Services

Process control and industrial automation engineering

TBC supports industrial process and petrochemical projects where PLC, SCADA, instrumentation, packaged equipment and electrical interfaces must be coordinated into a clear and testable control system.

Try the process demo

Process automation

Control built around the operating sequence

Process-control engineering starts with how material and equipment move through the system, then defines the permissives, trips, alarms and operator actions needed for safe, repeatable operation.

Pump, valve and packaged-equipment sequences
Process permissives, interlocks, trips and alarms
Instrumentation and status integration
PLC, HMI and SCADA implementation

SequencesStart, stop, transfer and operating modes defined around the process requirement.

InstrumentationAnalogue and discrete signals incorporated into control and diagnostics.

PackagesThird-party skids and equipment integrated through defined interfaces.

OperatorsClear HMI/SCADA status, alarms and control authority.

Petrochemical & brownfield

Brownfield changes have to fit around the plant that is already operating

Existing process sites rarely start with perfect drawings, current software and unlimited shutdown time. The first job is to establish the installed condition, the change boundary and how the modification can be introduced without losing control of existing operation.

Existing drawings, software and site condition verified before change
Shutdown windows and phased implementation considered in the design
Instrumentation, packaged equipment and process interfaces checked against the actual plant
COMAH and hazardous-area responsibilities kept explicit within the agreed engineering scope

SurveyInstalled equipment, available records and known discrepancies reviewed before the modification is fixed.

BrownfieldLegacy software and live operating constraints treated as part of the engineering problem.

InterfacesShutdown, overfill, fire-and-gas, instrumentation and packaged equipment boundaries defined clearly.

CommissioningChanges planned so affected functions can be introduced, proved and closed out in stages where required.

Testing

Process behaviour proved against real scenarios

FAT and commissioning should prove complete operating and failure scenarios rather than only individual devices or signals.

Sequence, permissive and interlock testing
Alarm and shutdown-interface verification
Simulation and software FAT
SAT, commissioning, fault finding and closeout

Normal modesExpected process sequences and operator actions.

Abnormal modesFailed equipment, unavailable permissives and trip conditions.

InterfacesPLC, SCADA, package, instrumentation and electrical communications.

HandoverFinal backups, drawings and evidence updated to the accepted condition.

Related engineering

Process-control changes depend on the plant, packages and shutdown interfaces around them.

A pump or valve sequence rarely exists in isolation. TBC coordinates the PLC, SCADA, instrumentation, packaged equipment and electrical interfaces so the modification can be reviewed against the actual operating process.

Functional designSequences, permissives, trips and interface responsibilities captured before modification.

PLC engineeringExisting or new control logic implemented around the agreed process behaviour.

FAT, SAT & commissioningNormal, abnormal and shutdown scenarios proved before final handover.

Control systems integrationPLC, SCADA, instrumentation, packaged plant and electrical interfaces coordinated around the operating process.

Have a brownfield or process-control modification to work through?

Send the available P&IDs, cause-and-effect, software backup or problem description and TBC can establish the change boundary and engineering route forward.

Discuss a project

Explore the process-control demonstration

Try tank transfers, blending and protective trips using simulated equipment.

Open process demo ↗View both demos

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