Abstract

This case study highlights how Feed4ward assisted Credfeld Ltd. in recovering ownership of their Fyrelogix Burner Management System (BMS). Through reverse engineering, Feed4ward developed a robust solution that improved design documentation, modernised hardware and software, and reduced dependency on hard-to-source components. The results include a cost-effective and reliable product that meets SIL standards, a comprehensive documentation package and enhanced traceability of software changes, all of which is supported by Feed4ward’s quality processes.

Introduction

Background

Credfeld Ltd. faced significant challenges in managing the lifecycle of their Fyrelogix BMS. Due to circumstance, Credfeld lacked control over intellectual property and up-to-date design documentation, making it difficult to manage software changes effectively. Additionally, their reliance on components with long lead times disrupted production and jeopardised the product’s reliability. These issues left Credfeld without the necessary control over their critical system, impacting product availability and system maintainability.

Objective

Feed4ward was tasked to develop a functionally equivalent product, improving design documentation, and de-risking the procurement of components by ensuring the use of readily available parts and introducing Feed4ward as a reliable supplier.

“This could have been a very stressful time for us and we needed to fully trust Feed4ward right from the start. If we weren’t able to replicate the original Firelogics box, we would be left without a product”

Simon Vine – Managing Director at Credfeld Ltd.

Methodology & Case Description

To address Credfeld’s challenges, Feed4ward conducted a detailed analysis of the existing Fyrelogix BMS, identifying and documenting key signals, alarms, and functionalities. Through reverse engineering, the team recreated a product with identical form and function while incorporating significant improvements. The new hardware and software design was made compliant with SIL standards, while a modular hardware approach was adopted to streamline assembly and enhance scalability. The redesigned system featured a modernised user interface, following clear and consistent UI design principles, that improved on user experience and feedback on the system status.

Credfeld played a crucial role by sharing their know-how and actively assisting in testing and validation of the system. This collaboration was instrumental in ensuring the project’s success and aligning the final product with Credfeld’s vision.
Despite challenges in interpreting outdated and incomplete flowcharts, Feed4ward successfully reconstructed the controller logic and validated the new system to ensure it met or exceeded the performance of the original BMS.

Results & Analysis 

Feed4ward delivered a comprehensive documentation package, including functional, hardware, and software design documents. This ensured enhanced traceability of software changes, facilitated by controlled software versioning and a well-documented build record. The use of cost-effective hardware enhanced reliability, while maintaining compliance with SIL standards. Additionally, the hardware modular design allowed for faster assembly and simplified maintenance, while the upgraded user interface enabled easier configuration and customisation for specific applications. The improvements in component availability reduced lead times and provided Credfeld with greater control over their supply chain, ensuring consistent production and maintenance capabilities.

“After we determined the design specification, it was vitally important we tested it to the ‘nth’ degree through the simulator. This gave me the confidence to proceed as we needed it to work first time on the other side of the world.”

Simon Vine – Managing Director at Credfeld Ltd. 

Conclusion

Feed4ward’s approach demonstrates the effectiveness of reverse engineering in recovering control over critical systems. By addressing both technical and supply chain challenges, the project showcased the value of modern engineering practices in extending product lifecycles and reducing risks.
The collaboration between Credfeld and Feed4ward highlighted the importance of a robust quality process in achieving compliance, traceability, and reliability. The project restored Credfeld’s ownership of the product, ensuring complete control over intellectual property, design documents, and source code.

“Everything that Feed4ward has provided has been rigorously tested. It is important to me that the margin for error is reduced as much as possible. I trust the engineers at Feed4ward and I would have no problem putting my faith in them again for future solutions. I’d recommend them to anyone”

Simon Vine – Managing Director at Credfeld Ltd.