Typical Contracts

Utilities
- Project: – Clean Water Production Control
  System: Siemens S7-300’s and WinCC SCADA
  Details: Automation and control of a complete Water Treatment Works is South Wales. with a capacity of over 200Mltrs per day. The build consisted of a new CocoDAFF plant and an electrical upgrade to the existing pressure filters control panels. The system was designed using Profibus extensively for both Remote IO and direct device control.
- Project: – Sludge Digestion Scheme
  System: Mitsubishi A series PLC’s, A870GOT HMI’s and MX32 SCADA
  Details: Automation and supervision of a new sludge handling facility near Hereford. Including control of new Rotamat screens within the inlet works, machine thickening plant and sludge digestion system, all of which were controlled by networked Mitsubishi A series PLC hardware, communicating via ethernet to a MX32, central works SCADA system. The SCADA also combined monitoring of existing works control systems via networked Siemens Ti PLC’s, providing flow reports and trending for the Environment Agency.
Electricity and Generation
- Project – Nuclear Waste Handling Control System
  System: Schneider Telemecanique TSX PLC
  Details: Control of a Waste Handling Crane system by PLC from operator manual selection. The PLC incorporated numerous complex, critical interlocks essential for the safe and reliable operation of the waste handling crane. The system was based upon a Telemecanique TSX PLC with programming terminal based upon an O/S 2 operating system.
- Project: – Water Turbine Generator Control System
  System: Allen Bradley SLC5/03 system
  Details: Control and synchronisation of a new Water Turbine Generator, exporting electricity to the National Grid network. Water flowing from an adjacent river was controlled through the turbine to bring the generator on line and then increased to export at up to 500 amps. Under/over voltage, frequency and current were also monitored along with water flow and level instruments, in order to provide protection for the generator set, within the software. The system was based upon a single Allen Bradley SLC 5/03 system, with Dtam micro operator interface providing manual controls and monitoring.
Aggregate, Roadstone and Coal Processing
- Project: – Quarry Routing and Batch Control System
  System: Allen Bradley SLC 5/04 system with CiTect SCADA
  Details:Retrofit of a new PLC based control system to an existing quarry plant handing the routing, crushing and screening of aggregate into various sizes. In addition to the conveying of aggregate from the Primary through to the Secondary section, blending of the stone in to various sizes was also controlled using a batch recipe system, from the SCADA system, with manufacturing/production reports archived for future reference. The process was controlled by a single SLC5/04 CPU with five remote I/O devices at within various motor control centres. Batch and recipe handling was overseen by a CiTect SCADA system.
- Project – Coal Processing Plant Control System
  System: Allen Bradley SLC 5/03 system and CiTect SCADA
  Details:Control and automation of a coal washing, grading and distribution centre, near Neath, South Wales. The facility was capable of processing up to 400tph of raw coal, under control of a single Allen Bradley SLC 5/03 system. A CiTect SCADA system was configured to provide operators and managers with access to rive control, real-time diagnostic data, trends and manufacturing reports.
Feed Production and Grain Handling
- Project – Royal Portbury Docks – Grain Export Terminal Control System
  System: Mitsubishi AnS series PLC’s with CiTect SCADA
  Details: Control and automation of routing conveyors and associated equipment, handling the delivery and movement of grain from vehicles, delivered to the Port, and transfer either to storage vessels or directly to sea bound vessels. The system was developed in order to ensure simultaneous route operation and flexible route changeover, whilst preventing cross contamination. The system was based upon the use of two Mitsubishi AnS series PLC’s connected by fibre-optic network, with supervision and management information provided by a CiTect SCADA system.
- Project – Animal Feed Mill Control
  System: Allen Bradley SLC/PLC systems with ‘AutoMate’ Supervisory Control
  Details: Control and automation of all aspects of the animal feed process, from Raw Material Intake, Weighing and Blending, Drug additives manufacture, Press Control, Finished Product Routing and Bulk Outloading. This is only one example of many Feed Mill control and management systems provided by Merlin Systems for this industry. Using the Allen Bradley range of SLC and PLC systems, in conjunction Merlins ‘AutoMate’ Feed Mill Supervisory and Management system, every aspect from a single area to, as in this case, the full Mill manufacturing process can be controlled. Merlin have approx. separate Feed Mill control systems in successful operation, throughout the UK, all of which are offered 24 hour maintenance support.
Manufacturing
- Project – HP Gas Cylinder Base Machining System
  System: Allen Bradley SLC 5/04 and PanelView 550 HMI
  Details: Control of a Machine Tool for the rectification of off-square bases in the manufacture of high pressure gas cylinders. The process included the handling and regulation of cylinders to and from the base machining operation, and positioning, clamping and precise machining of the base using VSD’s , proportional hydraulic valves and encoders to control cutting head rotation speed and feed rate. The control system used an Allen Bradley SLC 5/04 PLC, with PanelView 550 providing operator setpoint change and process monitoring.
- Project – Blow Moulding Plant Production and Services Control System
  System: Omron C1000H, C200HS and CQM PLC’s with USData FactoryLink SCADA
  Details: Control of a complete production facility with approx. 32 Blow moulding machines producing injection moulded PET preforms, including interface to material handling systems, and AGV transport systems. The system comprised of 5 networked major plant PLC systems controlling service equipment, including HP and LP compressed air systems, hydraulic cooling water systems with VSD cooling fans, machine cooling systems with water cooled by six chillers, and production hall ventilation systems. 32 additional remote PLC systems provided control of the bag filling systems and interface to the master AGV system, with a separate PLC controlling warehouse conveyors. The entire process was overseen by a Client/Server SCADA system, using a Wonderware application to provide process monitoring and historical data of process and manufacturing information, including real-time and historical trends, alarm and event logging.