Automation & Control Services

Controlled Engineering Solutions provides electrical engineering to automate various processes for our heavy industry clients.

Automation and control involves changing a manually operated system into an automated system, whereby the automated system has feedback from instrumentation and sensors that allow it to control and manage the process flow without intervention.

This results in positive outcomes relating to safety, efficiency, productivity, staffing and the integrity of operations.

The most common compliment CES P/L receives is not for the automation project itself, but for our ability to combine safety, business objectives, project management, longevity and a technically sound solution. This creates polished projects that are both systematically appealing and provide improved metrics.

Our Automation & Control Capabilities Include:

  • Conveyor Systems
  • Instrument Control
  • Networking
  • PLC Systems
  • SCADA Systems
  • Telemetry

Professional Coding Standards

CES P/L has programmers in-house to handle the code requirements for our projects. We are proud to employ programmers that are on top of their game. Our programming encompasses the design of processes, instrument control, SCADA systems and commissioning. We have a long history of delivering robust code.

At the end of the day, many programs can achieve the same outcome, but the structure of the program is so important.

We have a specific structure for our programs to ensure that they are optimised and consistent across all sites. This is referred to as standardised or universal code. Then, we can have any of our programmers understand and edit code remotely, and be certain of the functionality.

If programmers don’t structure the functionality within a PLC program, it will end up as an absolute dog’s breakfast. The core problem is that when updates or optimisation is required, sites usually have very few details on their code, so a programmer manually assesses the code line-by-line to understand how it’s functioning

Standardised code leads to better scalability, easier support, efficient commissioning and of course, better integrity of operations.

We consider software development architecture to be primary.

We also understand the importance of being able to support our remote clients. With the modernisation of 4G and 5G networks, clients who require our high-level technical support have the option for CES to assist with remote troubleshooting (i.e. alarms, data trends, flow issues etc).

Controlled Engineering Solutions

Automation & Control Projects Lead to Astonishing Results

In this example, we will reference a project at a power station in North Queensland.

The power station had seventy operators adjusting valves and air vents to control air flow into boilers to produce flames and steam to run the turbine. That manual process delivered power into the network.

We were part of the team to implement the re-design of the power station, automating all the manual functions. The solutions implemented allowed the site to reduce its staffing from seventy operators to three. 

Additionally, these operators could exit the control room and monitor site alarms through a tablet, allowing them to perform other tasks simultaneously.

The North Queensland project resulted in measurable outcomes to safety, efficiency, productivity, staffing and integrity. The client was also able to save costs from reduced house infrastructure and accommodation costs in the nearby town.

Recommending Equipment & Brands

We are across the major automation & control brands such as –

  • Rockwell – Allen-Bradley
  • Modicon
  • Omron
  • Wonderware
  • Citect
  • Siemens
  • And many more.

It depends upon the unique application as to what equipment we will recommend. The complexities typically relate to cost variations, technical support availability and software restraints. We help our clients understand the pros and cons of each pathway.

For greenfield projects there is an emphasis on identifying the appropriate brand. New sites or plant upgrades have a range of functionality and equipment to automate, so there is often more flexibility during procurement.

In contrast, for brownfield projects, we are mostly integrating with the existing equipment in place. Mixing and matching brands can lead to problems, namely, a site with mixed brands may require multiple support contacts, so troubleshooting is less streamlined. Equipment assets should offer stability and consistency.

Automation & Control Project Notes

In most cases, electricians will be subcontracted to perform the physical installation of the upgrades. Afterwards, we apply the programs and begin the commissioning phase to confirm the safety and the integrity of the system.

From that point the solution is handed over to the site. CES may exit the project or adopt a maintenance role for code modifications, remote support or onsite support to assess how instruments are reporting information into the PLC over a length of time.

Each automation & control project we have worked on has been totally unique, so we have developed a high level of diversity in our skillset and the ability to support multifaceted electrical functionality.

Engineering for Heavy Industries

CES partners with many different heavy industries, including mining, industrial plants, quarries, extractives and more. We are able to automate isolated or site-wide processes, with contingency and expandability in mind.

We are versed in handling different materials, fluids and chemicals in our designs to optimise the functionality of the plant. We work in with other engineering arms and disciplines (i.e. metallurgist, chemists) to ensure that our automation delivers the optimum output.

For example, a chemist will provide us with the best-practices for extracting copper ore, such as flow rate, desired mineral density, adding thickener and mineral recycling, so our automation will be controlled between these parameters.

Sites can lose a lot of products if their automation isn’t working properly.

Key Clients

Heron Resources, Woodlawn NSW

We developed the programming for the Human Machine Interface (HMI) to change manual processes into fully automated processes.

This removed manual interactions from operators, saving the company time and money. Put simply, the operation runs from inputs from level devices so that we can adjust pump speed so the water level remains constant.

Whitehaven Coal, NSW

We designed fully automated crushing plants. The systems could detect when conveyor systems become overloaded and could automatically slow the processing down.

We also introduced fail-safes to keep the plant safe and prevent it from burying itself in product.

The CES P/L Automation and Control Advantage

We are an electrical engineering arm that handles electrical engineering projects from start to finish. Our focus is to ensure systems are safe and function as flawlessly as possible.

  • We have over 30 years experience
  • We service Australia wide
  • We offer automation design, optimisation, commissioning & support
  • With the cost savings your site will yield, you can buy yourself a Rolex

Please contact us if you have any questions.