Network integration of bespoke product handling machines to fully automate the packaging and palletisation of product.

Real-time data transfer between systems was configured via a redundant ControlNet architecture using the Produced/Consumed tag data protocol within RSLogix 5000. 

Design, production and commissioning of high speed palletisation plant for a national paper manufacturer based in the UK.

Integration of real-time product tracking system, automation of conveyor routing to warehouse distribution centre.

Development of a fully automated interface for ASCII data exchange with legacy robotic labelling machines.

Integration of  system from palletiser outfeed to loading bay.

The migration of a bespoke deep trench silicon wafer etching system posed new challenges for accurate and deterministic logic execution.  The PLC (RSLogix 5000) application was required to be fully flexible to allow the integration of new or upgraded devices to any I/O point.

The gases used in the etch/deposition process had to be cycled to an accuracy that could only be determined by evaluating task scan periods in real time as a method for accumulating time.    The final solution gave an etch accuracy to +/- 0.1 microns. 

 The brewing industry has been a principal focus for many projects in the UK, mainland Europe and Asia.These include the automation of the brewing process:

• Dry Goods Systems
• Mash Vessels
• Wort Boilers
• Wort Coolers
• Yeast Press
• Fermentation
• Conditioning

Key roles within the mainland European projects included the successful implementation of a design documentation system from initial consultation through to customer FAT          Projects within the confectionery industry of automation of high speed plant with full integration of RSLogix5000 and FactoryTalkView SE.      The S88 standard to the modular software approach for batch processing included the full integration of plant floor data to the enterprise layer which allowed analysis of plant availability and an increase in efficiency for production planning. 

One of the most presitigious and challenging projects was the Shell GTL (Gas to Liquids) plant in Qatar.

Development of an OPC serial interface from all areas of gas analysis throughout the process to a fiscal metering/archive database was undertaken.     The development required close consultation with all projects from Air Separation, Feed Gas Preparation through to Liquid Processing Units.

OPC products from Matrikon, Kepware and Honeywell were used throughout the design, test and simulation stages of the project.       Ineos Fluor

 PROJECT LEAD ENGINEER

• HP Heater Feedwater System
• Fuel Oil Storage and Control Systems
• Boiler Sootblowers Control
• Water Treatment Plant Upgrades
• Boiler Water Cannons Cleaning System

Budget planning, tracking and control. Personal responsibility for capital projects totalling £1.2m. Project planning and scheduling using analogous and parametric estimation techniques. Management and procurement of instrumentation and 3rd party installations. Responsible for design review and approval processes with Competent Body peer review

• System analysis, functional design and system development.
• HAZOP studies, LOPA analysis, FMEA assessment, Risk Analysis to design Safety Instrumented Systems to IEC 61508 & IEC 61511.
• System compliance to COMAH regulations.
• Management of system implementation, installation and commissioning.