Microfusion Engineering Laboratories
Microfusion Engineering Laboratories, Inc. (MEL), headquartered in Atlanta, Georgia, has provided engineering services worldwide since 1995. MEL brings extensive experience in process control, system integration, SCADA, telemetry, industrial network security, and dynamic control simulation. The company serves a broad range of industries, including power generation, utilities, manufacturing, and pharmaceuticals.
Services
MEL delivers automation migration projects on a full-scope turnkey basis or as an application services provider. Services may include complete control and instrumentation system design and implementation, system checkout, operator training simulators, commissioning support, and overall project management. To ensure control system quality, MEL uses its THiNK™ dynamic simulation platform for testing, checkout, and operator training. This approach helps identify configuration errors, logic gaps, tuning issues, and operator interface concerns early in the project, reducing commissioning time and improving startup reliability.
Extensive Knowledge in Control and SCADA Systems:
- Inductive Automation: Ignition UI
- Honeywell: TDC3000/Experion
- Rockwell/AB: CLX PLCs, and Drives
- Emerson: Ovation/DeltaV
- ABB: Infi90, AC800, S+
- Siemens: T3000/Simatic
- Yokogawa: Centum
- Foxboro: I/A
Network Management:
- Network Configuration
- Firmware and Bug Fixes Patching
- Backup and Storage
- Policy Validation
- Network Resiliency and Roadmapping
Cybersecurity Consulting:
- Cyber Vulnerability Assessment (CVA)
- Security Gap Assessment/NERC-CIP Consulting
- Security Architecture Design
- Firewall Assessment
Control Systems & Integration
MEL designs, implements, and supports integrated automation systems that help industrial facilities operate safely, efficiently, and reliably. MEL integrates PLCs, DCS platforms, SCADA systems, HMIs, instrumentation, sensors, and plant-floor data systems to provide effective process monitoring, control, and operational visibility. See Project Experience
MEL helps facilities transition from legacy automation platforms to modern PLC, DCS, SCADA, and HMI systems with minimal operational disruption. Each migration is carefully planned and phased to improve system reliability, cybersecurity, maintainability, and long-term supportability.
MEL combines control engineering, software development, and field commissioning expertise to deliver practical, cost-effective DCS, PLC, SCADA, and system integration solutions. Each system is designed to support reliable performance, minimize downtime, and meet the facility’s operational requirements.
MEL provides engineering and design services for telemetry, SCADA systems, and industrial communication networks. Services include system architecture, remote monitoring and control, PLC/RTU and HMI integration, industrial communications, network infrastructure, cybersecurity, and system modernization. MEL designs solutions that improve reliability, security, connectivity, and operational visibility across industrial facilities and remote sites.
MEL designs SIL-rated burner management and safety instrumented systems in accordance with applicable NFPA 85 and NFPA 86 requirements. These systems incorporate proven safety practices for interlocks, trip logic, flame safeguards, and emergency shutdown functions.
MEL develops high-performance HMI graphics that present critical process information clearly and consistently. Well-organized displays help operators quickly recognize abnormal conditions, identify root causes, and take effective corrective action.
MEL develops structured alarm management strategies that prioritize meaningful alarms and support effective operator response. Simulation-based testing is used to validate and optimize alarm behavior before implementation.
MEL uses simulation-based virtual startup to test control logic, process behavior, and equipment responses before the plant goes online. Early validation helps identify issues before commissioning, reducing startup risk, project delays, and costly operational disruptions.
MEL validates control systems prior to commissioning to reduce startup risk and help prevent equipment damage and operational issues. MEL supports new installations, re-commissioning, and return-to-service projects to help facilities achieve safe, reliable operation with reduced downtime.
MEL integrates DCS platforms, PLCs, SCADA systems, HMIs, instrumentation, sensors, and plant-floor data into cohesive automation solutions. These integrated systems improve process visibility, coordination, control, and overall production performance.
THiNK™ Dynamic Simulation
MEL’s Thermal Hydraulic Integrated Network (THiNK™) is a cost-effective, high-fidelity simulation platform for control system validation, operator training, and system testing. THiNK™ reproduces realistic process behavior so control logic, operator graphics, alarms, interlocks, permissives, trips, and operating sequences can be tested before startup. By connecting the control system to a simulated process, engineers and operators can evaluate system performance under normal, upset, failure, and abnormal operating conditions without risk to personnel, equipment, or production. See Project Experience
THiNK™ provides a realistic, hands-on environment where operators can practice routine operations, startups, shutdowns, process upsets, equipment failures, and emergency scenarios. This training strengthens decision-making, improves response to abnormal conditions, reduces operating errors, and builds operator confidence before similar situations occur in the live plant.
THiNK™ allows engineers to test and validate control logic against a realistic process model before commissioning or implementation. Graphics, alarms, interlocks, permissives, trips, control responses, and operating sequences can be verified in advance, helping identify issues early, reduce commissioning risk, and improve overall control system reliability.
THiNK™ provides a production-like simulation environment for testing and validating critical system changes before deployment. Utilities can evaluate modifications, confirm system behavior, and support applicable NERC CIP compliance activities without exposing live operational systems to unnecessary risk.