Electrical, control, instrumentation and hazardous area compliance support

Client: Ecolab
Location: Llantrisant, Wales
Duration: Approximately 3 months
Services: Electrical, control and instrumentation, commissioning and proving, hazardous area compliance

Commissioning and proving activities undertaken as part of the Unit D Improvements Project.

Overview

C&P Engineering Services supported Ecolab’s Unit D Improvements Project at its Llantrisant facility, delivering electrical, control and instrumentation upgrades across multiple operational areas.

The works included the design and installation of new control panels, process instrumentation, waste-handling controls and associated systems, together with commissioning support and hazardous area compliance activities. Delivery was undertaken within a live operational environment, requiring close coordination across multiple engineering disciplines.

Scope of Works

  • Installation and integration of new electrical control panels and process instrumentation.
  • Waste management control system upgrades.
  • Integration of hardwired and PLC-based control systems.
  • Commissioning, proving and validation of safety-critical functions.
  • Hazardous area inspection and verification activities in accordance with ATEX and BS EN 60079 requirements.
  • Production of commissioning records and compliance documentation.

Key Challenges

  • Delivering design, procurement, installation and commissioning activities within a compressed programme.
  • Coordinating multiple disciplines across several work areas while maintaining ongoing site operations.
  • Managing design development and technical integration requirements throughout delivery.
  • Maintaining hazardous area compliance across specialist installation works.
  • Supporting successful commissioning and system handover whilst maintaining programme commitments.

Hazardous area installation and compliance activities completed in accordance with ATEX and BS EN 60079 requirements. / Completed control and instrumentation equipment delivered as part of the project scope.

Completed control and instrumentation panel delivered as part of the project scope.

Solution

C&P adopted a proactive and collaborative delivery approach, maintaining a strong on-site presence throughout installation, commissioning and proving activities.

Daily coordination between the client, contractors and engineering teams ensured works remained aligned with programme objectives, while close collaboration between design, manufacturing, installation and commissioning teams supported efficient project delivery.

Specialist hazardous area oversight ensured installations remained compliant throughout the project lifecycle and supported a safe and successful system handover.

Results

  • Project delivered on schedule despite programme and coordination challenges.
  • Successful completion of commissioning and proving activities.
  • Hazardous area compliance maintained throughout delivery.
  • Quality and safety standards maintained across all project activities.
  • Improved process control and waste-management functionality.
  • Fully operational and compliant control system delivered to the client.

Project Team

The project was led by James Thomas, with support and delivery from colleagues across operations, designers, manufacturing, installation, commissioning and hazardous area compliance disciplines, ensuring a coordinated approach throughout the project lifecycle.

Conclusion

The Unit D Improvements Project demonstrates C&P Engineering Services’ ability to deliver complex EC&I projects within live operational and hazardous area environments.

Through effective project management, multidisciplinary collaboration and a strong commitment to safety and compliance, C&P successfully delivered a fully operational and compliant solution that supported Ecolab’s operational objectives while maintaining programme commitments.