Process Control System
Hallam-ICS’ specialists have an extensive hands-on experience with the design, installation, programming and validation of batch control systems.
Challenge
BYK USA Inc. has expanded their specialty chemical production operations by constructing a new, fully automated manufacturing facility. To meet customer demands, BYK stressed the importance of having a flexible system that could deliver a range of batch sizes and was able to easily facilitate recipe changes. To achieve these goals, BYK required that the process control system be designed and implemented in accordance with the S88 Batch Programming Standard.
Solution
Hallam-ICS was brought on to the project team to provide the required S88 design expertise for the process control system. Hallam-ICS was responsible for the design of the software, hardware, and networks required for system implementation including the following subsystems:
- Programmable Automation Controllers (PAC) and associated I/O
- Batch Control System
- Process and Alarm Data Historian
- Network and Domain Systems
- Reporting and Data Analysis Systems
- Disaster Recovery Systems
Hallam-ICS took the requirements from BYK and designed a system to specifically meet the current objectives while also being flexible and scalable for future needs. The system includes 2,400 I/O points and utilizes the Rockwell Software PlantPAX platform.
Results
Our team accomplished the following:
- Flexible and Scalable Batch Control System: Designed and implemented a process control system aligned with the S88 Batch Programming Standard, delivering flexibility for various batch sizes and recipe changes while ensuring scalability for future production needs.
- Comprehensive System Integration: Successfully designed and integrated subsystems, including Programmable Automation Controllers (PACs), a Batch Control System, Alarm and Data Historian, and reporting tools, supporting a fully automated and efficient manufacturing facility.
- Robust Disaster Recovery and Network Design: Developed a resilient network and domain system, complete with disaster recovery capabilities, ensuring operational reliability and safeguarding critical production data for BYK's advanced chemical production operations.