Translate the process into operating behaviour
Controls connect the engineering intent with what the equipment actually does. A hydrogen rig needs a defined operating sequence, meaningful operator information and a record of the conditions experienced during a test. Hy-7 brings controls into the process and electrical design conversation from the outset.
The controls scope includes PLC programming in Structured Text on TwinCAT, PLC hardware configuration, HMI design and data acquisition. This sits alongside experience in fuel cell test rigs, electrolysers and MOF CO₂ adsorption demonstrators. The aim is to connect equipment operation with the requirements of the experiment or system, rather than treating software as a separate final stage.
Define sequences before writing code
Start-up checks, permissives, normal operation, standby and shutdown need an agreed description. Alarm handling and recovery after a fault also need to be considered. These operating states should refer back to the process design, equipment requirements and the limits established for the system.
The P&ID, electrical diagrams and control philosophy describe related parts of the same installation. Reviewing them together helps identify where a signal, actuator or equipment interface needs clarification. Changes to process requirements should remain connected to their consequences for the control sequence and operator display.
Make the HMI and data useful
An HMI should help an operator understand the current state of the system and the actions relevant to that state. Measured values, commands and alarms need clear meaning. The interface should reflect the operating sequence and the equipment it represents.
Data acquisition needs to follow the test question. Sampling rate, timestamps and measurement locations influence whether the record can explain a transient or compare operating points. Preserving raw measurements alongside calculated values allows the interpretation of results to be checked later. Recording operator actions and alarms adds context to the measured behaviour.
Keep protection within the engineering scope
The appropriate architecture depends on equipment interfaces, response times and required safety functions. Protective functions may require independence from routine control; a software alarm alone does not establish adequate protection. HAZOP and risk assessment help connect identified deviations with the responses that need to be designed and tested.
Hy-7 follows Scope → Design → Build → Test & hand over. Bring the process diagrams, equipment interfaces and intended operating sequence to an initial discussion to define the TwinCAT PLC, HMI and DAQ work.