Our Services

What We Can do for You!





Merlin CSI is a San Diego Corporation, specializing in software design, implementation and support of industrial automation and control systems with an emphasis on data acquisition and analysis.

President and chief consultant, Tom Voorhees, is a Computer Engineer with over 20 years of experience in software specification, design, development, deployment and management of projects with such well known companies as Pfizer, Solar Turbines, Miller Brewing Company and Nestle.

We are strategically aligned with highly trained and experienced professional software, mechanical and electrical engineers, Hydraulics Specialists and IT professionals in the industry enabling us to provide project teams to handle projects of diverse sizes and disciplines.
  • Software Development
  • Electrical Engineering
  • Mechanical Engineering
  • Controls Engineering
  • Data Acquisition
  • Project Management
  • IT and Networking
Product Development
Merlin CSI provides modeling and simulations for product design, process design, machine design and supply chain reliability. We have expert CAD designers with experience in metal, plastics and machinery. We have experience with embedded electronics, 3D modeling and PCB & Circuit board design.
Software Development
ASP, WPF, WCP, C#, VB.NET, Visual C++, Visual Basic, SQL Server, Oracle, Embedded C programming, all IEC 1131 languages, Ladder Logic, Assembly, many others.
Business Intelligence
Merlin CSI develops computer-based techniques used in spotting, digging-out, and analyzing business data. Key performance Indicators such as sales revenue by products and/or departments is provided in “Real Time” actionable Information for decision making. Our services include the following:
  • Data integration
  • Data mining and analysis
  • Predictive analysis
  • Dashboards and reports
  • Compliance automation
  • Green business intelligence
Industrial System Design
Programmable Logic Controllers (PLC’s) are extensively used today to automate industrial processes and control machinery on factory assembly lines. Unlike general-purpose computers, PLC's are specifically designed to operate in harsh environments and most manufacturers offer a wide range of I/O and communication options to choose from. While the fundamental concepts of PLC programming are common to all manufacturers, differences in I/O addressing, memory organization and instruction sets mean that PLC programs are never perfectly interchangeable between different makers. Even within the same product line of a single manufacturer, different models may not be directly compatible. At Merlin CSI, our diverse experience in a variety of manufacturing environments has allowed us to specialize in a wide range of PLC brands and platforms. Some of the well known PLC brands we are familiar with include: Allen Bradley, Siemens, GE Fanuc, Omron, Modicon/Telemecanique, Toyopuc, Mitsubishi, Bristol Babcock, SCADAPack, Koyo, and Panasonic (a brand name of Matsushita). Let our staff of experienced engineers and programmers assist you with all your design and programming needs.

Supervisory Control and Data Acquisition (SCADA) and Human Machine Interface (HMI) systems are being implemented with a greater regularity in today's ultra competitive manufacturing environment. SCADA systems are used to perform data collection and control at the supervisory level while HMI's are typically seen as local user interfaces that allow operators to manipulate the machine or process locally. Data collection begins at the PLC level and includes readings and equipment statuses that are communicated to SCADA as required. Data is then compiled and formatted in such a way that a control room operator using an interface terminal (typically a desktop computer) can make appropriate supervisory decisions that may be required to adjust or over-ride normal PLC controls. The tags (data) are collected locally in the SCADA software database or into a Historian (distributed database) to allow trending and other analytical work. These distributed measurement and control systems provide manufacturers with a flexible software solution that can be tailored to meet their specific manufacturing needs. It also allows for a common framework and ensures operators experience the same "look and feel" when controlling any part of the system. In the past, implementing a distributed control system quite often required end users to purchase the system from a single supplier. Today, with OPC connectively, it is more common to assemble a SCADA system from hardware and software components from a wide variety of manufacturers. At Merlin CSI, our extensive knowledge and experience implementing distributed control systems over the years in a wide range of industries has provided us with the technical expertise to tackle your toughest applications. We have implemented software solutions from many different vendors including: Allen Bradley (Panelbuilder, RSView SE/ME, RSView 32), GE (Panelmate Power Pro, FIX32, iFIX, & Cimplicity), Siemens (WinCC & WinCC Flexible), Wonderware, Iconics (Genesis), Omron (CX Supervisor), Mitsubishi (GT Works), Koyo (Direct Touch, Think & Do), Telemecanique(Magelis).

System Consulting:

  • Evaluation of capabilities/limitations of existing systems.
  • Evaluation/recommendation of field instrumentation, data acquisition devices.
  • Pipeline design and leak detection studies.
  • Evaluation of client requirement and development of CPM System Specifications.
  • Development of comprehensive pre-qualification and bid specifications packages.
  • Development of Software Specification Documents (SSD) and Statements of Work (SOW)

Project Support Services:

  • Design specification and reviews.
  • Development of acceptance tests.
  • Performing factory and site acceptance tests (FAT and SAT)
  • Planning and performing deployment and cut-overs
  • Implementation of customizations.
  • Development of custom data interfaces or specialized software or HMI.
  • Configuration of CPM databases and graphical user interfaces.
  • Support (Systems, hardware, software and network)

Specialized Services, Analysis/Programming:

  • Specialized networking and hardware consulting, LAN/WAN, VPN, VSAT, Router, Switch, Hub, Terminal Server and Modem setup/programming and related network design.
  • NT, Linux, Unix, VAX/AXP VMS System management and hardware support.
  • Development of data interfaces to transfer SCADA data to the outside world (internet or intranet).
  • Provide specialized services on pipeline related software such as Nomination and Pipeline Scheduling Systems.
  • Analyze/modify existing systems/applications to interface with new instrumentation, data acquisition devices, and applications.
  • Design/enhance application packages to improve data flow / work process.
  • Facilitate user/customer access to system/application data through Internet web pages and PC data management packages.
  • SCADA System and operational audits.