Koch Modular Process Systems specializes in designing and constructing mass transfer systems and providing automation solutions for the chemical processing industry. The company offers custom control systems, integration services, and comprehensive testing procedures to ensure functionality and compliance with industry standards. Their capabilities include process control design, HMI optimization, historical data configuration, and regulatory documentation support.

1. Telephone: 201.267.8670
kochmodular.com
Engineered Smarter. Built Modular.
Automation and
Control System
Capabilities
Koch Modular Process Systems, LLC
45 Eisenhower Drive, Suite 350, Paramus, NJ 07652 / Tel: 201.267.8670 / Fax: 201.368.8989 / kochmodular.com

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For over 20 years Koch Modular has successfully designed and constructed
mass transfer systems for the worldwide Chemical Processing Industry. Our
customers rely upon Koch Modular for our quality products and technical
expertise.

3. M O D U L A R S Y S T E M S | D E V E L O P I N G T E C H N O L O G I E 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 | P I L O T T E S T I N G
Telephone: 201.267.8670
kochmodular.com
Control System Capabilities
Koch Modular Process Systems, LLC (Koch Modular) provides process control system and automation
solutions for standalone turnkey applications or integration within a customer's existing PLC, DCS, or
SCADA infrastructure. Koch Modular engineers work directly with the customer to design a custom
solution specific to meet their plant, industry, standards, and needs. Koch Modular 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 S Y S T E M S | D E V E L O P I N G T E C H N O L O G I E 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 | P I L O T T E S T I N G
Telephone: 201.267.8670
kochmodular.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 S Y S T E M S | D E V E L O P I N G T E C H N O L O G I E 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 | P I L O T T E S T I N G
Telephone: 201.267.8670
kochmodular.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
Koch Modular 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 S Y S T E M S | D E V E L O P I N G T E C H N O L O G I E 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 | P I L O T T E S T I N G
Telephone: 201.267.8670
kochmodular.com
Control System Documentation
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Control Loops
 Type, Action, Tracking, and Scaling
 Cascade, Slave, Ratio, and Equations
I/O
 Signal/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
Koch Modular 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 S Y S T E M S | D E V E L O P I N G T E C H N O L O G I E 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 | P I L O T T E S T I N G
Telephone: 201.267.8670
kochmodular.com
Code Compliance Documentation
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When required by industry or customer, Koch Modular 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 S Y S T E M S | D E V E L O P I N G T E C H N O L O G I E 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 | P I L O T T E S T I N G
Telephone: 201.267.8670
kochmodular.com
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
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 Panel Shop Assembly Shop

9. M O D U L A R S Y S T E M S | D E V E L O P I N G T E C H N O L O G I E 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 | P I L O T T E S T I N G
Telephone: 201.267.8670
kochmodular.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 S Y S T E M S | D E V E L O P I N G T E C H N O L O G I E 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 | P I L O T T E S T I N G
Telephone: 201.267.8670
kochmodular.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 S Y S T E M S | D E V E L O P I N G T E C H N O L O G I E 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 | P I L O T T E S T I N G
Telephone: 201.267.8670
kochmodular.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
Koch Modular provides a site acceptance test (SAT) document after delivery to plant site.
Koch Modular assists plant engineers and operators with the SAT where desired.

12. M O D U L A R S Y S T E M S | D E V E L O P I N G T E C H N O L O G I E 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 | P I L O T T E S T I N G
Telephone: 201.267.8670
kochmodular.com
Control System HMI Graphics
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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
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 Koch Modular can implement into the design.

13. M O D U L A R S Y S T E M S | D E V E L O P I N G T E C H N O L O G I E 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 | P I L O T T E S T I N G
Telephone: 201.267.8670
kochmodular.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 S Y S T E M S | D E V E L O P I N G T E C H N O L O G I E 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 | P I L O T T E S T I N G
Telephone: 201.267.8670
kochmodular.com
Custom Control Modules
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Koch Modular 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. Koch Modular 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.
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
On/Off Control Module Custom Siren/Light Sequence Control
Valve Output/Flow Characterization
Master/Slave Controller
Sequential Flow Chart
Feedforward Control

15. M O D U L A R S Y S T E M S | D E V E L O P I N G T E C H N O L O G I E 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 | P I L O T T E S T I N G
Telephone: 201.267.8670
kochmodular.com
Control System Sequence
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Koch Modular 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 S Y S T E M S | D E V E L O P I N G T E C H N O L O G I E 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 | P I L O T T E S T I N G
Telephone: 201.267.8670
kochmodular.com
Control System Sequence
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Single Referenced Sequential Document

17. M O D U L A R S Y S T E M S | D E V E L O P I N G T E C H N O L O G I E 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 | P I L O T T E S T I N G
Telephone: 201.267.8670
kochmodular.com
Process Historian and Data Acquisition
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Koch Modular 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

18. M O D U L A R S Y S T E M S | D E V E L O P I N G T E C H N O L O G I E 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 | P I L O T T E S T I N G
Telephone: 201.267.8670
kochmodular.com
Electrical Design
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Koch Modular 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

19. M O D U L A R S Y S T E M S | D E V E L O P I N G T E C H N O L O G I E 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 | P I L O T T E S T I N G
Telephone: 201.267.8670
kochmodular.com
Control Panel Design
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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

20. M O D U L A R S Y S T E M S | D E V E L O P I N G T E C H N O L O G I E 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 | P I L O T T E S T I N G
Telephone: 201.267.8670
kochmodular.com
Control Panel Fabrication
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21. M O D U L A R S Y S T E M S | D E V E L O P I N G T E C H N O L O G I E 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 | P I L O T T E S T I N G
Telephone: 201.267.8670
kochmodular.com
Control System Integration & Migration
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Koch Modular controls group provides system integration and migration from many automation
platforms. Koch Modular 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)

22. M O D U L A R S Y S T E M S | D E V E L O P I N G T E C H N O L O G I E 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 | P I L O T T E S T I N G
Telephone: 201.267.8670
kochmodular.com
Simulated Start-Up Training
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Koch Modular 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.
Operating Manual Simulation Module Simulated Process

23. M O D U L A R S Y S T E M S | D E V E L O P I N G T E C H N O L O G I E 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 | P I L O T T E S T I N G
Telephone: 201.267.8670
kochmodular.com
Operator Training
23
Koch Modular provides operator training tailored specifically to the project and plant needs.
Koch Modular includes a customized on-site training package including direct training presentations.
Sample Training Presentation

24. Telephone: 201.267.8670
kochmodular.com
Engineered Smarter. Built Modular.
Thank You!
Koch Modular Process Systems, LLC
45 Eisenhower Drive, Suite 350, Paramus, NJ 07652 / Tel: 201.267.8670 / Fax: 201.368.8989 / kochmodular.com