What We Do
Controlled Engineering Solutions delivers electrical engineering services to industrial plants, from general engineering, power systems engineering and modelling, automation, hazardous areas and safety audits throughout Australia and internationally.
We are mindful of the Work Health and Safety legislation, Australian standards, and codes of practice in regard to actually working in and around industrial plants. We have developed job safety analysis forms and safe work method statements to be able to work safely in those environments as a part of our commitment to client site safety.
Our scope of work and execution of a project is based on safe, compliance design. When we visit a site to gather data for our designs, we do this via our internal safety management systems that ensure that personnel are safe and remain safe.
Our Experience
We have experience on a range of different industrial plants, namely:
- Power generation sites
- Metal and fabrication mills
- Water treatment plants
- Refining plants
- Food manufacturing plants
- Bulk materials handling
- Commercial explosives
Key Industrial Clients
Staff from CES P/L have past experience successfully working for the following key industrial plant clients:
- Tomago Aluminium
- One Steel
- Kooragang Bulk Facility
- Orica
- Flyash Australia
- Incitec
- And many more
Reducing Bottlenecking for Industrial Plants
When working on brownfield plants, reducing bottlenecking is a key method to improve processing and output metrics.
In one case, we were engaged to optimise a conveyor crushing system, which consisted of the typical:
- Boot / ROM bin
- Input conveyor belts
- Output conveyor belts
- Transfer chutes; and
- Oversized product return conveyor belt
The crushing system was experiencing spillages, and as a result, the secondary crusher was overloaded and would trip, stopping the process and requiring the crusher and belts to be dug out.
Through the implementation of additional controls / feedback and process control changes to the product bin door (controlling the valves and opening aperture of the feed supply), and in addition, the introduction of Variable Speed Drives (VSD’s) on input and output conveyors to control the flow rate, we were able to eliminate continued spillage.
Additional optimisation was achieved with the use of weightometers to assess how much product would be feeding into the secondary crusher, and the inclusion of a VSD on the crusher alleviated the need to dig product from the bowl, as we could achieve sufficient torque to get the crusher away.
Put simply, we are able to reduce bottlenecking and introduce automation simultaneously.
Project Management
Controlled Engineering Solutions is a dependable company with vast experience in all areas of project lifecycle for industrial projects, including:
- Concept stage (milestone planning, progress control, cost control, etc)
- Risk assessment
- Design
- Detailed design
- Implementation
- Commissioning & handover
- Development of maintenance packages
Certain staff from CES also comprise our second company, SCR, which is responsible for ongoing safety auditing, so CES can forward ongoing requirements to SCR appropriately.
We are an ideal choice for those looking for a world-class experience for turn-key electrical engineering solutions.
Performance Testing & Commissioning
After the systems are installed, we conduct a thorough commissioning phase. During this process we basically tune the sensing instruments until we get the optimum output.
Optimum performance is achieved through correct setup and commissioning, including:
- Calibration of all instruments
- Pressures, temperatures & bandwidth are programmed into the device(s)
- Work with relevant stakeholders (i.e. metallurgist) to ensure we are achieving the correct concentration of product and output
- Implementing relevant processes
Electrical Engineering for Industrial Plants with Contingency
CES is mindful of contingency and scalability, handling this is always a juggling act between sites.
We always look for the potential for change, this takes place early in the project during the concept stage, where we conduct an opportunity assessment to align our efforts with immediate and long term goals.
For example, on a materials handling project, the client asked for the possibility to include a pre-coating plant to coat an aggregate mix in the power system design. The current design didn’t have enough power to operate a second plant, nor did the client have the budget, so we were requested to design with 20% contingency so the client can execute that pathway when the time arises.
It is obvious that large infrastructure should be designed with contingency, however, we are mindful of contingency on a granular level. For instance, when designing a simple motor circuit, we would design cable size, switchgear and peripherals to be able to support an upgrade to the next size motor. That way, when processes change and the industrial plant requires more efficiency from that motor, upgrading it is much easier.
As mentioned, it’s always a balancing act between current capital and future upgrades, so we work closely with our client to safeguard their decisions and long term considerations.
Ready to Optimise your Industrial Plant with CES?
We are a team of highly skilled electrical engineers with a proven track record throughout Australia and internationally. The outcomes we deliver are multifaceted and lead to both immediate and long lasting improvements for:
- Safety of personnel
- Efficiencies in processes
- Resource management
- Technical work procedures
- Reliability and maintenance frequency of equipment
Please leave your enquiry on our contact page or visit us at Redhead NSW, we’ll put the kettle on.
