Case Studies
The Training Centre
Challenge
The client was relocating their business to a larger facility and wanted to take the opportunity to re‑design and expand their highly successful training rig. Their goal was to create a modernised, larger‑scale system with additional flow lines of different sizes, allowing more instrumentation to be installed and tested. They also wanted to incorporate the latest technologies from leading suppliers such as Emerson, Siemens, Rheonik, and VEGA. The challenge was to deliver a fully modernised, industry‑relevant training rig on time, within budget, and to the highest quality standards.
Our Solution
To deliver the full project lifecycle — from dismantling the original training rig through to the final handover of the new facility.
Key steps included:
Design & Planning – Dismantled the original rig, redesigning it to increase capacity with multiple flow lines, and integrated modern instrumentation. Prepared business cases for client approval, including detailed budget forecasts, project risk registers, resource plans, and schedules of work.
Procurement & Fabrication – Procured major equipment including vertical and horizontal tanks, support frameworks, and interconnecting pipework. Oversaw fabrication and delivery of structural and piping elements.
Installation – Installed tanks, pipework, and instrumentation (flow, pressure, temperature, and level). Installed IS and non‑IS cabling between instruments and junction boxes, connected Remote I/O, and completed panel wiring.
Controls & Automation – Installed the main PLC in the control room, linked to Remote I/O via TCP/IP. Installed a Rockwell PlantPAx DCS/SCADA system. Developed, tested, and validated control logic routines prior to wet commissioning.
Testing & Commissioning – Performed full Site Acceptance Testing (SAT) with the client. Commissioned the entire system safely and efficiently.
Handover – Delivered complete documentation, including red‑lined, re‑drawn AutoCAD schematics, loop diagrams, and single line drawings, all issued “As‑Built.”
Results
Fully modernised and expanded training rig with industry‑standard instrumentation and control systems.
Project delivered on time and to budget.
Comprehensive technical documentation provided to support ongoing use and maintenance.
Enhanced training capability, providing engineers and technicians with hands‑on experience of real‑world process plant systems.
Positive client feedback following successful commissioning and handover.
