Company Services & Manpower

Engineering Manpower

SKILL NO
1. Electrical Professional Engineer ( 33KV) 1
2. Mechanical Professional Engineer 1
3. Instrument Engineers 2
4. Instrument Supervisors 4
5. Instrument Technicians 12
6. Electrical Chargeman ( 33KV) 1
7. Electrical & Mechanical Technicians 2
8. Certified Scaffolders 17
9. Riggers 9
10. Trainees 3
11. Sales & Administration Staff 11

Services
Electrical , Instrumentation and Control System Integrator
Control Systems Analysis 
Business Systems Analysis
Electrical Panel Design and Assembly
Field Installation
Software Engineering
Reliability and Availability
Start up Engineering
Project Management
Documentation and Training
Service Contracts

Electrical , Instrumentation and Control System Integrator

PLC System provides E,I + C engineering and integration services to meet our customers’ industrial automation needs. We can supply a complete end-to-end service from the initial concept to ongoing maintenance and training.  A turnkey solution includes system analysis, electrical panel design, fabrication, hardware test, field electrical design, installation, control software development, start up, project management, documentation, and training.  Our philosophy is to provide functional, reliable, practical, safe, robust, and cost effective process and machine control systems.

We provide a wide range of services to assist in assuring the successful design, development, production and delivery of your system. Although all of the services listed below are available, you may choose the nature and extent of your interest. 

 

Control Systems Analysis 

The system analysis documentation can range from simple to rigorous depending on the size and criticality of the project.  A simple numerical I/O count specification may be all that is necessary for a control system retrofit.  Larger or unusual project definitions may include a Process Functional Operational Description (PFOD), and a critical system may need a Failure Modes Effects Analysis (FMEA).

A rigorous interface control program may be needed in a large Distributed Control System (DCS), particularly one with multiple vendors.  AeroSoft has developed database applications for change control and instrument specification control where the equipment and software vendors’ management tools are not sufficient.  The amount of attention put into these tools will certainly vary according to the project needs.  This information becomes the basis of the Operations and Maintenance Manual. 

 

Business Systems Analysis

PLC System engineers will work with our customers to develop control system specifications and designs that are practical, usable, extensible, and can integrate with the present and/or future information technology (IT) systems.  The promise of “Open Systems” interconnectivity remains elusive with competition among multiple field bus standards and stand alone legacy systems.

Standards are now being proposed and accepted.[1]  PLC System can provide hardware, database software, and protocols to collect and disseminate information in a reliable and secure manner across your network, or over the Internet. 

 

Electrical Panel Design and Assembly

PLC System will work with our customers to specify the correct control hardware, software and firmware.  We provide the design for the control component enclosures, controllers and field termination panels.  We provide electrical engineering services for complete systems integration from the trenches to plant wide control.  Panel and control equipment test may range from powered I/O tests to insure the integrity of the panel, to a rigorous simulation of the process and network configurations. 

 

Field Installation

PLC System will provide on site field installation of the control panels, and connect to the existing and supplied equipment.  We provide the engineering required to integrate all associated control hardware to the field devices.  We will provide field integration services or subcontract the field wiring installation portions to licensed electrical contractors based on practicalities.  We will generally use local contractors and provide an PLC System engineering manager to supervise the field installation. 

 

Software Engineering

PLC System engineers will procure or develop, and document the software associated with the machinery, field devices, process controls, operator interface, and the information systems.

The attention paid to the functional description and interface control documents can pay large dividends in this phase of development.  The early design of the data structures (data dictionary), prototype operator interface, and standardized software structures aids in the coding and integration phases of the various hardware and software components.  Even for smaller systems, the definition and documentation of the inner workings is crucial for the understanding, maintenance and modification of the systems.

PLC System has experience with numerous standard and proprietary programming languages, including all of the IEC 1131-3 defined languages.  The specific language may be mandated by the equipment vendor or specified by the customer.  The preference of PLC System is to provide universally available standard products.  Some examples: A Microsoft SQL server with VB or C++ scripts can be supported by millions of programmers around the world, as apposed to a vendor’s proprietary system that may require flying someone across the country.  Software drivers for specific manufacturer’s control equipment are available and maintained by independent companies, and frequently at a lower cost and better performance than the drivers provided by the equipment vendor.  All of this adds up to a lower systems cost and lower ownership cost over the long term. 

 

Reliability and Availability

Putting the critical functions at the most directly coupled control element enhances reliability. Dedicated devices handle motors and burner interlocks, and the status is passed to the control level (PLC).  Analog alarm thresholds that control equipment should be detected in only one place, and the status passed upward.  Sometimes the addition of an economical interlock can be quite effective.  For example, adding a current sensor to a pump can detect faults based on higher than average current, a dry pump, a valved off pump, or a local disconnect open.

Machine availability is a combination of reliability and the average time to repair.  All of these techniques contribute to systems that can provide functionality in a safe and effective manner. 

 

Start up Engineering

PLC System will be available, on site, during the start up phase of each project.  The device test and calibration operations frequently can be combined to save time and detect errors.  For example, reading a thermocouple and driving the analog input can be accomplished in one visit to the device to provide verification and validation.  Once the data is verified at the lowest control element, the process continues to the next level.  Change orders are handled in an expeditious manner and verified that each affected documentation level of the control system is included in the communications.

PLC System can provide calibration and test for most common temperature, pressure, vacuum, and control devices.  This service can be accomplished on site and can be continued as part of a scheduled maintenance agreement. 

 

Project Management

PLC System will provide project management for all projects.  Even a small system requires fitting together the price, performance, and delivery schedule.  More formalized management tools include a Statement of Work (SOW), and a Work Breakdown Schedule (WBS).  We can provide a multi-tier PERT/CPM schedule with resource loading to your desired format.  The manager will oversee the engineering analysis, software development, hardware design and implementation, and the start up phases of these projects.  This individual will coordinate all efforts between PLC system engineers, production, outside vendors and our customers during the entire design-build process. 

 

Documentation and Training

PLC System methodology of creating the core documentation up front, and then building the hardware and software around it is a very simple principle in concept, but is somewhat rare in actual industrial control system implementation.  In practice, ongoing engineering changes and field modifications are less likely to get included throughout the documentation package.

Functional descriptions, theory of operation, and maintenance procedures are more often an afterthought than they are a planned part of the system.  The result of a poorly documented and patched together system is one with higher maintenance costs, shorter life cycle times, a higher lifetime ownership cost, and lower availability.  Many systems are removed and replaced with a new one simply because it is more economical to replace them than it is to figure out what is really out there.

No one enjoys working on a system with missing, incorrect, or obscure information.  We can produce a “Intranet” based documentation system that maintains the information on your server for access anywhere along the network.  The information is accessed with a standard web browser by selecting the piece of equipment, the subsystem, and drilling down to the exact information needed.  This procedure frequently takes less time than just finding the manual or drawing set.  Maintenance of the documentation is feasible due to the single collection point for manuals, drawings, photos, and maintenance logs.

We normally provide an Operations & Maintenance (O&M) Manual along with operator and technician training materials.  The former is based on the materials produced early in the program while the latter can range from simple view foils and handouts to a complete technician-training program.  

 

Service Contracts

PLC System can provide several types of service contracts for on site service work. These contracts can consist of standard hourly rates or fixed price term rates based on the scope and nature of the work.  Contract rates include on site service, unlimited phone support for the length of the contract.  Naturally, we honor our warranty commitments.        

 

 

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