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04 · Control systems, instrumentation and power

Control systems designed, built and commissioned, then kept running.

We design, integrate and commission every kind of control system, from a single PLC panel to a 980 MW HVDC converter platform. We work in oil and gas, power, renewables and any plant that automates, and we stay on site until the system runs.

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980 MWTenneT's 980 MW HVDC offshore wind platform, commissioned at McDermott's Jebel Ali yard.
Siemens S7-400H redundant IMAC and PMS controllers with ET 200SP HA I/O on TenneT's HVDC platform
Two redundant Siemens S7-400H controllers in one cabinet on TenneT's HVDC platform: KE0001 runs integrated monitoring and control (IMAC) and KE0002 the power management system (PMS). Each connects to SIMATIC ET 200SP HA distributed I/O over labelled PROFINET and fibre links.
What we deliver

PLC, DCS and SCADA, instrumentation and power, through to handover.

System integrationPLC, DCS, SCADA, RTU and HMI; emergency shutdown, fire and gasTurnkey projectsDesign, procurement, installation and commissioningCommissioningAll control system types; FAT, SAT and loop checksFault findingTroubleshooting, root cause analysis and call-out supportInstrumentationField instruments, analysers, metering and calibrationPower and networksLV and MV distribution, motor control centres, drives and UPS; Profibus, Profinet, Modbus and Ethernet/IPUpgrades and securityReplacement of obsolete systems and OT cyber security
Case study

TenneT HVDC platform, Jebel Ali.

Control system commissioning on the 980 MW HVDC converter platform that McDermott built for TenneT at its Jebel Ali yard in Dubai. The platform connects offshore wind farms in the German North Sea to the grid.

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HVDC platform power management system controller: Siemens S7-400H with CPU 410-5H, CP 443-1 modules and fibre I/O
Power management system (PMS) controller for TenneT's 980 MW HVDC platform: a Siemens S7-400H rack with a PS 405 power supply, a CPU 410-5H, two CP 443-1 Ethernet modules and redundancy sync modules. The ET 200SP HA station below connects over fibre and is wired out to terminal blocks.
On site

Inside the control cabinets.

Siemens SIMATIC S7-400H redundant PLC rack with CPU 410-5H and CP 443-1 Ethernet modules
Integrated monitoring and control (IMAC) controller for TenneT's HVDC platform: a Siemens SIMATIC S7-400H rack with a PS 405 power supply, a CPU 410-5H and three CP 443-1 Ethernet communication processors. Beside it, ET 200SP HA interface modules connect to the controller over LC fibre and serve eight I/O module slots.
Redundant 24 V DC power distribution with ABB switch-disconnectors, SITOP PSU6200 supplies and E-T-A breakers
Redundant 24 V DC power distribution on the HVDC platform: two incoming feeds through ABB switch-disconnectors and Siemens miniature circuit breakers, two trains of SITOP PSU6200 power supplies joined by a SITOP RED1200 redundancy module, and E-T-A REX12D electronic circuit breakers (1 to 10 A) protecting each outgoing circuit.
Siemens SCALANCE XF204-2BA industrial Ethernet switches with LC fibre and PROFINET connections
The platform network: Siemens SCALANCE XF204-2BA and XF204-2BA DNA industrial Ethernet switches, fitted with BusAdapters for LC multimode fibre and RJ45 copper. The DNA version gives dual network access for redundant (PRP) networks. Fibre and green PROFINET cables are labelled and routed separately.
Control panel with two vertical columns of interface relays and push-in terminals for field signal marshalling
Field signal marshalling on the HVDC platform: two vertical columns of plug-in interface relays with push-in terminals keep field wiring separate from the controller I/O. Every wire is labelled and routed in slotted trunking, which makes loop checks and fault finding faster.
Close-up of labelled interface relays, cabinet thermostats and SITOP 24 V DC power supplies
Close-up from a platform control cabinet: interface relays KF37 to KF48 and their terminals, with cabinet thermostats BT1 to BT3 and SITOP power supplies TA1002 to TA1006. Every device is tagged to the IEC 81346 reference designation system, so each one can be traced straight back to the drawings.
Siemens PLC control cabinet with SCALANCE network switches on the door, fibre optic and PROFINET cabling
A control cabinet on TenneT's HVDC platform, with its network built into the door: Siemens SCALANCE industrial Ethernet switches linked by multimode fibre and green PROFINET cables. Inside are the 24 V DC power distribution, E-T-A electronic circuit breakers, cabinet thermostats and SIMATIC ET 200SP HA distributed I/O.
Commissioning

Commissioning from cabinet to start-up.

We test and commission control systems at every stage: factory acceptance tests (FAT) at the panel builder, site acceptance tests (SAT), loop checks, cause and effect tests, and start-up support. We work with Siemens PCS 7, S7-400H, ET 200SP HA, SCALANCE networks and other major platforms.

For large jobs we bring a full team of 50 or 100 people with its own supervisors.

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Planning an upgrade, or need commissioning support?

Talk to an engineer about your control system.

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