Automation Control Systems for High Pressure Testing Applications

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All of our pressure testing systems have built-in intelligent control systems designed and implemented by our fully qualified and experienced controls engineers; enabling functions and environmental conditions to be accurately and efficiently automated, controlled and recorded.

Our pressure testing control systems are designed and developed to improve efficiency, reliability and productivity much more safely. Any version of TIA Portal, from version 11 through to the latest, 17, is catered for. Siemens S7-1200 and S7-1500 range PLC systems are used with a combination of local and distributed IO.

High Pressure Testing System Dashboard

The dashboard or visualisation system can be either; HMI (Human Machine Interface), SCADA (Supervisory Control and Data Acquisition) systems, or a combination of both. HMI’s are usually the Siemens Comfort panel range using TIA version 11 to version 17. SCADA systems can be either TIA WinCC SCADA version 16 onwards or WinCC SCADA version 7.0 onwards, AVEVA InTouch is available upon special request. All communications protocols can be utilized, for example, Profinet, Profibus, ASI-Bus, etc.

HMI and SCADA systems are sleek and intuitive in design for ease of use. Controls available for the equipment modules include all states from the S88 transitions.

User Access Control

Our user access control can be configured to any desired level which allows multiple users to have their own unique username and password to log in and operate the system. This system allows the user access to be controlled by job title or operator level. RFID login systems are available upon special request.

Operator – The operator can carry out tests in the manual control mode and input test set points, only values that fall within the system limits can be entered. An operator can also execute pre-defined profiles but cannot create new profiles or edit existing ones stored within the system.

Supervisor – The supervisor can do all activities that an operator can execute, however, a supervisor can create and edit profiles.

Engineer – The engineer can do all activities that a supervisor can execute, however, an engineer can; modify engineering parameters, take ‘in-hand’ control of plant items.

Administrator – The administrator can do all activities that a supervisor can execute, however, an administrator can access all areas of the system.

We have 2 types of HMI data logging available. The first is a standard CSV (Comma Separated Values) file, which can hold up to 500,000 data points per CSV file. The second can hold up to 1,048,575 data points with each data point having its own column and a variable capture rate. SCADA Systems have the capability of creating custom-made reporting packages.

Programmable Logic Controller

PLC’s (Programmable Logic Controllers) are used to control our current standardised pressure testing equipment modules, including controlling variable pressures, along with filling and draining the pressure testing vessel. The PLC also controls additional features such as the tilting, mate de-mate, temperature and agitation functions of the pressure testing system.

The PLC’s can be written in all predominant languages, LAD (Ladder Logic), STL (Statement List), SCL (Structured Control Language) and FBD (Function Block Diagram). Standard packages utilize the LAD language. Written to the BS EN 61512 (S88) standard, broken down into equipment modules and control modules.


Referred to as recipes, each equipment module can be selected in a profile or recipe. Up to 20 recipes can be stored and each recipe can hold up to 100 functions. Recipes are able to loop between steps, whole recipes can also be looped. SCADA system recipe functions and limits are defined by customer requirements.

There are 3 modes of operation: Automatic (recipe) Mode, Manual Phase Mode (pressure and fill), Manual ‘in-hand’ Mode (fully manual process, open valves, etc).

Control Modules: High-high, high, low, low-low alarm generation, individual debounce timers, ‘hours ran’ for motors.

Functional process and machinery safety can be developed adhering to BS EN 61508 up to SIL 3, and BS EN 13849.

It is also vitally important to ensure the highest standards of safety, by ensuring alarm conditioning and safety interlock systems are in place.

In addition to the above, our control systems have many more features, a demonstration of our control system can be arranged upon request.

For more information please contact our team of sales engineers on +44 (0)1257 474 507, to discuss your requirements, or email

Typical Applications:

Automation and Control Software for Pressure Tesing Applications
KWDS Products - Automation & Control Systems - HMI Screen Graphic