Our Case Studies
Explore our success stories and discover how Hale Engineering has transformed industrial landscapes through cutting-edge automation and control solutions.
Case Study: Industrial OT Network Survey Improves Plant Network Visibility and Fault Finding
Hale Engineering completed an industrial OT network survey after frequent shutdowns were linked to an unlabelled, undocumented network. Engineers traced every network cable, identified connected devices and IP addresses, and produced a clear network diagram and...
Case Study: Industrial PLC Modernisation for a Waste-to-Energy Plant From Total Shutdown to Reliable Operation
Incineration plant control system upgrade projects are often driven by ageing equipment, repeated faults, poor circuit selectivity and limited visibility across critical plant systems. A single failed sensor, damaged cable or shared fuse can cause unexpected...
Case Study: Legacy Siemens 505 PLC, WinCC SCADA and Industrial Instrumentation Fault Finding
This case study shows how Hale Engineering Consultancy & Services Ltd supported a client with a critical industrial automation fault affecting a legacy Siemens 505 PLC, WinCC Explorer SCADA, flow metering system and weighing instrumentation. The work focused on...
Case Study: Removing Redundant Equipment Safely from a Live Incineration Plant
Removing redundant equipment from a live incineration plant can be technically demanding, especially when redundant equipment remains connected to operational systems. In older industrial plants, legacy cabling, historical modifications and equipment changes can...
Case Study: PLC Modernisation of Industrial Incinerator Control System
This case study looks at the successful delivery of a major control system upgrade for an industrial incinerator, where long-term reliability, safety and operational resilience were critical. The goal was to replace a 30-year-old Mitsubishi PLC system with a fully...
Case Study: Incinerator Control System Upgrade: Improving Reliability, Motor Protection and Plant Visibility
This incinerator control system upgrade case study explains how control system risk can build over time across incineration and industrial process sites. It does not always appear suddenly; it often develops through repeated drive faults, ageing protection devices,...
Case Study: Full MCC Replacement & Plant Rewiring at Industrial Incineration Facility
This case study looks at the successful delivery of a critical electrical upgrade at a high-capacity industrial incineration plant, where reliability, safety and operational continuity are essential. The goal was to modernise the plant’s ageing electrical...
Case Study: Delivering a Smart Safety Solution for a Complex Negative Pressure Requirement
A client approached our engineering team with a critical safety concern involving the monitoring and control of negative pressure within their ventilation system. The requirement was highly specific: the system needed to detect negative pressure values reaching –70 Pa...
Upgrading an ageing industrial system with a modern Motor Control Centre (MCC)
Hale Engineering has been approached to replace an ageing system in an industrial facility with a modern Motor Control Centre (MCC) and enclosure. The existing system was outdated and inefficient, leading to increased maintenance costs, operational challenges, and...