Established in 1975 to provide quality system integration service solutions into a wide range of industrial market sectors, MCS Control Systems Ltd experienced rapid growth and has now established a firm reputation for manufacturing quality MCC and PLC solutions, including SCADA, MES and PLC software.
The company also has an experienced software team, providing expertise in the design and implementation of HMI, SCADA, CIM, MES and specific integration at the top-end of control systems and materials handling, meeting the need for information connectivity between IT and production.
This combination of expertise means that MCS Control Systems Ltd. is now fully equipped to offer full turnkey systems capabilities, incorporating CDM 2007 Principal Contractor status, for process control system solutions, whilst the individual divisions are able to offer personal, specialist solutions to meet client specific project needs.
In a recent project involving the upgrade of a joint-council operated waste disposal and energy generation centre in the UK – which produces 17.7 MW of electrical energy from 245,000 tonnes of waste – it successfully upgraded a now obsolete control infrastructure to one that leveraged the contemporary performance and flexibility of an Allen-Bradley® ControlLogix® programmable automation controller (PAC) and associated automation solutions from Rockwell Automation.
MCS was tasked with replacing an aging Allen-Bradley PLC-5®-based control architecture, which controlled two steam turbines and three furnaces, with a more up-to-date solution without changing the footprint of the installation and using the existing cabling and wiring infrastructure.
The plant’s operators were finding that maintenance and repair were becoming difficult and were no longer cost effective; indeed if both primary and secondary PLCs failed all three incinerator units would become disabled.
According to Stewart Foster, sales director at MCS Control Systems, the big question is ‘do you migrate to a newer solution or replace the entire infrastructure’? “To replace the entire control platform would have meant major long-term downtime and would require a solution that would need proving and testing prior to installation and commissioning,” he explains. “By using the existing infrastructure, it can be a lot cheaper and there are significant advantages for the end customer. All in all it is a better idea and in this case a better solution.
MCS was given a four-day window to perform the changeover, testing and configuration on the common services, this included two of the four days with no power on site as the company had to take all power off line.