automation and control system capabilities

Automation and Control System

Capabilities

4 5 E i se n h o w er D r i v e , S u i te 35 0 , P ara m u s , N J 0 76 52 | Te l : (2 01 ) 26 7 - 86 70 | F a x : ( 20 1 ) 3 68 -8 98 9 | w ww. m o d u l ar p ro c es s . c o m

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For over 20 years KMPS has successfully designed and constructed mass transfer systems for the worldwide Chemical Processing Industry. Our

customer’s rely upon KMPS for our quality products and technical expertise.

M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G

3 Telephone: (201) 267-8670www.modularprocess.com

Control System Capabilities

Koch Modular Process Systems, LLC (KMPS) provides process control system and automation solutions for standalone turnkey applications or integration within a customer's existing PLC, DCS, or SCADA infrastructure. KMPS engineers work directly with the customer to design a custom solution specific to meet their plant, industry, standards, and needs. KMPS can also assist in modification of existing control systems to upgrade or integrate enhanced functionality.

Controller Software: Emerson DeltaV

Distributed Control System (DCS)PMO Configuration Standard for DeltaV

(PCSD)Safety Integrated System (SIS)

Rockwell Automation Studio and RSLogix 5000/500Siemens SIMATIC STEP 7 (TIA Portal)

HMI Software: Rockwell Automation FactoryTalk View SE/ME and

PlantPAxSiemens WinCC (TIA Portal)Wonderware System Platform and InTouch



Control System Project Flow

Customer RFQ Detailed Proposal

Customer Review

Controls Functional Description

The Customer Provides Input at

Every Step!

Programming Factory Acceptance Test

Control System Design and Fabrication

Site Acceptance Test and

Commissioning



Control System Capabilities

Capabilities:

Design Continuous, Batch (ISA-88), and Semi-Batch Processes

Create and Configure Custom Control Module Logic and Algorithms

Streamline Full Automation Process Sequencing

Optimize HMI Interface

Perform Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT)

Deliver Complete Control System Documentation

Integrate Process Historian and Data Storage Analysis

Execute Control System Migrations

Industrial Protocols:

HART, FOUNDATION Fieldbus, PROFIBUS DP/PA, DeviceNet, Modbus, AS-Interface

EtherNet/IP, PROFINET, Modbus TCP/IP

KMPS provides the full scope of control system design, implementation, testing, and support of each and every control system we build. To ensure seamless integration of process requirements into the automation system our controls engineers work side-by-side with our process engineers through the duration of the project: Design -> Programming -> Testing -> Startup -> Training.



Control Loops

Type, Action, Tracking, and Scaling

Cascade, Slave, Ratio, and Equations

Sequencing

I/O

AI, AO, DI, DO

Instrument Types and Channel Assignments

Scaled Ranges and Scan Rates

Motor Control and VFD Configuration

Alarms & Interlocks

Setpoints and Priorities

Delays, Conditional Alarming, and Interlock Actions

Cause and Effect Matrix

Control System Documentation

KMPS develops a Controls Functional Description (CFD) or Functional Requirements Specification (FRS) to serve as the master document used to communicate requirements between all members of the multi-discipline engineering and operations staff.



Code Compliance Documentation

When required by industry or customer, KMPS assists in the development of the User Requirement Specification (URS), Functional Requirement Specification (FRS), System Design Specification (SDS), and Hardware Design Specification (HDS) to support the required level of control system validation.

Code Compliance Include:

21 CFR Part 11: Instrument Qualification, Operational Qualification, Performance Qualification Validation Documentation

ISA-82: Safety Standard for Electrical and Electronic Test, Measuring, Controlling, and Related Equipment

ISA-88: Batch Process Control

ISO 16484: Building Automation and Control Systems

cGMP: Current Good Manufacturing Practice

GAMP: Good Automation Manufacturing Practice

ANSI/NEMA 250: Enclosures for Electrical Equipment



Control System Panel Shop Assembly Shop

Factory Acceptance Testing (FAT)

Each control system is subjected to three phases of rigorous factory acceptance testing (FAT) to ensure the final control system will be ready for commissioning when delivered.

Control System Software Test

Completed In-House

Process Simulation

Screen Layout and Operation

Control Loop Functionality

Alarms and Interlocks

Sequence Programming

Complete Software Functional Test




Control Panel Hardware Test

Completed at Panel Shop

Control System with HMI

AI, AO, DI, DO Card Wiring

Verify Scaled Ranges

Test Each Physical I/O Point in Panel

Simulate 4-20mA Signal Output/Input

Verify All Control Panel Wiring, Functionality, and Control System Integration

Provide As-Built Documentation


Witness and functionality testing of all Control Panels supplied with the Control System including temporary connection of networking and wiring if possible. Performed at the Panel Fabricator Shop.




Full Loop Test

Completed at Module Assembly Shop

Full Control System with HMI

Full Loop: HMI -> I/O -> Instrument

All Instrument Wiring and Functionality

Simulate 4-20mA & Discrete

Half Loop FAT

Test Each Physical I/O Point in Panel from Instrument

Verify All Electrical and Conduit Wiring


Witness, configuration, and inspection of all Instrumentation and Panels including temporary connection of networking and wiring if possible. Performed at the Module Assembly Shop.



Site Acceptance Testing (SAT)

Start-Up Site Acceptance Test

Completed at Plant Site

All Instrument Functionality Tested with Respective Reference Variables

Use Real-Time Process Data

Verify Field Electrical Installation

KMPS provides a site acceptance test (SAT) document after delivery to plant site. KMPS assists plant engineers and operators with the SAT where desired.



HMI Graphics Optimization

High Performance HMI Improves Operator Usability

Quick access to PID, PFD, and Equipment Data with 1-Click

Custom Screen Navigation

Strategic Positioning of Critical Buttons and Switches

Visual and Text Indication of Commands and Status

Increase Operator Response Time

Optimize Display of Process Variables, Alarms, and Interlocks

Control System HMI Graphics

Graphic screens are customized and designed for the customer and arranged in a realistic and easy to understand fashion. Traditional, customer standards, or high-performance HMI (high contrast) are examples of themes KMPS can implement into the design.



Control System Operator HMI

Each operator screen interface is designed to show realistic equipment arrangements and process conditions. Quick access to equipment drawings and detailed dynamos to instruments, motors, and valves give an easy visualization of the process conditions.



Custom Control Modules

KMPS develops custom control designs to fit the needs of the project and customer. Our team works closely with our customers to develop the best algorithms and calculations for complex process control conditions. KMPS has experience with all IEC-61131-3 Languages including Ladder, Function Block, Structured Text, and Sequential Functional Chart. We are very flexible using and modifying, if necessary, plant programming standards. On/Off Control Module Custom Siren/Light Sequence Control

Valve Output/Flow Characterization

Custom Control Modules

Multiple Modes of Operation

Complex Control Schemes

Cascading Control Loop Sequencing

Feedforward Cascading Control

Timed Proportional Control

On/Off Control

Valve/Flow/Output Characterization Module

Moving Average Controller

Pulsating Output Valve Control

Feedforward Control

Sequential Flow Chart

Master/Slave Controller



Control System Sequence

KMPS can provide fully automated systems with sequential operation for batch and continuous processes.

Key Points:

Detailed step-by-step logic for automatic system operation

“Push button operation”

Integrated visual alarms & interlocks built into each custom designed sequences

Sequences developed by process engineer then reviewed and finalized with process controls engineer

Single referenced document for process engineers, control engineers, and operators (See Next Slide)



Control System Sequence

Single Referenced Sequential Document



Process Historian and Data Acquisition

KMPS provides a fully integrated historical data configuration and collection system. Historized process variables, setpoints, outputs, alarms, operator changes, and downloads are a few of the many data that can be accessed online and offline for analysis and trending.

DeltaV Historian

Fully functioning historian on every workstation and easily assessable on operator displays

Scalable plant historian available on the Application Stations

Supports connectivity to OSIsoft PI Server

Data groups are easily customizable

Data can be import/export to and from MS excel

Open connectivity using OPC and XML



Electrical Design

KMPS creates a complete set of Control System and Electrical design drawings. Documentation can be provided in native AutoCAD format and per Customer Standards if required.

Control Panel Assembly and Schematics Electrical and Instrument Installation Drawings Instrument Loop Drawings Fieldbus and Network Drawings Hazardous Area Design Lighting Design and Optimization Motor Control and Variable Frequency Drives One-Line Diagrams and Protection



Control Panel Design

Each Control Panel, Remote I/O Enclosure, Motor Control Center, Junction Box, or Instrument Panel is custom designed and fabricated to ensure safe and efficient protection of the enclosed system.

PLC/DCS and Remote I/O Panels Terminal Junction Boxes and Fieldbus Tap Boxes Custom IEC Motor Control and Drive Panels Hazardous, Intrinsically Safe, and Purged Panels Power Panels, Lighting Control, and Transformers Compliance with NEC, NEMA, UL 508A, IEC, ATEX, and More



Control Panel Fabrication



Control System Integration & Migration

KMPS controls group provides system integration and migration from many automation platforms. KMPS is adept at upgrading legacy Emerson, Siemens, Wonderware, and Rockwell Automation control systems to the latest version or technology with little to no downtime.

Sample Migration of PROVOX to DeltaV (including SIS)



KMPS tests the control system along with the operating manual by using simulation data to mimic process and alarm scenarios to ensure the control system is optimized the day it arrives at the customer site.

Simulated Start-Up Training

Operating Manual Simulation Module Simulated Process



Operator Training

KMPS provides operator training tailored specifically to the project and plant needs. KMPS includes a customized on-site training package including direct training presentations.

Sample Training Presentation

Thank You!

4 5 E i se n h o w er D r i v e , S u i te 35 0 , P ara m u s , N J 0 76 52 | Te l : (2 01 ) 26 7 - 86 70 | F a x : ( 20 1 ) 3 68 -8 98 9 | w ww. m o d u l ar p ro c es s . c o m

automation and control system capabilities

Engineering