Control layerThe layer your operators live in
Control that follows your process, not a template.
PLC logic, operator screens and plant alarms designed together, so the system behaves the way the plant actually runs. New installations, upgrades, or a change to what you already have.
How we approach it
Designed around the process, built on the platforms listed below.
Control architecture
The architecture decides what you can change later. Kairos designs it around the process, then builds on your existing platform where it is one of those listed below, so an upgrade does not force you to replace everything that works.
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Projects run from small changes to existing plant through to multi-million rand installations: adding to existing systems, upgrading PLCs and building new control systems.
Siemens experience covers S7-300, S7-400, S7-1200 and redundant S7-400H, using Step 7 and TIA. Rockwell Allen-Bradley platforms include Micro, Nano, PLC-5, CompactLogix and ControlLogix, using RSLOGIX.
The team also works with Schneider Modicon Quantum, Premium, M340, Momentum and Advantys STB; Omron Micro PLC, CJ1 and CS1; and Mitsubishi A-series, FX series and Q series. National Instruments Programmable Automation Controllers and CompactRIO running LabVIEW extend this work into PC-based control.
- PLC architecture
- Control narratives
- Interlocks and alarms
Operator experience
The operator screen is where the plant is actually run, at three in the morning by someone who did not design it.
Kairos builds HMI and SCADA to be read quickly and trusted, for new installations and for upgrades to systems already in service.
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Platforms include Siemens WinCC in standalone and fully redundant configurations; Rockwell RSView32 and FactoryTalk machine and site editions; Wonderware Archestra, InTouch and Historian; and Adroit.
In Automill's batching workflow, recipe and order information follows the batch through holding points. SCADA presents the status and alarms of connected instruments, motors and valves.
- HMI design
- SCADA integration
- Alarm presentation
Commissioning and support
A control system is proved on the plant, not on a drawing. Factory acceptance testing, cold and hot commissioning and fault finding, and the same engineers afterwards when something needs looking at. The records are written so your maintenance team can work on it without us.
- Factory acceptance testing
- Cold and hot commissioning
- Fault finding and support
Platforms we work on
Find the controller you already run.
Controllers
- SiemensS7-300 · S7-400 · S7-1200 · S7-400H redundantStep 7 and TIA
- Rockwell Allen-BradleyMicro · Nano · PLC-5 · CompactLogix · ControlLogixRSLogix
- Schneider ModiconQuantum · Premium · M340 · Momentum · Advantys STB
- OmronMicro PLC · CJ1 · CS1
- MitsubishiA-series · FX series · Q series
- National InstrumentsProgrammable Automation Controllers · CompactRIOLabVIEW
HMI and SCADA
- Siemens WinCCStandalone · Fully redundant
- RockwellRSView32 · FactoryTalk machine edition · FactoryTalk site edition
- WonderwareArchestra · InTouch · Historian
- Adroit
At a plant
From the weighbridge through production and pelleting to outloading, every process was automated and is now run by one person in a central control room. A third pelleting line has been added since.
Control layer
The operator needs to see what the plant is doing.
PLC logic, HMI screens and SCADA connect the control sequence to equipment status, alarms and the people responsible for the plant.