Automation and control system capabilities

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Automation and
Control System
Capabilities
45 Eisenhower Drive, Suite 350, Paramus, NJ 07652
| Te l : ( 2 0 1 ) 2 6 7- 8 6 7 0
| Fax: (201) 368-8989
| www.modularprocess.com
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.
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Control System Capabilities
MO D U L A R P R O C E SS S Y S T EMS | D I S T I L L ATI O N | L I Q U I D E XT R A C T I O N | E N G I N EER I NG | P I L O T T E S T I NG
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 5000/500
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
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www.modularprocess.com
Telephone: (201) 267-8670
Control System Project Flow
MO D U L A R P R O C E SS S Y S T EMS | D I S T I L L ATI O N | L I Q U I D E XT R A C T I O N | E N G I N EER I NG | P I L O T T E S T I NG
Detailed
Proposal
Customer RFQ
The Customer
Provides Input at
Every Step!
Controls
Functional
Description
Control System
Design and
Fabrication
Customer
Review
Factory
Acceptance Test
Programming
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Site Acceptance
Test and
Commissioning
www.modularprocess.com
Telephone: (201) 267-8670
Control System Capabilities
MO D U L A R P R O C E SS S Y S T EMS | D I S T I L L ATI O N | L I Q U I D E XT R A C T I O N | E N G I N EER I NG | P I L O T T E S T I NG
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.
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
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www.modularprocess.com
Telephone: (201) 267-8670
Control System Documentation
MO D U L A R P R O C E SS S Y S T EMS | D I S T I L L ATI O N | L I Q U I D E XT R A C T I O N | E N G I N EER I NG | P I L O T T E S T I NG
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.
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
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www.modularprocess.com
Telephone: (201) 267-8670
Code Compliance Documentation
MO D U L A R P R O C E SS S Y S T EMS | D I S T I L L ATI O N | L I Q U I D E XT R A C T I O N | E N G I N EER I NG | P I L O T T E S T I NG
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
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www.modularprocess.com
Telephone: (201) 267-8670
Factory Acceptance Testing (FAT)
MO D U L A R P R O C E SS S Y S T EMS | D I S T I L L ATI O N | L I Q U I D E XT R A C T I O N | E N G I N EER I NG | P I L O T T E S T I NG
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
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Telephone: (201) 267-8670
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
www.modularprocess.com
Factory Acceptance Testing (FAT)
MO D U L A R P R O C E SS S Y S T EMS | D I S T I L L ATI O N | L I Q U I D E XT R A C T I O N | E N G I N EER I NG | P I L O T T E S T I NG
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.
Control System
Panel Shop
Assembly Shop
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
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www.modularprocess.com
Telephone: (201) 267-8670
Factory Acceptance Testing (FAT)
MO D U L A R P R O C E SS S Y S T EMS | D I S T I L L ATI O N | L I Q U I D E XT R A C T I O N | E N G I N EER I NG | P I L O T T E S T I NG
Witness, configuration, and inspection of all Instrumentation and Panels including temporary
connection of networking and wiring if possible. Performed at the Module Assembly Shop.
Control System
Panel Shop
Assembly 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
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www.modularprocess.com
Telephone: (201) 267-8670
Site Acceptance Testing (SAT)
MO D U L A R P R O C E SS S Y S T EMS | D I S T I L L ATI O N | L I Q U I D E XT R A C T I O N | E N G I N EER I NG | P I L O T T E S T I NG
KMPS provides a site acceptance test (SAT) document after delivery to plant site. KMPS assists plant
engineers and operators with the SAT where desired.
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
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www.modularprocess.com
Telephone: (201) 267-8670
Control System HMI Graphics
MO D U L A R P R O C E SS S Y S T EMS | D I S T I L L ATI O N | L I Q U I D E XT R A C T I O N | E N G I N EER I NG | P I L O T T E S T I NG
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.
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
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www.modularprocess.com
Telephone: (201) 267-8670
Control System Operator HMI
MO D U L A R P R O C E SS S Y S T EMS | D I S T I L L ATI O N | L I Q U I D E XT R A C T I O N | E N G I N EER I NG | P I L O T T E S T I NG
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.
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www.modularprocess.com
Telephone: (201) 267-8670
Custom Control Modules
MO D U L A R P R O C E SS S Y S T EMS | D I S T I L L ATI O N | L I Q U I D E XT R A C T I O N | E N G I N EER I NG | P I L O T T E S T I NG
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
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
Master/Slave Controller
Sequential Flow Chart
Valve Output/Flow Characterization
Feedforward Control
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www.modularprocess.com
Telephone: (201) 267-8670
Control System Sequence
MO D U L A R P R O C E SS S Y S T EMS | D I S T I L L ATI O N | L I Q U I D E XT R A C T I O N | E N G I N EER I NG | P I L O T T E S T I NG
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)
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www.modularprocess.com
Telephone: (201) 267-8670
Control System Sequence
MO D U L A R P R O C E SS S Y S T EMS | D I S T I L L ATI O N | L I Q U I D E XT R A C T I O N | E N G I N EER I NG | P I L O T T E S T I NG
Single Referenced Sequential Document
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www.modularprocess.com
Telephone: (201) 267-8670
Process Historian and Data Acquisition
MO D U L A R P R O C E SS S Y S T EMS | D I S T I L L ATI O N | L I Q U I D E XT R A C T I O N | E N G I N EER I NG | P I L O T T E S T I NG
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
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www.modularprocess.com
Telephone: (201) 267-8670
Electrical Design
MO D U L A R P R O C E SS S Y S T EMS | D I S T I L L ATI O N | L I Q U I D E XT R A C T I O N | E N G I N EER I NG | P I L O T T E S T I NG
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.
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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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www.modularprocess.com
Telephone: (201) 267-8670
Control Panel Design
MO D U L A R P R O C E SS S Y S T EMS | D I S T I L L ATI O N | L I Q U I D E XT R A C T I O N | E N G I N EER I NG | P I L O T T E S T I NG
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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www.modularprocess.com
Telephone: (201) 267-8670
Control Panel Fabrication
MO D U L A R P R O C E SS S Y S T EMS | D I S T I L L ATI O N | L I Q U I D E XT R A C T I O N | E N G I N EER I NG | P I L O T T E S T I NG
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www.modularprocess.com
Telephone: (201) 267-8670
Control System Integration & Migration
MO D U L A R P R O C E SS S Y S T EMS | D I S T I L L ATI O N | L I Q U I D E XT R A C T I O N | E N G I N EER I NG | P I L O T T E S T I NG
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)
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www.modularprocess.com
Telephone: (201) 267-8670
Simulated Start-Up Training
MO D U L A R P R O C E SS S Y S T EMS | D I S T I L L ATI O N | L I Q U I D E XT R A C T I O N | E N G I N EER I NG | P I L O T T E S T I NG
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.
Operating Manual
Simulation Module
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Simulated Process
www.modularprocess.com
Telephone: (201) 267-8670
Operator Training
MO D U L A R P R O C E SS S Y S T EMS | D I S T I L L ATI O N | L I Q U I D E XT R A C T I O N | E N G I N EER I NG | P I L O T T E S T I NG
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
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www.modularprocess.com
Telephone: (201) 267-8670
Thank You!
45 Eisenhower Drive, Suite 350, Paramus, NJ 07652
| Te l : ( 2 0 1 ) 2 6 7- 8 6 7 0
| Fax: (201) 368-8989
| www.modularprocess.com
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