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Automation and
Control System
Capabilities
45 Eisenhower Drive, Suite 350, Paramus, NJ 07652 | Tel: (201) 267-8670 | Fax: ...
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For over 20 years KMPS has successfully designed and constructed mass
transfer systems for the worldwide Chemical Proces...
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 ...
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 ...
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Thank You!
45 Eisenhower Drive, Suite 350, Paramus, NJ 07652 | Tel: (201) 267-8670 | Fax: (201) 368-8989 | www.modularproc...
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Automation and Control System Capabilities

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Koch Modular Process Systems, LLC. (KMPS) provides turnkey solutions complete with fully programmed and customized process control systems. KMPS features Emerson DeltaV as its control system manufacturer of choice. We can also supply the full range of other manufacturer’s available PLC’s, HMI’s, SCADA systems, etc. KMPS can custom engineer the complete control system to meet your plant’s specific needs and standards.
PLC Programming Software:
Allen-Bradley: RSLogix 5000 and RSLogix 500
Siemens: SIMATIC STEP 7 TIA Portal and SIMATIC STEP 7
HMI/Visualization Software:
Allen-Bradley: FactoryTalk View SE/ME/Studio
Siemens: WinCC TIA Portal , WinCC, and WinCC Flexible
Wonderware: Archestra System Platform and InTouch HMI

Published in: Engineering

Automation and Control System Capabilities

  1. 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
  2. 2. 2 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. 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. 3 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. 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 4 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. 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 5 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. 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 6 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. 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 7 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. 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) 8 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. 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) 9 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. 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) 10 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. 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) 11 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. 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 12 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. 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 13 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. 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. 14 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. 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 15 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. 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 16
  17. 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. 17 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. 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 18
  19. 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 19
  20. 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 20
  21. 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. 21 Sample Migration of PROVOX to DeltaV (including SIS)
  22. 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 22 Operating Manual Simulation Module Simulated Process
  23. 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. 23 Sample Training Presentation
  24. 24. Thank You! 45 Eisenhower Drive, Suite 350, Paramus, NJ 07652 | Tel: (201) 267-8670 | Fax: (201) 368-8989 | www.modularprocess.com

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