CASTLET LTD

TECHNICAL CATALOGUE

July 2011

14 Crofton Drive, Allenby Road Ind. Est. Lincoln, UK

Registered to ISO9001: 2000 AES code 18/19
Registered in England No. 3729745
2 of 23

CONTENTS

1. COMPANY INFORMATION / BUSINESS ACHIEVEMENTS

2. COMPANY STRENGTH’S

3. CERTIFICATION

4. LIST OF EXPERIENCE

5. SIMILAR KEY PROJECTS HANDLED

(DESCENDING ORDER)

6. PRODUCT CATALOGUE

7. PRODUCT INFORMATION
 3 of 23
1 Company Information
Castlet Limited are an independent company,
primarily involved in the design, manufacture, test and
commissioning of ESP power supplies,
microprocessors controls and auxiliary equipment.
Established in 1974, the company has invested heavily
in Research and Development year on year to ensure
its products and equipment are market leaders in the
relevant industrial areas. The equipment has been
installed in Power Stations and other industrial
processes world wide, with a particularly strong
installation base in Europe, Asia and South America.
Castlet is a private, medium sized company, housed in
two adjacent buildings in the historic city of Lincoln.
Lincoln is approximately 200km north of London.
Multi Licensees strategically located throughout the
world serve key markets to ensure focused service
and support world-wide.
All equipment is designed in-house, including electrical
& mechanical design, Electronics, PLC software and
PC SCADA design.
Castlet's expertise is in the design, manufacture and
commissioning of electrical equipment for industrial
processes, traditionally for the power generation
industry. Over many years Castlet Limited have also
been providing bespoke control solutions to other
industrial areas, and installed on a world wide basis.
Castlet Limited - Manufacturing Facility
History of Castlet
Castlet (Electronic Engineers) Limited was founded in
1974 by Mr. Bryan Carr, who had previously worked for
International Rectifier. The introduction of thyristor
devices offered improved control of power, and opened
up new opportunities. Seeing a niche market, Bryan
founded Castlet Limited to provide new equipment to
Power Plants to replace existing rotary rectifiers with a
typical 30s response time, to thyristor controlled
equipment with a 10ms response. Three trial units were
initially supplied to the CEGB on a trial or return, firm
orders were received within 3 months.
The company continued to expand, resulting in the
acquisition of Richmond Electronics in 1985 and three
other companies in the early 1990's.
Subsidiary companies including Castlet South Africa
were also set up, to provide a local service and support
to key markets.
Castlet Limited released the 3rd generation ESP
controller, the MCSI in 1988 which later won the Queens
Award for Technology. Now Castlet supply the MCSII
family of products.
The company was sold to OMI international in 1994, who
in 1997 renamed the company Solvera.
A management buyout took place in 1999, led by the
previous owner, Bryan Carr. Now the majority of Castlet
employees are shareholders within Castlet Limited.
With Castlet’s revamped company structure and new
technologies, the Company continues to be a world
leader in ESP power supplies, controls and auxiliary
systems.
4 of 23
5 of 23
6 of 23

2 Company Strengths

Development Department
This department is responsible for the design and build of all of Castlet’s new Printed
Circuit Boards, this department also writes and tests the hard code to meet the
application specific requirements. The following list covers the majority of code
languages used:

Java

C++

C#

C

Ansi C

MFC
They also implement the following communication protocols

Modbus

Profibus

Post Design Services Department

The work carried out by this department is primarily for the UK Ministry of Defence,
however, any work relating to defence equipment, as required by MOD or its
principal contractors (i.e., Rolls Royce, Westland etc) is completed by this
department. Aerospace applications are also undertaken. Typical examples include;

New equipment design

Modification to in service equipment

Reverse engineering of obsolete equipment

Modification to drawing sets

Engineering Department
There are two sub sections to this department, the drawing office and the
electrical/mechanical design. The two sections function as a complete department,
with all staff being able to work to a limited degree in either section. This department
is responsible for the design of the majority of equipment produced by Castlet.

The Drawing Office staff are currently using AutoCAD 2000, and AutoCAD 2004.

The Electrical Design Section staff are all capable of PLC programming along with
writing SCADA package applications. The typical PLC software packages used are:

Allen Bradley

Siemens

ABB

Mitsubishi

Schneider

GE Fanuc
The typical SCADA packages used are:

Citect

Ifix

Castlet In House System
7 of 23

Site Service Department

Although there are staff who are dedicated site service personnel, all of the technical
employees at Castlet are capable of performing site/ servicing work when required.
The type of work performed on site for our customers include;

Installation of new equipment

Commissioning of equipment

Calibration of equipment

Maintenance contracts

Project management

Site Surveys

Production / Test Department

The Production Department is housed in a dedicated workshop, with a total floor area
of 1,600m2. The workshop has a 3.2 Tonne overhead crane mounted 8 mtr above
floor level and running the full length of the workshop. The workshop has the
following Equipment and Test Facilities;

415V AC, 300A 3φ supply

Environmental Chamber

Environmental Enclosure, max item equipment size 4m x 4m x 4m

High Voltage Test Facility, rated up to 200,000V

Assorted step up / step down transformers

Load Bank, rated up to 250kW

PLC dummy test facility (100 digital inputs+ 75 digital Output, 12 Analogue
inputs and outputs)

Air test equipment, up to 150 PSI

Welding Plant

Dye Test, for the inspection of welds

Equipment for the testing of painted components

Equipment for Audible Noise tests

Equipment for Electrical Harmonics testing

Various electronic test equipment

Clean Room with controlled environment

Production Department staff capabilities include, but are not limited to, the following:

Electro-Mechanical Assembly

Electrical Testing

Environmental Testing

PCB Assembly

PCB Test / Repairs

Copper Busbar Fabrication

Light Metalwork Fabrication
8 of 23

3 Certification
9 of 23
10 of 23

4 List of Past Experience

2008-2009
1 LODGE STURTEVANT £3,756K
2 BALCKE DUERR (GERMANY) £446K
3 HITACHI £390K
4 REDECAM £351K
5 MHI JAPAN £314K
6 E-ON UK £290K
7 VALNAMEX £239K
8 INTERPROJEKT £192K
9 CLYDE BERGEMANN £176K
10 DIECO £161K

2007-2008
1 MHI JAPAN
2 E-ON UK
3 REDECAM
4 HAMON
5 CLYDE BERGEMANN
6 AREA IMPIANTI
7 DRAX
8 ENVIROTHERM
9 AEROSPACE / MOD
10 CASTLET SA

2006-2007
1 HAMON
2 CASTLET SA
3 AREA IMPIANTI
4 LODGE STURTEVANT
5 AEROSPACE / MOD
6 CENTRAL ASIAN CEMENT
7 BALCKE DUERR POLAND
8 VALNAMEX
9 BALCKE DUERR AUSTRIA
10 ELWO

2005-2006
1 LODGE STURTEVANT
2 MHI JAPAN
3 ELWO
4 DRAX
5 BALCKE DUERR (POLAND)
6 CASTLET S.A.
7 E-ON UK
8 ENVIROTHERM
9 TAI & CHYUN
10 FOWLEREX
11 of 23

5 Similar Key Projects

WO21368
Castlet manufactured a Zone 2 Hazardous area “Purge Pressurised” Container.
• The rating of the equipment was 415 V supply
• The unit was designed to operate in an ambient temperature of -10Deg to 50Deg C
with a humidity up to 85%
• The protection method was to IP65 with EEx ‘P’ purge protection to meet Zone 2,
Gas Group IIC T3. The equipment was fitted with a dual / redundant blower system
capable of maintaining the purge with the operator door open
• The container was finished suitable for a marine environment, 3 coats with a TDFT
of 275 micron
The container was fitted out with the following equipment
• 3 x HV control cubicle with an input rating of 183A two phase
• 1 x Auxiliary Cubicle for Miggi Rapping control
• 1 x MCC cubicle with an 800A incoming ACB
• Busbar system designed at 400V 3ph + PEN and rated a minimum of
800A Line Current 65kA 1s
• 1 x Marshalling Cubicle
• 2 x Redundant 20kW Hazardous Area certified AC units

WO21013
Castlet manufactured five “Zone 1” Hazardous area purge pressurised Transformer
Rectifier units with one “Zone 1” Hazardous area purge pressurised PLC control system.
T/R Units

The rating of the equipment was 415 V supply, and each system contained the
system motor drives ( pumps, blowers etc), the individual units had the following DC
ratings;
o 3 streams each at 75V DC @ 450A output
o 3 streams each at 75V DC @ 450A output
o 3 streams each at 45V DC @ 500A output
o 3 streams each at 90V DC @ 500A Output
o 1 stream at 30V DC @200A Output

The units were designed to operate at an ambient temperature of 0 Deg C to 50 Deg
C, with a humidity level between 10-95%.

The protection method was to IP65 with EEx ‘P’ purge protection to meet Zone 1,
Gas Group IIC T3. The equipment was fitted with a titanium heat exchanger for each
stream with a dissipation of 5 kW for water / air cooling

The Enclosures were constructed from 2 to 3mm 316 stainless steel sheet with
suitable stiffening as required. The cubicles were sectionalised with removable
covers for access.
PLC Panel
• The unit was fitted with a Dual Redundant Control Logix PLC and a 15” Touch
Screen.
• The protection method was to IP65 with EEx ‘P’ purge protection to meet Zone 1,
Gas Group IIC T3.
• The Enclosure was constructed from 2 to 3mm 316 stainless steel sheet with
suitable stiffening as required.
12 of 23

WO20590
Castlet manufactured two Hazardous area “Purge Pressurised” Transformer Rectifier
(T/R) units with two safe area PLC control systems.
T/R Units

The rating of the equipment was 415 V Supply with the first unit having a 13V DC @
600A output and the second unit having 105V DC @ 600A output.

The units were designed to operate at an ambient temperature of 0 Deg C to 50 Deg
C, with a humidity level between 10-95%.

The protection method was to IP65 with EEx ‘P’ purge protection to meet Zone 2,
Gas Group IIC T3. The equipment was fitted with a titanium heat exchanger with a
dissipation of 5 kW for water / air cooling

The Enclosures were constructed from 2-3mm mild steel sheet with suitable
stiffening as required. The cubicles were sectionalised with removable covers for
access.

The T/R units were painted to a high offshore paint specification, 4 coats with a total
DFT of 300micron

Control Cubicle

The units were designed to operate at an ambient temperature of 0 Deg C to 50 Deg

C, with a humidity level between 10-95%.

The enclosure is a Rittal 5884.500 from the ES5000 Range as specified by the end
customer.

The PLC was an Allen Bradley with the following configuration
o PLC 503 with 13 slot rack including;
o 5 x 16 Way Digital Input Modules
o 2 x 16 Way Digital Output Modules
o 2 x 16 Way Analogue Input Modules
o 1 x 8 Way Analogue Output Modules

The Unit had a 10” Colour Touch Screen HMI

The Control Cubicle was fitted with the following Intrinsically Safe Galvanic Barriers
o 8 x Digital Input Channels
o 4 x Digital Output Channels
o 22 x Analogue Input Channels ( HEART Transparent)
o 2 x Analogue Output Channels ( HEART Transparent)
13 of 23

WO20499
Castlet manufactured three Safe area Transformer Rectifier (T/R) units with One MCC.
T/R Units

The rating of the equipment was 11,000V supply and 160V DC @ 8000A output.

The units were designed to operate at an ambient temperature of 0 Deg C to 55 Deg
C, with a humidity level between 10-100%.

The unit was designed to IP31 for Ventilation, IP52 for main enclosure and will be
naturally/ forced air cooled. Cooling was designed to dissipate a total heat loss of
45kW.

The enclosure were constructed from 2-3mm mild steel sheet and box section for the
support frames, designed for the final weight of approximately 10,000kg

The T/R units were painted to Castlet standard paint specification with a total DFT of
120micron

MCC

The unit was designed to operate at an ambient temperature of 0 Deg C to 40 Deg

C, with a humidity level between 10-95%.

The enclosure is a proprietary design.

The Unit was supplied with the following outline specification;
o Two 1000A Main Incoming ACB ‘s(Air Circuit Breaker type)
o The two Main Incoming breakers were mechanically and electrically
interlocked with an Auto changeover function.
o MCC was configured so that the duty and standby drives were on different
sections, allowing for redundancy in case of a supply failure
o Busbar system will be 400V 3ph + PEN and rated a minimum of 1000A
Line Current 65kA 1s
o MCC’s will have withdrawable starters, dead front type
o IP rating IP31 or higher
o Paint colour RAL7032
14 of 23

WO20253
Castlet manufactured three Safe area Transformer Rectifier (T/R) units.

The rating of the equipment was 400V supply and 45V DC @ 600A output.

The units were designed to operate at an ambient temperature of 3 Deg C to 49 Deg
C, with a humidity level between 10-100%.

The protection method was to IP42. The equipment was fitted with titanium heat
exchanger’s, each with a dissipation of 4.5 kW for water / air cooling

The enclosures were constructed from sheet mild steel, with a minimum thickness of
2mm.

The T/R units were painted in accordance with the supplied SHELL paint
specification

WO20192
Castlet manufactured one double safe area Transformer Rectifier (T/R) units controlled by
a single combined MCC / PLC system.
Transformer rectifier

The rating of the equipment was 400V supply and 2 x 45V DC @ 600A output.

The units were designed to operate at an ambient temperature of 0 Deg C to 55 Deg
C, with a humidity level between 10-100%.

The protection method was to IP41, and the unit was designed for forced air cooling
via Two 100% Cooling fans to each section. The fans were fitted with automatic
change-over should the Duty Fan Fail.

The enclosures were constructed from sheet mild steel, with a minimum thickness of
3mm.

The T/R units were painted in accordance with the supplied Customer specification
suitable for installation in a harsh coastal environment

Combined MCC/ PLC Control System

The units were designed to operate at an ambient temperature of 0 Deg C to 55 Deg
C, with a humidity level between 10-95%.

The enclosure was a “Wardrobe style” enclosure manufactured from 3mm sheet
steel.

The PLC was an Allen Bradley with the following configuration
o PLC 503 with 13 slot rack including;
o 4 x 16 Way Digital Input Modules
o 4 x 16 Way Digital Output Modules
o 1 x 16 Way Analogue Input Modules
o 1 x 4 Way Analogue Output Modules
 15 of 23

o 1 x Modbus card for remote communications

The Unit had a 10” Colour Touch Screen HMI

The Unit was fitted with the following Intrinsically Safe Galvanic Barriers
o 6 x Digital Repeater Channels
o 3 x Solenoid Output Channels
o 10 x Analogue Input Channels

The Cubicle was fitted with various rated motor drives / power supplies to control
all the system motors.

The following is a table of older Hazardous area projects completed by Castlet; additional
information is available if required.

Castlet Quantity of Kg CL2 / H Kg CL2 / H

Reference Independent Capacity Combined DC DC
Number Customer Project Country Systems per Stream Capacity Volts Amps

00059 Electrocatalytic North Nemba Africa 1 10 10 92 440

99250 Electrocatalytic Angsi Offshore 1 19 19 95V 800A
98105 Electrocatalytic Asgard B Offshore 1 10 10 90V 440A
97019 Electrocatalytic Bos Apache Stag Offshore 1 21 21 100A 91V
97012 Electrocatalytic Elf Ofan Offshore 1 2.5 2.5 96V 100A
96271 Electrocatalytic Cabinda Offshore 1 12.5 12.5 115V 440A
95185 Electrocatalytic Brittania Offshore 1 19 19 90V 840A
95259 Electrocatalytic Wandoo China 1 15 15 70 880
04491 Electrocatalytic SHW UK 4 14 56 72 800
94061 Electrocatalytic Beryl B Offshore 1 10 10 92V 440A
04296 Electrocatalytic Neelam Offshore 2 12 24 60V 800A
03000 Electrocatalytic Shell Dragon Offshore 1 9 9 64V 580A
02594 Electrocatalytic Snorre Offshore 1 30 30 88V 1,420A
02479 Electrocatalytic Unknown Offshore 2 16.5 33 82V 800A
02478 Electrocatalytic Mossgass Offshore 2 16.5 33 83V 800A
02596 Electrocatalytic Oseberg Offshore 1 7 126 86V 340A
02595 Electrocatalytic Herra Offshore 2 7.5 15 72V 420A
 16 of 23

6 Product Catalogue
Purge Pressurised TR Unit with electrical rating of 105V DC @ 600A, designed for
use in a Zone 2 hazardous area

Oil cooled TR unit with an electrical rating of 126V DC @ 10,750A, designed for use
in a safe area
 17 of 23

Air cooled TR unit with an electrical rating of 125V DC @ 5,400A, designed for use
in a safe area

PLC control system for electro chlorination package

 18 of 23

Hot Standby Allen Bradley PLC system

Combined PLC / MCC for electro chlorination package

 19 of 23

Castlet High Voltage T/R unit control cubicle with integrated motor drives

Castlet High Voltage TR units with typical ratings up to 3,000mA and 140kV POC
 20 of 23

7 Product Information

High Power Equipment

Product History
Castlet Limited design, manufacture, install and commission
a wide range of bespoke DC power supplies and
sophisticated controls for various industrial applications,
including Electro-chlorination, Electroplating, Hydrogen
Generation and Cathodic Protection.

Features
The power supplies and controls are designed for “On
Shore” or “Off Shore” applications, the equipment being
manufactured to exacting customer standards and
specifications, with outputs typically up to 450V, 11,000A DC
with mains input up to 11kV.

The units can be designed using various transformer

options, i.e. Hex-phase with IPT, Dy11, or most other
configurations as specified by the Client. The transformer Specifications
options include cast resin, air cooled or oil immersed.
Typical values and ratings:
The units typically have a half or fully controlled bridge
rectifier, with multiple devices connected in parallel if • Primary Voltage Rating:
necessary. The cooling options for the rectifier assemblies 400V to 11,000V AC 50 or 60 Hz
include air natural, forced Air, oil immersed or liquid cooled
heat transfer blocks. • Power rating:
Typically up to 5MW
The units have a typical ripple content of 6% on a fully
controlled bridge rectifier; however a choke can be • Ambient:
incorporated to meet any reduced ripple requirements the Typically up to 65˚C
process might require.
• Enclosure Type:
The units can be designed for either manual control or Typical Stainless Steel to A4 316 grade or
controlled via a remote SCADA package, and fully integrated Painted mild steel
into a process using digital or analogue signals. This enables
the output of the units to vary according to the demand • Certification:
placed on them. Output control is typically from 10% to Typically ATEX Ex p Zone 1 or
100% with a regulation of +/- 2% of set value. NEC DIV 1, CLASS1, GROUPB

• Ingress protection:
Typically up to Nema 4x / IP65
Purge Pressurised

• Cooling:
Typically Natural, forced air heat exchanger or oil
 21 of 23

PLC & HMI Control Systems

Product History
Castlet Limited designs and manufactures process control
systems utilizing proprietary PLC systems for a wide range
of industrial applications including Chemical, Automotive,
Water Treatment, Pulp/Paper, Offshore, and Thermal Power.

Typical PLC System Features

PLC Systems are usually housed in bespoke control
cubicles, however we are able to design and build cubicles
to customer specifications including size, IP rating, paint
finish etc.

PLC systems may be interfaced with any propriety

supervisory controller such as HMI or SCADA systems, via
standard RS232/RS485 links or via any other manufacturer’s
proprietary communication networks.
PLC’s may be stand-alone or they may communicate with
Castlet’s SCADA/HMI or 3rd party controllers including
redundancy features to minimise system disruption
maintaining plant operation and safety. Redundancy may
include dual processors, dual power supplies, dual
communications and in some instances dual input/output
cards.
Where redundant processors are included the PLC
programs would normally be identical but can be different if a
“safe shutdown”, “limited production” mode is required.
The typical change-over time from the master processor to
slave is in the order of 30-50ms, which would not normally
cause process interruptions.
Typical HMI Features
HMI example;
Display size: 2 lines x 16 characters with a Backlit LCD
up to 640 x 480 pixels with a Backlit TFT, with 256 colours.
Display type: Monochrome, greyscale or colour.
Operator input: Touch screen or keypad.
Communications: Typically DH-485, RS-232, DH+,
ControlNet, Profibus or Ethernet.
Communications
Typical Communication Protocols;
RS485, RS232, DH+, ControlNet, Ethernet & ProfiBus.
Communications Redundancy may be configured in any
design.

Typical Specifications
• Proprietary PLC systems including
• Rockwell - Allen Bradley PLC5, SLC500 and
ControlLogix.
• Siemens S7.
• ABB.
• Schneider Modicon Quantum.

PLC’s may be connected to a variety of Human Machine

Interfaces (HMI) as well as System Control and Data
Acquisition (SCADA) PC based systems.

PLC programming logic is based on customer specifications.

. Our engineers and customers liaise closely to achieve a
mutually agreed design including the flexibility to incorporate
changes that are inevitably required during commissioning.

Typical IO counts are from 20 up to over 15,000 points.

 22 of 23

Power Distribution Systems

Product History
Power distribution systems are commonly used in
switchboards where a number of control cubicles are suited
together.

By suiting the cubicles together, the main incoming power

supply can be distributed using a system of busbars
providing a neater and more efficient solution compared to
traditional cabling methods. This can also considerably
reduce the amount of installation time at site.

The power distribution cubicle is normally supplied with a

main circuit breaker and associated power monitoring
equipment.

Features
Each distribution cubicle can be supplied with either an
MCCB or air circuit breaker for either a single or dual supply
distribution system. With dual supplies, an automatic or
manual change over system can be implemented ensuring
constant supply of power with the minimal supply interruption
on changeover.

Monitoring devices may include voltage, current & power

meters and transducers.
Specifications
The incomer cubicle is then coupled directly to the busbar
system of the control cubicles. Each incomer system is bespoke, being designed to
particular standards and ratings depending on the equipment
being supplied.

. Generally systems are rated up to 690V, 2000A, however

alternatives can be accommodated for.

• Typical rating:
Operating voltage: 690V
Current rating: Up to 3000A

• Typical MCCB/ACB options:

Single manual circuit breaker
Single motorised circuit breaker
Dual motorised circuit breaker

• Indication options:
Primary voltage, current, power
MCCB status, phase status
 23 of 23

Design Services
As an ISO9001:2000 accredited organisation Castlet Limited puts
the customers’ requirements first and foremost. Each project is
carefully managed under our quality control systems covering
design, documentation, procurement and manufacture.

Our team of highly skilled engineers and support staff are able to
offer a range of design services including the following;

Project Management
We allocate an engineer to take responsibility for the
management of each project from conception through to
commissioning followed by after sales support. This provides the
customer with a single point of contact for all technical matters
and ensures continuity of progress.

Documentation
Project Specifications
Our project engineers produce all the required documents
Customer specifications are thoroughly reviewed to ensure the using Microsoft Office. We provide our clients with a range of
design requirements can be fulfilled within the project time documents, typically;
schedule. Castlet offers a range of ‘standard’ specifications that Project Manual – including Installation, Operation and
may be customized for specific applications. We may propose Maintenance.
enhanced specifications for an alternative, possibly more Device manuals – including Hardware, Software and
economical, solution prior to customer approval. Operataion.
Quality plans.
Cable schedules.
Drawings Hardware and software IO lists

Castlet’s engineering draughtsmen produce all the required

drawings using the latest AutoCad software packages. We
Technical Support
provide our clients with a range of drawings, typically;
System overviews. We offer comprehensive technical support even during the
Equipment arrangements. project enquiry stage. Specifications are first reviewed at the
Logic diagrams. enquiry stage then produce example project drawings for
Circuit diagrams. submission with our bid.

Drawings may be produced within customized borders to our

Castlet’s success has been achieved through flexibility and
customer’s standards.
compromise. We understand our customers’ requirements
and appreciate they may change from time to time. We do
everything possible to fulfil these requirements without
incurring additional costs.

Our experienced commissioning engineers are able to offer

comprehensive site support including training of site
personnel. The Castlet office provides additional support
where necessary.

Post commissioning support is free during the warranty

period – subject to the warranty term.

Extended warranties are available. Post warranty support is

available and may be free if a ‘quick fix’ is identified. Fault
reports are assessed on a case by case basis.