KMPS provides automation and control system capabilities including design, implementation, testing and support. They have expertise in common control system platforms such as DeltaV, Rockwell, Siemens and Wonderware. KMPS works closely with customers throughout a project from design through programming, testing, startup and training. Rigorous factory and site acceptance testing is performed to ensure systems meet requirements.

1. Automation and
Control System
Capabilities
45 Eisenhower Drive, Suite 350, Paramus, NJ 07652 | Tel: (201) 267-8670 | Fax: (201) 368-8989 | www.modularprocess.com

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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.

3. 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
Telephone: (201) 267-8670
www.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.
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Controller Software:
Emerson DeltaV
Distributed Control System (DCS)
PMO Configuration Standard for DeltaV (PCSD)
Safety Integrated System (SIS)
Rockwell Automation Studio and RSLogix 5000/500
Siemens SIMATIC STEP 7 (TIA Portal)
HMI Software:
Rockwell Automation FactoryTalk View SE/ME and PlantPAx
Siemens WinCC (TIA Portal)
Wonderware System Platform and InTouch

4. 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
Telephone: (201) 267-8670
www.modularprocess.com
Control System Project Flow
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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

5. 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
Telephone: (201) 267-8670
www.modularprocess.com
Control System Capabilities
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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.

6. 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
Telephone: (201) 267-8670
www.modularprocess.com
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
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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.

7. 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
Telephone: (201) 267-8670
www.modularprocess.com
Code Compliance Documentation
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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

8. 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
Telephone: (201) 267-8670
www.modularprocess.com
Control System Panel Shop Assembly Shop
Factory Acceptance Testing (FAT)
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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

9. 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
Telephone: (201) 267-8670
www.modularprocess.com
Factory Acceptance Testing (FAT)
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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
Control System Panel Shop Assembly Shop
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.

10. 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
Telephone: (201) 267-8670
www.modularprocess.com
Factory Acceptance Testing (FAT)
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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
Control System Panel Shop Assembly Shop
Witness, configuration, and inspection of all Instrumentation and Panels including temporary
connection of networking and wiring if possible. Performed at the Module Assembly Shop.

11. 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
Telephone: (201) 267-8670
www.modularprocess.com
Site Acceptance Testing (SAT)
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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.

12. 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
Telephone: (201) 267-8670
www.modularprocess.com
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
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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.

13. 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
Telephone: (201) 267-8670
www.modularprocess.com
Control System Operator HMI
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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.

14. 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
Telephone: (201) 267-8670
www.modularprocess.com
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.
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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

15. 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
Telephone: (201) 267-8670
www.modularprocess.com
Control System Sequence
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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)

16. 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
Telephone: (201) 267-8670
www.modularprocess.com
Control System Sequence
Single Referenced Sequential Document
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17. 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
Telephone: (201) 267-8670
www.modularprocess.com
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.
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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

18. 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
Telephone: (201) 267-8670
www.modularprocess.com
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
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19. 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
Telephone: (201) 267-8670
www.modularprocess.com
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
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20. 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
Telephone: (201) 267-8670
www.modularprocess.com
Control Panel Fabrication
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21. 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
Telephone: (201) 267-8670
www.modularprocess.com
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.
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Sample Migration of PROVOX to DeltaV (including SIS)

22. 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
Telephone: (201) 267-8670
www.modularprocess.com
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
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Operating Manual Simulation Module Simulated Process

23. 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
Telephone: (201) 267-8670
www.modularprocess.com
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.
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Sample Training Presentation

24. Thank You!
45 Eisenhower Drive, Suite 350, Paramus, NJ 07652 | Tel: (201) 267-8670 | Fax: (201) 368-8989 | www.modularprocess.com