Control systems engineering
Risk Control Engineering provides practical control systems engineering support for industrial machinery, process equipment and automation systems.
With more than 30 years of experience across PLCs, HMIs, SCADA, industrial networks, motor control and machine automation, we help clients design, review, upgrade, troubleshoot and commission control systems that are reliable, maintainable and fit for purpose.
Our services include control system architecture, PLC and safety PLC engineering, functional descriptions, I/O design, industrial communications, HMI and SCADA systems, variable speed drives, remote I/O, system integration, commissioning support and independent design review.
We can support complete projects or work alongside existing electrical contractors, machine builders, OEMs and system integrators to provide specialist engineering input where required.
Design & Specify Control Systems
Develop practical control system architectures for new machinery, plant upgrades and automation projects.
Services include PLC and safety PLC architecture, I/O design, functional descriptions, control philosophies, industrial network design, HMI and SCADA requirements, motor control and variable speed drive integration.
We can also prepare technical specifications, scopes of work and design documentation for contractors, OEMs and system integrators.
Integrate, Upgrade & Modernise
Support the integration, modification and upgrade of industrial control systems across machinery and process applications.
This includes PLC, HMI and SCADA upgrades, legacy system replacement, remote I/O, industrial Ethernet networks, third-party equipment integration, drive systems and control panel modifications.
We can work with existing systems or provide independent engineering support alongside your automation supplier or electrical contractor.
Commission, Troubleshoot & Optimise
Provide practical commissioning and site support to get control systems operating reliably and as intended.
Services include I/O testing, commissioning, startup support, fault finding, network troubleshooting, control system diagnostics, performance improvements and rectification of existing system issues.
We also provide independent design reviews and recommendations to improve system reliability, maintainability and future support.
Practical Engineering Experience
Multi-zone robotic cell safety validation
Safety lifecycle support for a complex robotic system with guarded zones, controlled access, teach modes, emergency stops and pneumatic safety functions. The work covered risk assessment, safety requirements, design review, verification and validation testing.
Safety PLC and networked I/O review
Independent review of safety-related control architecture, including safety PLC logic, remote safety I/O, redundant outputs and industrial safety networks. The focus was a practical, maintainable design that could be verified and tested.
Guarding and access control engineering
Assessment of guarded machinery, interlocking arrangements, emergency stops and trapped-key access concepts. Recommendations aligned the safety functions with the machine hazards, operating modes and required Performance Level.
Legacy machinery safety upgrade review
Structured engineering support for upgrading older equipment and closing safety gaps identified during audits or modification projects. Reviews considered energy isolation, pneumatic and hydraulic control, emergency stopping and ISO 13849 verification.