We provide expertise and tailored solutions for the design and execution of replacement, upgraded or new control systems.

We use our knowledge of engineering, information technology and business to integrator plant equipment to automate manufacturing and processes from the plant floor to the enterprise level. We manufacturers and processors to automate to reduce cost, increase production, use less energy and lower environmental impact.

Here are the typical services we offer covering the full life cycle of an integrated automated control system:

CONSULT

Client sometimes do not have enough information about a process or system to provide a requirement specification or even know if a project is feasible. In these cases our engineers carry out a feasibility study and provide the client with a report and what technical solutions are available with order of magnitude budget costs to allow clients to plan and apply for their budgets. Our engineers can then take this process one step further and produce a User Requirements Specification.

As well as feasibility studies and user requirements specifications our engineering teams can produce other special reports, investigations and audits. These can vary from obsolescence reports, where we carry out a detailed assessment of the status of assets, to independent incident investigations, where we provide a detailed report looking at the design, operation and any defects within a system involved in a incident.

DESIGN

At Abalto, we have multiple engineering teams who carry out the design of control systems with in-house design capabilities for all elements of the control systems design process from specification and hardware design to the production of software, build and installation documentation.

From sizing equipment to designing custom control panels, our in-house engineers have a wide range of hardware design capabilities. All our electrical schematics are produced in an electrical drawing package, ensuring consistency in the drawing styles as well as allowing automatic referencing and production of documents such as cable schedules and cable block diagrams for consistent and quick panel builds.

Our in-house Software Design Engineers have extensive knowledge of DCS and PLCs from all major manufacturers and can produce software in many languages including Ladder Logic, Statement List, Structured Text, Sequential Function Chart (Grafcet) and more. Our engineers work closely with clients to produce a user friendly system Graphical User Interface (GUI) with Human Machine Interface (HMI) providing process status and diagnostics and/or a Supervisory Control and Data Acquisition system (SCADA) with a Historian and Reporting capabilities.

BUILD

As part of our turnkey solution following the design stage of a project, we assemble and build all elements of a control system typically consisting of Control panels, Motor Control Centres (MCC), Control desks, Operator stations, Network and server racks, DC & PLC systems, Server systems, Network equipment, Thin clients & thick clients and Instrumentation.

As well as building systems to British and European Standards, we provide systems worldwide, including China (CCC), Canada (CSA) and the USA (UL), meeting all appropriate local standards ending with a Factory Acceptance Test.

INSTALL

During the design process our engineers will produce installation documentation such as cable block diagrams, cable schedules and termination schedules. These documents are used by our installation team and ensure the systems are installed accurately as per our design.

Our installation technicians teams provide a full service, including cable management systems, power cabling, control & instrumentation cabling, panel installation, testing, certification and remedial works and instrumentation installation.

Should our client prefer to carry out the installation in-house or with their preferred subcontractor, Abalto will provide the all necessary installation documentation. If required, we provide a supervisor to oversee the work who can test the installation to ensure it is as per our design documentation.
In addition to electrical installation as part of a turnkey package, Abalto can offer mechanical installation services for minor works.

COMMISSION

We have a dedicated team of Commissioning Engineers and Technicians who have experience in commissioning complex control systems on many different sites all over the world. Our Commissioning Engineers will oversee and test the installation of a system before commissioning.

Our Engineers routinely undertake the following tasks including Installation verification, System power-ups, Input/output (I/O) checking, Instrumentation calibration and validation, Hardware commissioning, Software commissioning (DCS/PLC/SCADA), Safety validation, Process & application commissioning, Site Acceptance Testing (SAT).

TRAINING

We routinely provide operator training on the processes and systems equipment as well as training maintenance staff. To support this we offer a comprehensive training program, structured and tailored to the projects specific requirements which will generally include providing operations staff with detailed knowledge of all operator interfaces and how to operate the system to maximum performance and benefit.

WE also provide maintenance staff with detailed knowledge on how to diagnose faults, plan maintenance, rectify faults and quickly return the system to full performance, giving technical support staff in-depth knowledge on how to modify the system to achieve desired changes in functionality and providing management with a summary of the systems available with an explanation of performance monitoring and extraction of available information.

SUPPORT

Our Service Team offer a completely bespoke preventative maintenance and support service. Currently, this team is responsible for over 20 sites throughout Europe with clients from all of our industry sectors.
Our service support is your insurance against unplanned and potentially costly plant outages. We are experts in the support and maintenance of software and complex control and instrumentation systems.

As well as our own expertise, we have teamed up with strategic partners to offer full turnkey support, including mechanical and hydraulic services.

It is important that our support services meet the requirements of our clients and so we create a tailor-made support agreement which can include any or all of the following services; scheduled preventative maintenance visits, scheduled instrument calibration visits, 24/7 callout support with guaranteed response times, remote telephone support, remote diagnostics via secure connection, holding and servicing of spare parts, system auditing, online reporting services and obsolescence management.