Control Panel Design, Fabrication & Retrofit
Control Panel Fabrication
We design, build, wire and test mimic boards, operator control panels, PLC/DCS system cabinets, high- and low-voltage switchgear and MCCs, mosaic panels, and PLC retrofits of aging control panels.
GENEQ handles everything in one place, from logic design to panel fabrication, wiring, retrofits and commissioning.
What we build
Item | Purpose |
|---|---|
Mimic Board & Panel | Mimic board showing the plant system as a diagram; status lamps show the system flow at a glance |
Operator Control Panel | Control panel operated directly by operators |
Operator Simulation Panel | Panel for operator training and simulation |
PLC & DCS System Cabinet | System cabinet housing controllers and I/O modules |
HV/LV switchgear, MCC | Power distribution boards and motor control centers |
MOSAIC PANEL | Mosaic-tile panel; modified tile by tile when the system changes |
How far we go
Stage | Scope |
|---|---|
Design | Single-line diagrams, schematic wiring diagrams, panel layouts, bills of materials |
Fabrication | Sheet metal work and painting, device mounting, wiring and termination |
Testing | Insulation and withstand voltage tests, wiring checks, factory acceptance test (FAT) with the logic loaded |
Site | Delivery and installation, electrical and communication works, instrumentation piping and wiring |
Completion | Commissioning, operator training, as-built documentation |
You can also order panels alone. We have supplied many cabinets and MCCs built to match existing systems.
With relay control panels that have been in service for more than 20 years, the bigger problem is not failure itself but the fact that parts are no longer available.
When a single timer is discontinued, the whole plant stops. Faulty contacts make starts intermittent, and after years of ad-hoc changes the drawings often no longer match the hardware. For panels like these, converting to commercial PLC logic ends up cheaper than repairing them.
Consider a retrofit if you see these symptoms
1. Repeated start failures or malfunctions due to faulty contacts
2. Relays and timers are discontinued and spares cannot be sourced
3. Drawings no longer match the actual wiring after repeated modifications
4. No operating records, so the cause of a shutdown cannot be traced
What changes
Item | Before retrofit | After retrofit |
|---|---|---|
Control logic | Relay wiring or MICOM board | Commercial PLC logic |
Operation | Push buttons and lamps | Touch HMI; existing operating buttons can be kept if required |
Operating records | None | Operation and alarm history stored, Excel reports |
Logic changes | Rewiring | Program modification |
Spares | Sourcing discontinued parts | Immediately available as commercial products |
How we keep downtime short
The most sensitive question in a retrofit is how many days the plant has to stop. We first assess on site how much of the existing wiring and instrumentation can be kept.
If the terminal blocks can be reused as they are, downtime drops sharply. The new panel is built and logic-tested in our workshop before it goes to site, so the work that actually requires a shutdown is narrowed to removing the old panel, terminating and commissioning.
Plants that cannot be stopped all at once are replaced system by system, in stages.
