Control systems written by process engineers
We design, commission and maintain control systems for power plants and refineries. The difference between us and an automation contractor shows up in the fuel bill.
What we do that others do not
Six DCS platforms and experience on SIL 2 and SIL 3 applications are the baseline. What sets us apart is the process engineering behind the control system.
Island mode, proven on a running plant
When a refinery loses the grid, its CHP plant has seconds to decide whether the refinery keeps running. We implemented that transition and proved it on a live plant in two trials, holding 13–14 MW in the island, agreed in advance with the transmission and distribution system operators. It is one of the most demanding tests in power plant commissioning and most contractors are never asked to run it.
Fuel accounting inside the control system
A CHP plant makes two products from one fuel stream, and no measurement separates them. We implement the allocation, the boiler efficiency by direct and indirect method, and the turbine heat balance as live calculations in the DCS, archived, with the cost of every deviation from design attached. Most plants get this as a spreadsheet at month end, if at all.
Plant performance and fuel accounting
Combustion that follows the fuel
On a CFB boiler firing petroleum coke, the fuel changes constantly. We calculate its calorific value automatically from the combustion result and distribute solid fuel across the feeders by heat value. That control strategy cannot be written without understanding what is happening in the furnace.
Advanced controllers for CFB boilers
Eleven years on one plant — and back again
Three boilers of 120 t/h, a 260 t/h CFB boiler, three 12 MW turbines and one of 30 MW, five steam headers, a refinery on the other end. Designed, commissioned and maintained continuously from 2007 to 2018, and under maintenance again since 2022. Process knowledge of a plant is not bought; it accumulates.
What we do
- Process AutomationDCS and ESD from design through commissioning.
- Process optimisation / Advanced process controlDCS optimisers for load, fuel and emissions, delivered as a set.
- MES and production data systemsProduction data, efficiency and loss analysis over OPC.
- Safety Systems and Burner Management SystemsBMS and SIS to SIL 2 and SIL 3 under IEC 61511.
- Industrial furniture / Control centersISO 11064 control room design and operator furniture.
- MaintenanceLifecycle support for major DCS platforms.
Industries
- Power GenerationAutomation for steam, gas and hydro turbines, HRSG, boilers and district heating.
- Oil and GasBurner management, safety instrumented systems and control room architecture.
- Bulk material handlingConveyors, bins, crushers, mills and weigh batching — from concrete plants to solid fuel handling on boilers.
- Control CentersDesign, manufacture and supply of control centers and operator furniture.
Selected projects
See the full project list under References. SIL 2 and SIL 3 on HIMA HIQuad, Foxboro Triconex and ABB AC800; DCS on Emerson Ovation; remote dispatch over IEC 60870-5-104. We also manufacture our own DIN-rail automation modules, taken through the applicable EU conformity assessment procedures — see HomeMaster and Compliance and Testing.