Services
Control Specialists Ltd have provided process control related services to the Process and Manufacturing industries since 1989 and have worked in the UK and Abroad.
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Software Design
"There are major business benefits in having a defined process that delivers systems that are fit for intended use, on time, and within budget. Systems that are well defined and specified are easier to support and maintain, resulting in less downtime and lower maintenance costs - ISPE, GAMP 5, A Risk-Based Approach to Compliant GxP Computerized Systems"
Whilst GAMP 5 (Good Automated Manufacturing Practice) is primarily aimed at the pharmaceutical industry, the principles it promotes, and the benefits of following procedures that are based on it, can be applied to all industries.
Control Specialists have over 20 years of control system software design experience in a wide range of industries including pharmaceuticals. Our design processes are regularly audited by external organisations and the feedback we get from our clients shows that our approach to software design and validation is a robust one.
As well as being conversant with the latest PLC / HMI / Scada systems from the likes of Siemens, Rockwell, Eurotherm, Emerson & Wonderware, we also have practical experience in obsolete systems such as Siemens Step 5 and Turnbull Control Systems (TCS) S6000 range of Programmable Controllers (Forth and Loopdraw).
Validation & Documentation
Whether you are looking for control system software to be developed to meet GMP regulations, need assistance with the validation of a new system or simply want to improve the level of documentation available for the support or upgrade of an existing system, Control Specialists can help.
We have over 15 years of experience working in a GMP environment following GAMP guidelines and covering the entire design life cycle of computerised control systems. This experience has been gained in software-design, validation management and the on-going support of gmp-critical control systems.
We can provide examples of the following documents on request: Validation Plan, User Requirements Specification, Functional Design Specification, Hardware Design Specification, Software Design Specification, Code Review, Configuration Management, Hardware Acceptance Test Specification, System Acceptance Test Specification.
PID Loop Optimisation
PID Controllers are the workhorses of industrial automated process control yet are often neglected when it comes to ensuring that they are optimised to a process. Poor tuning can hide under lying process issues which can lead to deterioration in system response and product quality. Control Specialists have over 25 years of experience in the optimisation of process control loops in many industries. This experience has been recognised by us being appointed an Approved Solutions Partner of ExperTune whose software is used around the world on plants having 1000’s of control loops. Our approach to loop optimisation goes beyond tuning and includes valves, transmitters, installation and software reviews.
We have practical experience in identifying and resolving issues associated with Single loop PID Control, Cascade Control, Feed forward, Gain Scheduling, PV Filtering, Deadtime dominant systems, Valve Oversizing, Hysterisis, Stiction and incorrect characterisation.
Production Data Applications
We have the ability to develop and support bespoke applications to allow the data with a control system to be made available to a wider audience in many different formats. Whether your need is for simple reporting or the development of a larger data collection and reporting system, we have the experience and can help.
Control System Support
We offer as-need and contract based / guaranteed response support on PLC and Scada-based automated control systems in both GMP and non-GMP industries. Very often this support is for systems that we have not supplied but where our clients have recognised the experience we have, our flexibility and our proactiveness in putting forward suggestions for on-going improvement.
Profibus Network Support
The fact that your Profibus Network is working now does not mean that will always be the case. Regular checking of its performance is a proven way of reducing downtime and improving its robustness.
Control Specialists Ltd is a member of the Profibus Group UK and is an accredited Profibus Company. We offer as-need, or contact-based support using the latest industry-standard tools which, together with our software-design experience, allows us to address software related issues as well as those associated with network installation and performance.
PID Training
In addition to having extensive practical knowledge of control systems, we have an excellent reputation for providing PID training courses. The training uses PC-based simulation of the most common process loops and aims to be the missing piece of the jigsaw linking the theoretical world with the practical one. An analysis of the feedback from the most recent training courses we have provided can be found on the Client Feedback page of this site. Details of our ExperTune-approved training courses can be found on the Partners – ExperTune page of this site.
