client.

Unipart EberSpracher Cognex

Unipart Eberspracher Cognex - Case Study

Case Study: Cognex Checker Installation, Unipart Eberspacher, Coventry

Project Description: MCS Control Systems were contracted by Unipart Eberspacher to design and install an automated Poka Yoke system on Line 8 which assembles exhaust cans for Landrover. A major quality issue on a vehicle lead Unipart to review and improve the Poka Yoke system on the Can Stuffing station, which had been allowed to misassemble an exhaust can.

Approach: On the initial site survey, MCS considered using photo-electric sensors to detect the differences in the exhaust can components prior to assembly. After experimentation however, this turned out to be impractical due to the number of variants coming down the production line. After further tests on site and at our premises, MCS decided that the best approach would be the Cognex Checker system which is essentially a cost effective, very reliable Vision System, comparing up to 8 images against a live image to detect differences and not allowing the machine to function if the operator misloads components. Rigorous functionality tests were carried out on live jobs to validate the robustness of the Cognex system for all exhaust can variants. The Siemens S5 PLC that controls the line was modified and tested to prevent the exhaust cans being assembled if a misload is detected.

Results: Working closely with the client the new Cognex systems were installed and commissioned over a 3 day period with no down time and disruption to production.

Huhtamaki

Huhtamaki Case Study

Case Study: Sidewall Printer Update
(Including upgrade to S7 – 1500 PLC)

As part of an expansion programme, Huhtamaki needed increased production at their Gosport plant for producing food packaging. A Sidewall Printing machine was a critical part of this expansion, and a suitable used machine was identified and purchased. However, as the machine was imported, the electrical, control, and safety systems of the machine needed reviewing and updating to meet the plant Health and Safety Standards.

Project Description:

Approach: Time was of the essence in this project, as the new production was urgently needed to increase capacity. MCS Control Systems has a proven methodology, developed over many years, for upgrading and replacing business critical systems spanning many industry sectors including: Food/FMCG, Automotive, Aerospace, Utilities, Process, Construction Products and Building Services.

Results: The machine was rewired, its safety systems reviewed and updated, the Siemens PLC control system updated from S5 to S7- 1500, with program conversion, and put into production within 7 weeks of MCS receiving the order. MCS also provided commissioning and production support.

Ben Newton, Electrical Team Leader stated:

“I would like to pass on my gratitude to MCS for the work completed on the above project. The task of upgrading the machinery to the required standard, within the tight timescale we had set out was always going to be challenging, but all at MCS involved approached and completed the project with upmost professionalism. The project threw up a number of unique problems that were quickly overcome and all work was completed according to the criteria set out by the scope of works"

"Every member of staff involved in this project are deserving of thanks however I would like to pass on my special thanks to Russell, Barry and Mateusz who spent a lot of time on site ensuring that the project was a success"

KP Snacks

KP Snacks Case Study

Case Study: Wheat Crunchie Fryer Control Panel Replacement
Control Panel Replacement
(Siemens PLC upgrade)

KP Fryer

Project Description: One of MCS Control Systems customers, KP Snacks in Teesside, needed a Specialist Systems Integration Contractor who could successfully replace an obsolete and unreliable business critical control panel for their Wheat Crunchie Fryer , upgrading the safety systems at the same time. The Control Panel included an upgrade to a Siemens S7-1500 PLC, new safety systems, a TP1200 HMI, with the system controlling new Siemens G120 drives on Profinet, and MCS renewing all the necessary wiring. The software was written using TIA Portal

Approach: This project was deemed to be the most risky replacement project ever undertaken by KP Snacks as it involved replacing a complete control panel, not just a component within the panel such as a PLC.

MCS Control Systems have a proven methodology, developed over the years, for upgrading and replacing business critical systems spanning many industry sectors including; Food, FMCG, Automotive, Aerospace, Utilities, Process, Construction Products, and Building Services.

The system was fully re-tested against an agreed site acceptance test specification, and following comprehensive training of KP Snack’s operatives and technicians, the Fryer was put back into service half a day ahead of schedule.

Results: At the end of the project, John McGuire , Process Engineer, commented: “I'd like to pass on my sincere thanks for the excellent work completed by MCS on the above project. The job had the potential to be extremely testing due to the condition of the original panels and the lack of available information. It would be fair to say that this was the highest risk upgrade project that I have been involved in to date”

“All of your staff involved in this work have been a credit to MCS but Russell deserves a special mention for the effort and expertise he put into the job to ensure that the project was a success and that the equipment was available for production ahead of schedule”

Müller

Müller - Case Study

Case Study: Müller, Pallet Checker System (Siemens S5/S7 PLC upgrade)

Project Description:  One of MCS Control Systems customers, Müller Dairy(UK) at Market Drayton, needed a specialist system integration contractor who could successfully replace obsolete business critical PLC’s in their multi-million pound production and automated warehouse operation, with minimum downtime and disruption.

Approach:  MCS Control Systems have a proven methodology, developed over the years for upgrading and replacing business critical PLC’s spanning many industry sectors including; food, fmcg, automotive, utilities, process and building services.  Karl Jordan, the MCS contracts manager on the project stated: “It’s all in the planning”, our approach is to validate the existing system, extract and convert the software, factory test/simulate and then transplant the PLC and HMI’s in a pre arranged and well planned shutdown.

At all stages, the key to success is to work with the client and understand their business, their risks and their people.  MCS’s progress was continuously monitored at all stages throughout the shutdowns against a detailed plan, this coupled with a robust contingency plan minimised any business risks to Müller.  Finally the system was fully re-tested against an agreed site acceptance test specification and following comprehensive training at Müller’s operatives and technicians, the machines were put back into service.

Results:  The engineering supervisor for the warehouse and MHE at the Market Drayton site, responsible for the project on behalf of Müller stated; “An exceptional, first-class service from MCS Control Systems with a thoroughly professional approach relating to all aspects of the project.  Extemporary cross-communications at all levels allowed for smooth integration of the new equipment with almost unnoticed disruption.  Including physical install, the machines were up and running again within a matter of hours – very impressive.”

Laundry Heat Exchanger

Aquatherm Laundry Heat Exchanger Control System

Case Study: Laundry Heat Exchanger Control System

Aquatherm Panel

Project Description: Supply of a Control System to Control and Optimise a Heat Exchanger for Energy Recovery for Industrial Laundries

Modern industrial laundries are capable of washing, drying and finishing several tonnes of linen an hour, returning clean sheets and pillowcases to their busy hotel customers in neatly folded packs ready to put straight onto guest beds. Other sectors of this important service market provide sterile linen for hospitals, clean uniforms for factory workers, entrance mats for banks and supermarkets – in fact we all encounter the output from this hidden industry every day of our lives in some form.

The processes use a significant amount of energy and water – think of a domestic washing machine multiplied by 200 – and that is just the equivalent of a single ‘tunnel washer’, of which there could be several. A typical laundry can discharge 20 tonnes of hot dirty water to drain each hour, every litre of which has been heated using gas or oil. Energy bills can run into hundreds of thousands of pounds each year, to say nothing of the environmental impact that result from these losses.

In theory it should be straightforward to recover much of this lost heat and use it to heat fresh water for the next production cycle. However, the cocktail of lint, fibre, dirt and grease, together with the industrial strength chemicals used to cleanse the fabrics is more than a match for most types of heat exchanger, which is where Aquatherm’s unique design, developed over 30 years comes into play.

The Aquatherm Heat Exchanger contains 1000 metres of specially indented stainless steel tubes, specially designed so they don’t get clogged up with loose fibres dislodged from garments during the washing process.

The heat exchangers recover heat from outgoing waste water which is used to heat incoming fresh water in the exchanger. This saves a typical laundry £ 50-100,000 per year, usually enough to recover the capital cost in the first year of operation.

A key element of the design is the control system. Whilst being a relatively standard unit, each Laundry configuration is slightly different, so the MCS Control Panel has options for 1 to 3 Variable Speed Drives to drive the pumps pumping the water through the Heat Exchanger, temperature inputs from thermocouples to optimise the flows from the temperature gradients of the ingoing and outgoing streams , inputs from flow meters and tank level sensors to control tank levels, and outputs to control the system valves.

The system is set up and controlled via an HMI in the front door of the panel, and the system also logs data and efficiencies which can be viewed historically on the HMI to monitor system performance and energy savings.

MCS have supplied controls systems for Aquatherm installations as far away as Manila, Norway, along with several installations in the UK.

Airbus

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.

HRH Prince Andrew at Airbus Exhibition

Photo & Logo© Airbus UK 2006

Coventry and Solihull Energy from Waste Plant

Coventry and Solihull Energy from Waste Plant Case Study

Case Study: Upgrade three off 90KW Inverter Drive Panels
Control Panel Replacement - Coventry and Solihull energy from waste plant
(Inverter Drive upgrade)

Project Description: The Plant operates on a 24 hour, 7 days a week continuous basis for 52 weeks of the year. In a normal year it will process in excess of 220,000 tonnes of household and commercial waste which is incinerated in three furnaces. Steam is raised from each incinerator and used to generate electricity from two turbine generators to supply heat to a local factory.

This contract was for the replacement of 3 off 90kw variable speed drive panels, the drives being of ABB manufacture. The existing drive panels where removed and the new drive panels where relocated and sited in a new MCC room. New IP60 enclosures and all associated power and control cabling was supplied, installed and commissioned by MCS .
MCS was free to offer any standard product that we recommended so long as the equipment offered met the detail within this specification and any others pertaining to it.

Coventry and Solihull Energy Waste Plant
Approach: The contract was for a turnkey project that included all aspects of surveying, removal of existing drives, installation of new drive panels and commissioning. Every aspect of the project had to ensure the plant remained operational.
The key requirements of the new inverter drive panels are:
1. Standard product
2. Reliability, trip & fault free
3. Service support availability if required
4. Performance
5. Efficiency

Harmonics Study
MCS was required to undertake full harmonic studies on the existing drive panels prior to removal and to ensure the new drives met the current harmonic legislation after installation. The studies where required to evaluate the performance of the new drives against the previous installed units.

It was an improvement to the performance and efficiency of the new inverter drive units that the client required. The directive was that the new installed drives must achieve harmonic levels lower than the existing drives..

Reliability
The Inverter drives are connected to fans associated to the incineration process of household waste. It was important that the drive panels once installed are fault free offering the highest reliability. Any failure within any of the drive panels could cause a fire hazard within the plant.
Spinning loads
The drive had to be set up to catch/stop a spinning load .A controlled stop was incorporated to ensure that the customer could initiate the drive to start again overcoming the need for any drive selected under a Stop condition to come to a standstill before requesting a drive re-start.
Service Support
In the event of a fault or breakdown condition within the first two months, the client required an immediate response from MCS. The contract also required that the Inverter drive panels and associated ancillary equipment was offered with a spares’ availability for 10 years.

Yodel PLC Transplant

Yodel Conveyor control system PLC Update

Case Study: Conveyor System PLC update
(Including upgrade to S7 – 1200 PLC)

Yodel Conveyor control system PLC Update

Project Description: A business critical M340 PLC needed replacing at Yodel’s Lichfield Depot. The replacement was required urgently to ensure the Depot was running with the New PLC before the Christmas peak period.

Approach: Time was of the essence in this project, as the new PLC was urgently needed to ensure reliable running of the depot during the critical Pre- Christmas delivery period. MCS Control Systems has a proven methodology, developed over many years, for upgrading and replacing business critical systems spanning many industry sectors including: Food/FMCG, Logistics, Automotive, Aerospace, Utilities, Process, Construction Products and Building Services.

Results: The system was designed, the panel rewired, the M340 PLC control system updated to a S7- 1200, with program conversion, and was up and running again over a weekend shutdown period within 3 weeks of MCS receiving the order. MCS also provided commissioning and production support.

Andy Rowe, Engineering Manager, commented:

““I’d like to express my sincere thanks to the whole team at MCS who completed the project. The time scale given to MCS for the design and build of the PLC was extremely small and coupled with the set installation period made this project what we thought very challenging. But right from day one when they took on the project it was handled with complete professionalism. With good communication throughout the whole process, through to the successful completion of the project on time”

RS PLC Transplant

RS Components - Case Study Two

Case Study: Siemens PLC Upgrade, RS Components, Nuneaton

Project Description: MCS Control Systems were contracted by RS Components to upgrade one of their Siemens PLC’s in the One-Liner area from the S5 range to the current S7-300 range. The S5 PLC Rack included a serial interface card as the PLC interfaces with Warehouse Management System to alert FLT drivers that they are required to collect an order from the area. This functionality was to be replicated in the S7 PLC.

Approach: On our first visit to site, the existing S5 PLC code was uploaded. This was then converted as far as possible using the Siemens S5 to S7 conversion package. As this is a critical area in the warehouse, this transplant had to be approached with a view to contingency. Our first step on site was to place the S7 PLC temporarily in the PLC cubicle and connect the I/O cabling in parallel with the existing S5 PLC cabling. On the initial swap over, communications proved to be unstable with the WCS. At this point we decided to revert to the S5 PLC and use some data logging software to capture and analyse the string of data on the RS232 bus. Using this data, we were able to replicate data block lengths and the data string using the S7 standard function blocks. Various tests were carried out to prove the stability and robustness of the system.

Results: Working closely with the End User the new S7 PLC was tested and installed over a 3 weekend period with no down time or disruption to production.

Argos Distribution Centre Conveyor Control System Upgrade

Argos Warehouse Conveyor Control System upgrade

Case Study: Argos Conveyor Control System update

Project Description: MCS Control Systems, working for Vanderlande Industries, were responsible for the electrical design, installation, software and commissioning of the conveyor and sorter system at the Argos distribution centre at Barton-under- Needwood. The conveyor system comprised over 1100 motors and used various starters including DOL, variable speed drives and soft starters. The project also involved the integration into the conveyor system of third party equipment.

Argos Distribution Centre
Approach: The conveyors were divided into eight separate areas, these being FSC and PLCs one to seven. The FSC (Flow System Controller) monitored all stock going into the warehouse. The FSC comprised of a main PC panel linked to the warehouse stock control system and a main control panel linked to FSC PC panel. The FSC system used local I/O enclosures for the connection of the conveyor devices these being linked together using an Interbus network. The PLC panels all used Siemens S7-400 PLCs with a Profibus to ASi (actuator sensor interface) gateways. The PLC panels also included an HMI. ASi was used for the connection of conveyor devices and motor control as this would simplify the amount of cabling required. The emergency stop system was also connected to the ASi network using ASi safe monitors also greatly reducing the site cabling required. Third party equipment was integrated into the system via either the profibus or ASi network.

Original Project ScopeEnhancements
Panels:
- 7 Form 2 PLC Control panels
- 50 off Local Link 20 Panels with ASi Safe
- approximately 1000 Local motor starter panels (ASi Bus)
Electrical Installation:
- 50 of ASi bus network
- 10 Profibus network; all power and control cabling
Software:
- 7 off S7-400 PLC with local HMIs
Panels:
- 2 Form 2 Control panels
- 2 off Local Link 20 Panels with ASi Safe
Electrical Installation:
- 3 of ASi Bus network
- 1 Profibus network
- all power and control cabling
Software:
- Goods Inward EMI System: 1 off WinCC SCADA station

Dounreay Sodium Disposal Project

Dounreay Nuclear Waste Case Study

Case Study: Project: Dounreay KNK Sodium Disposal Project -
MCC, PLC & SCADA system, System Integration, Commissioning & O&Ms

Project Description: MCS Control Systems were contracted to design, build and commission a Motor Control Centre to control Super Heated Steam Skid including PLC & SCADA System Integration.

Dounreay Nuclear Plant - PLC & Scada system integration

The Super Heated Steam skid is a first stage of KNK sodium disposal project with a number of interconnected skids. The Super Heated Steam skid is used to supply dilution water, steam, superheated steam and high/low flow hot nitrogen to the other process skids and the reaction vessel as required.

System integration includes PLC system, SCADA and integration of package plant. MCS successfully completed the commissioning of the Motor Control Centre and customer training in Janetstown, Thurso.

Scope of Supply:

  • Design and manufacture of the MCC & ICA panel
  • Design and configuration of PLC logic
  • Design and configuration of the SCADA control system
  • Electrical Design
  • Control of drives, valves and instruments via conventional I/O
  • Commissioning the control system
  • Production of documentation and calculations to prove BS7671 compliance & O&Ms
  • Onsite customer training and support
Taw Torridge Pumping Stations

Pumping Stations - Case Study

Case Study: Taw Torridge - Full turnkey Control System (included MCC’s, PLC’s and Electrical Installation)

Project Description

The Taw Torridge scheme comprises a main works (Cornborough) and 5 remote pumping stations at Bideford, Northam, Yeland, Westleigh and Londonderry Farm.  Working in partnership with BVCL to an agreed Target Cost the contract comprised the design and manufacture of six substantial new MCC/ICA Panels, upgrade of a further existing MCC at Londonderry Farm, configuration of all PLC software, site commissioning and electrical installation works at all sites.  All MCCs supplied under the contract were of conventional Form 4 design to WMES and client specific standards.

Cornborough

The site had a 5.9metre 2000A LV switchboard manufactured to Form 4 Type 3 with a fault rating of 50kA / 1 sec.  The LV switchboard fed the two other MCCs the Aeration and Sludge panels and had ABB manufactured Harmonic Filters incorporated as part of the switchboard.  The Aeration MCC was 13.2m long and rated at 1000A with a fault rating of 25kA / 1 sec. The MCC consisted of 4off 90kW Blowers and 6off 22kW VSDs all 6 pulse with the Harmonic correction being carried out on the LV Switchboard.  The Sludge MCC was 6.9m long rated at 400A with a fault rating of 16kA / 1 sec. The MCC consisted of up to 17 starters.

Remote Pumping Stations

The Pumping stations varied in size and configuration from just backplate and door replacements for new starters at Londonderry Farm P.S. to large MCCs at Bideford. The MCCs ranged from 400A to 1000A with fault ratings of 20kA / 1sec. At Bideford P.S. the MCC consisted of 3off 200kW 6 pulse ABB drives for the 3off transfer pumps. Harmonic filtering was provided to G5/4 compliance. At Yelland P.S. due to building limitations MCS designed a 3.7m back to back 1200 deep MCC to contain 4 off Soft Starts in excess of 30kW – this was done as a value engineering exercise to prevent additional civil works to the building and saved considerable costs to the partnership.

ICA Controls

Modicon PLC’s with remote I/O were used for control and data acquisition of plant items. An Ethernet communications network was adopted, a first for South West Water, which transferred data between the PLC’s, PID controllers, SCADA system, telemetry outstations and pumping stations. The main works PLC, programmed using the Modicon Pro-Worx NXT software, controlled communications with both the remote pumping stations and the 13 dedicated local PID controllers. The PLC also manipulated data for the Paragon SCADA system for scaling, set-point entry and data display.

Electrical Installation

The electrical installation consisted of all cabling to plant equipment, HV transformers and communications links. Cables installed varied in size from 630mm singles to 0.5mm comms links. The installation was tested and inspected to NICEIC standards. All aspects of documentation were provided. E.g. Duct layouts, building services specifications, street lighting specifications, cable schedules, tray work layouts, block cable diagrams.

Referee

Dave Reedman Electrical Engineer for BVCL
Ian Aldridge Project Manager for BVCL

Margate, Weatherlees & Broadstairs

Margate, Weatherlees & Broadstairs - Case Study

Case Study: Black & Veatch – Costain – JV

Project Description:  MCS was awarded the £1.85 million contract for the complete electrical control package, encompassing MCC & ICA design, manufacture, PLC software, SCADA and commissioning. Working closely with our client Black & Veatch / Costain (JV), MCS successfully delivered and commissioned the following electrical packages:

Margate:

  • MCC complete with integral ICA measuring 29.9 metres in total
  • Top Entry 3200A Busduct
  • 3x 3200A incomers mains/generator complete with 3200A Bus coupler
  • 4x 315kW Transfer pumps – ABB Regenerative Drive
  • 5x 300kW Storm pumps – ABB PST Soft Starters
  • 2x 90kW Screw Lift pumps – ABB VSD’s
  • 2x 85kW Storm Return pumps – ABB VSD’s
  • 3x 18.5kW Washwater pumps – ABB VSD’s
  • 25x 0.7/5kW DOL Starters
  • 6x 11-15kW Star Delta Starters
  • 8x 32A feeder, 14x 63A feeder
  • Power factor correction, UPS, tripping battery
  • ICA Section – Mitsubishi PLC approaching 1500 I/O

Weatherlees:

  • 4x MCC’s complete with integral ICA measuring 44.82 metres in total and 1x 1250A Low Voltage distribution board
  • 8x Incomers totalling 14,800A . 5x Mains, 3x Generator
  • 4x 315kW Transfer pumps – ABB Regenerative Drive
  • 27x 0.25/55kW Pumps ABB VSD’s – RAS, Centrifuge, Sludge Cake, Return liquor, Drum Thickener and Floculators pumps
  • 4x 240kW Activated Sludge Blower Feeder’s
  • 1x 450A Active Harmonic Filter
  • 8x Distribution Boards Totalling 132 ways
  • 21x 0.7/5kW DOL Starters
  • 10x 11-15kW Star Delta Starters
  • 10x 32A feeder
  • 52x 63A feeder
  • 7x 100/1250A feeder
  • Power factor correction, UPS, tripping battery
  • 4x ICA Section’s – Mitsubishi PLC approaching 2400 I/O

Broadstairs:

  • shape MCC complete with integral ICA measuring 15 metres in total.
    1250A Mains incomer Section
  • 2x 180kW LS Outfall pumps – ABB Regenerative Drive
  • 2x90kW Storm pumps – ABB VSD’s
  • 3x 70kW Transfer pumps – ABB VSD’s
  • 2x 22kW Inlet Lift pumps – ABB VSD’s
  • 8x 0.7/5kW DOL Starters
  • 2x 32A feeder, 11x 63A feeder
  • Tripping battery
  • ICA Section – Mitsubishi PLC approaching 400 I/O

Scada image

Margate, Broadstairs & Weatherlees ICA Sections:

  • Mitsubishi Q06H / Q12H series PLC CPUs
  • Copper Ethernet link from each PLC to managed PLC fibre optic Ethernet ring spanning all three sites
  • Copper Ethernet link from each Weatherlees HMI to managed HMI fibre optic ring at Weatherlees
  • Copper Ethernet links from PLC fibre optic ring to UV, Blowers and Odour Control package plants at Weatherlees
  • Copper Ethernet link to Ferric Dosing package plant at Margate
  • Duty / standby Profibus DP networks to intelligent starters
  • Profibus DP / PA networks to field instrumentation and valves / penstocks
  • Duty / standby Modbus networks to Flygt MAS 711 pump controllers at Margate and Broadstairs
  • RS232 serial comms. to telemetry outstations at each site
  • Advantech PPC-174T panel PC for HMI / SCADA
  • SCADA – Wonderware InTouch 60K tag Runtime software without I/O
  • Dedicated E.A. display (Mitsubishi E1101) at Margate
  • IS equipment for zoned areas
  • UPS backed supplies for the main MCC PLC / SCADA at each site
  • Hardwired backup circuits to run critical plant on PLC failure
  • Hardwired telemetry for critical alarms
  • Installed I/O approaching 4200

Black & Veatch:

Black & Veatch’s Project manager, said “Black & Veatch and its JV Partner Costain are pleased to have worked with MCS in completing this important scheme which, already brings significant environmental benefit to the Thanet coast.

Balfour Beaty

Balfour Beatty - Case Study

Case Study: GE Fanuc PLC & SCADA Upgrade Location: Finlas WTW, Dumbartonshire

Project Description: MCS Control Systems were contracted by Balfour Beatty Civil Engineering Ltd to upgrade Finlas Water Treatment Plant – 2 off GE Fanuc 90/30. PLCs changed from the CPU350 to CPU374 Plus and GE Fanuc Redundant SCADA Servers Cimplicity 4.0 to Cimplicity 8.0 R2 with 2 associated GE Fanuc Panel PC HMI clients. These PLCs and SCADA/HMIs control the key-steps of water treatment process. Additionally, the scope of work included building panels and configuring new fibre optic Ethernet ring based on Hirschmann managed switches.

Approach: On the initial site survey, the existing GE Fanuc PLC’s code and SCADA application were uploaded and the system functionality was verified and recorded. The PLC software was then converted to Proficy Machine Edition 6.0 from Cimplicity Control 2.0 and the SCADA Redundant Servers software from Cimplicity 4.0 to Cimplicity 8.0 R2. Because of the huge version jump between existing and the latest software we focused very carefully on each detail of this transplant. The next step was to test converted software by simulating plant process in Wonderware InTouch 10.0 SCADA package against an agreed set of testing requirements. This allowed us to detect conversion defects and minimise plant downtime during commissioning. On commissioning, our first step on site was to prove the new SCADA Cimplicity 8.0 R2 Redundant Servers. Then the first PLC along with HMI were upgraded and tested for full plant functionality. Everything was as previously tested, so we approached to upgrade the second PLC and HMI, after which we tested the plant’s functionality again.

Results: Working closely with the End User, the new GE Fanuc systems were installed in two separate 6hr periods and were independently commissioned over a two week period with a minimum downtime to water treatment process.

Leading High Street Clothing Retailer

Leading Clothing Retailer - Case-Study

Case Study: Energy Saving & Availability Monitoring System

Project Description:  The European distribution centre of clothing manufacturer and retailer is situated in the Midlands. The conveyor systems are controlled by 8 Siemens S7-400 PLC systems. In May 2006 MCS Control Systems were contracted by our client to introduce energy saving into the each conveyor system and also to develop a system of monitoring, displaying and archiving system availability data. This data was required to provide unbiased and meaningful reports on equipment availability, including downtime, common occurring faults and response times which can be used by all parties.

Approach:  Firstly, to ascertain system power usage, MCS installed energy monitoring relays in all conveyor control panels. This then provided base-line power usage figures for each panel. The PLC software for each panel was then closely interrogated and modified to introduce configurable energy saving times for each logical group of conveyors.

To monitor Availability, MCS introduced a Siemens WinCC SCADA station to the system. This connects directly onto the existing established Ethernet network and gives a direct connection onto the 8 Siemens PLC systems. For availability calculations MCS used the sensible and logical rules of FEM 9.222 (“Standards of the acceptance and availability of installations with storage/retrieval machines and other machinery”). Working on site closely with our client’s engineering staff, MCS developed user friendly screens and automatic reports to detail system availability, downtime and response times.

Results:  With the new energy saving features in place, early indications show an overall average energy saving of 52%. With availability data on a per day/per shift basis, Our client now has the ability to identify and address recurring system faults, plan preventative schedules more efficiently and address response time issues to maintain and improve operational targets.

Thomas More Square, London

GE Fanuc Case Study

Case Study: GE Fanuc PLC upgrade

Project Description:  Thomas More Square is a 52,000 square metre office development situated on the eastern fringe of the City of London.  Each building in the development has a Smoke Management System (SMS) controlled by a GE Fanuc PLC and Genius remote I/O.  In December 2005 MCS Control Systems were contracted by GE Fanuc to upgrade the PLC’s in Apollo Court and Gemini Court from the now obsolete Series 5 range to the current 90-30 range.  Also as part of the contract the remote I/O inter-cabling would be replaced.  Minimum downtime and disruption would be paramount on this project to satisfy the buildings insurers.

Approach:  To minimise downtime to the SMS, the new remote I/O inter-cabling was installed and terminations prepared to run parallel with the existing cabling.  Meanwhile back at MCS’s offices in Coventry the new PLC software was written, conforming with the customer approved Functional Design Specification and existing PLC software.  After factory testing/simulation the PLC equipment for Apollo Court was delivered to site for installation.

Working closely with TMS on-site maintenance team the obsolete PLC was removed and the new 90-30 PLC was installed.  Concurrently the new remote I/O cabling was terminated at each Genius I/O node.  With power now re-installed and 100% I/O checking completed, MCS engineers carried out stringent testing to the system, simulating Fire & Sprinkler Alarms throughout Apollo Court.  The system was then witness tested with the client for approval.

Results:  Working closely with the end user and with careful planning, the new GE Fanuc 90-30 PLC system for the SMS in Apollo Court was installed, tested and completed over a four day period, with minimum downtime and disruption.  With confidence and experience, the Gemini Court system was upgraded soon after with identical results.