ICS - Industrial Automation and Process Control Systems

Industrial Control Systems is an engineering firm focused on the design, implementation and support of industrial automation and process control systems. We work on improving various processing plant stages, through introduction of precise control and automation systems, to enable our clients to run their plants more efficiently.

ICS provides a broad range of services to meet the needs of industrial automation, and process control projects. This includes process control system design and implementation for upgrades, replacements, expansions and new installations.

APPLICATION-SPECIFIC CONTROL SOLUTIONS

ICS provides application-specific control solutions. The combination of distributed control systems, emergence of open-system options and new software tools are giving us the opportunity to closely tailor a control system to a specific application or industry.

The granular functionality of the control system coupled with open-systems standards has led us to build custom control systems with off-the-shelf standard building blocks.

ICS control systems help:

• Minimize commissioning and start up time
• Maximize protection for the plants during start up and operation
• Operate plant more efficiently and effectively to maintain the designed produced quantity and quality
• Ensure that plant can be operated and maintained by semi skilled operators

ICS main areas of expertise (technology areas):

• Modern process control system design and implementation
• Control logic design, verification and implementation
• Control system retrofits and upgrades
• Plant control systems (DCS, SCADA) application software development
• PLC programming
• HMI systems
• PID loops and soft controllers
• Control panel design and construction
• Commissioning and start-up
• Operation and maintenance management applications
• Project documentation

WATER TREATMENT PLANT - PLANT CONTROL SYSTEM (PCS)

Below are some examples of our design and implementation of advanced control and monitoring plant control systems.

Sheikh Zayed Water Treatment Plant (450,000m3/day): the system covers approximately 7,000 I/O points. Our aim was to automate the water treatment process and system control. The plant control system consists of nine Siemens S7-400 PLC for automatic and manual functions, the control desks for manual operation and status feedback, and a mimic diagram for displaying the entire plant process flow diagram.

Convoy Water Treatment Plants Project: the three 800L/s plants each feature approximately 1,200 I/O points. The aim was to automate process and system control to a large extent. This was achieved using Beckhoff technology.

FILTER AUTOMATIC CONTROL SYSTEM

Our clients for filter automatic control systems include:

• 240 Villages Project - 199 filter control desks - Arab Contractors
• 240 Villages Project - 36 filter control desks - Kaha Chemical Industries
• 240 Villages Project - 33 filter control desks - Arab Organization for Industrialization
• West of Canal WTP Rehabilitation Project - 12 filter control desks

PLC-BASED FILTER CONTROL SYSTEMS

A PLC-based control system is provided for controlling the operation of the filter cell in all modes of operation:

• The PLC consists of CPU module, power supply module, digital input/output modules, and analogue input/output modules
• The filter PLC controls, monitors and coordinates the process in its various modes of operation
• The PLC has an industrial ethernet communication interface module that enables the individual filter cell PLC to be networked with other filter cells' PLCs for data movement and coordination of filter backwash
• The man-machine interface (operator console) is composed of selector switches, illuminated push buttons, and a 15in liquid-crystal display colour monitor
• Modes of operation can be selected from the selector switch positions
• In the case of local-manual mode each valve, blower, and wash-water pump can be operated via push buttons
• The LCD colour monitor displays the filter cell dynamic mimic, showing the modes of operation, real-time water level, head loss, valves position, low flow and high flow status, air blower status and faults

BATCH CONTROL SYSTEMS

A leading pharmaceuticals company DSM Anti-Infectives, Egypt (one of the world's leading producers of different bulk pharmaceutical intermediates and active substances) is one of our batch control systems clients. The DSM Cairo plant has a complex production train.

The production processes and equipment lend themselves well to complete batch automation using FactorySuite software. The works can handle liquid extraction, salt formation, distillation, and hydrogenation, gas / liquid reactions in loop reactors and catalyst separation and regeneration.