Process Automation & Machine Control
Inc.Past Process Projects
The projects described below are representative examples of process automation project work that HTSE Inc. has performed for its clients.
This listing does not reflect HTSE’s total process automation project portfolio.
Past Process Projects
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Agricultural Chemical Plant Process Capacity Increase Project
Multi-year project providing configuration and programming services for an agricultural chemical processing facility. Developed the process controls to match customer scope documents. Configured the system to control product drying belt filter and associated feed tanks, vacuum system, and packaging conveyor. Configured the system to load, run, and purge carbon bed filters for waste brine treatment system.
Chemical Manufacturing Plant Expansion Project
Multi-year project developing scope documents and process control software to meet customer scope requirements. System DCS controls included tank level, temperature, flow, pump start/stop and optimizing control strategies for 4 distillation columns in a fine chemical manufacturing facility. Conducted operator training, system wet testing, and startup coverage as part of overall scope. Provided loop checkout and loop tuning support using assisted and classical tuning techniques. Number of I/O was in the thousands.
Chemical Plant Batch Blending Project
Generated process control design specifications, DCS controller code, and process graphics for a significant portion of an automotive chemical batch blending plant, applying ANSI/ISA S88 standards. Supported plant startup through return to operations. In a related project, HTSE Developed DCS controller code for new installation of extremely large reactors in a major chemical plant, using ANSI/ISA S88 standards as well as state-based control. Integrated Basic Process Control System (BPCS) functionality with Safety Instrumentated System (SIS) functions (SIL 2 & 3).
Chemical Plant Process Automation Optimizations
Three year project optimizing control of fine chemical plant. Evaluated existing control schemes and performance of existing plant instrumentation. Developed optimized control schemes, presented proposed designs and reviewed with client. Prepared design specification documents consistent with client standards. Developed DCS control application and graphic screens. All code was tested in a simulation environment that HTSE assisted in developing. Prepared training documents and trained plant operations personnel in class room and simulation environments. Provided startup support. Developed process data trends to support process troubleshooting. Currently continuing to provide ongoing optimization support in the form of troubleshooting, alarm optimization and code modifications. Plant startups were consistently ahead of schedule and exceeded production goals. Systems include batch and continuous processing, distillation columns/solvent recovery processes, product drying and transport, recipe management, safety systems.
Chemical Plant Process Simulation Project
Multi-year project designing and configuring real time plant process simulation programs used to test new DCS Controls. Simulations included a complete fine chemical plant including: distillation columns, batch reactors, storage tanks, product washing, drying and packaging equipment. Worked with plant engineers to test simulation code and provide enhancements as necessary. Customer maintains simulation code for on-going operator training and certification.
CIP System Addition Project
Developed Clean-in-Place PLC programs for blending, heat treatment, storage tank, liquid to powder dryer and liquid transfer lines. System was created for manufacturing personnel to manipulate equipment cleaning time, chemical concentrations, and sequence of events via selection of standardized operation choices without the need for programming changes to the controller code. This allowed for increased effectiveness of the cleaning and decreased the costs of programming modifications.
Green-field Chemical Plant Process Automation Project
Multi-year, multi-project chemical plant process automation design and development. Proposed control strategies, developed new technologies, implemented client standards, coded controller and HMI systems, and system startup. Manufacturing areas of responsibility included: multipoint liquid and solid blending system, powder mixing and transport, utilities, safety systems, raw material and product storage, delivery, and packaging. Number of I/O was in the thousands.
Batch design and implementation on DCS batching system and controls to meet ANSI/ISA-88 standards. Batch procedures were created to interface with the chemical plant’s operations. These procedures contained operations which handled all S-88 control requests, batch reporting, MES interface commands and operator messaging.
Batch design and implementation on DCS batching system and controls to meet ANSI/ISA-88 standards. Batch procedures were created to interface with the chemical plant’s operations. These procedures contained operations which handled all S-88 control requests, batch reporting, MES interface commands and operator messaging.
Liquid to Powder Drying System Performance and Efficiency Project
HTSE’s responsibilities included project design, coding implementation, and startup coordination. Drying system variables were predicted and control points manipulated via equation set and multi-PID control loop integration on Allen Bradley and Modicon PLCs. Operational efficiencies were increased to run the system at previously uncontrollable rates and a higher ambient humidity. Startup and shutdown sequences were modified from a manual operation to an automatic sequence which greatly decreased the startup and shutdown times. The completed projects design is used as a model for installations on several other drying systems throughout the client’s manufacturing facilities nationwide.
Pharmaceutical Chilled Water System
Chilled water automation system consisting of approximately 500 I/O. Scope of work included the control the chillers, condensers, cooling towers, distribution pumps, and building isolation valves. HTSE performed I/O configuration, initial setup and networking, application development using function blocks, structured text, and sequential function charts. Tasks included creation of custom functions and devices, startup, troubleshooting, and commissioning of the entire system.
Pharmaceutical Multi-Unit Batching System Project
Design, development and validation of a new multi-unit flexible SCADA Batching System. The system was programmed using Wonderware InBatch and InTouch Software in a multi-client SCADA System architecture. Integration to field devices and S88 phase logic standards were developed within multiple Allen-Bradley ControlLogix PLCs. Kepware I/O Software was configured as the I/O System. Microsoft SQL Server was developed for historical and live data management and Crystal Reports for reporting. SCADA development involved replicating existing manual operations and development of material / process work flow in a sterile environment. The batching system PLC work involved the design, development and qualification for a multiple unit, multiple PLC S88 based design. Clean-In-Place phases and process PID Loops were utilized. Nine ControlLogix PLCs were used for the batch system controllers. RSTestStand was used for process simulation during the development phase.
Pharmaceutical Process Automation Project
Project consisted of the automation of several skid-units. Skid types included mixers, dryers, pumping stations, reactors, and temperature controls. The control system was designed in small, self-contained segments, to allow for a flexible, on-demand process configuration. HTSE provided I/O configuration, phase design and implementation, creation of custom control functions, start-up, troubleshooting, and commissioning.
Pharmaceutical Purified Water system
Multi-year project purified water system process automation design and development. HTSE held the instrumentation and controls lead role on the project. Responsible for automation design, start-up, troubleshooting, and commissioning of sand filters, AG filters, carbon columns, softeners, RO units, UV sterilizers, deionization trains, chemical feed, holding, and distribution tanks. I/O was approximately 500.
Plant-wide Process SCADA / HMI Upgrade Project
HTSE upgraded the existing Intellution iFix HMI / SCADA system for a nutritional supplement manufacturing plant. The new system consisted of 1,200+ display screens and 20,000+ I/O points within 5 major categories. Responsible for technology direction, application development, programming standards, and techniques. Unique software solutions and methods were created for customer driven requirements of seamless cut-over and integration from existing HMI system to the upgraded system with no operational downtime. The completed project’s design and development methodologies are now client utilized as a standard for all site projects.
Process Controls Remediation Project
Multi-year project that consisted of a total plant automation code rewrite. Preformed all of the control design, engineering, and development of the process control software.
Chemical plant tank farm automation project to fully automate a large tank farm with prioritized destination determination system, automatic best flow path determination, fault detection, and compensation logic with new flow path determination logic, and manual flow path determination.
Implementation of batch quality tracking and product traceability system with QA system interface and interfaces to material management, order processing and system optimization systems.
Chemical plant tank farm automation project to fully automate a large tank farm with prioritized destination determination system, automatic best flow path determination, fault detection, and compensation logic with new flow path determination logic, and manual flow path determination.
Implementation of batch quality tracking and product traceability system with QA system interface and interfaces to material management, order processing and system optimization systems.
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- Platform Experience
- Past Process Projects
Exceptional performance requires exceptional capability.
In the world of process automation and machine control, the state-of-the-art changes continuously. The winning formula for keeping up is platform training plus related experience. We institute continuing employee education and training programs. This ensures our staff is not only experienced in the support of legacy systems, but also knowledgeable and skilled in the design and deployment of emerging control platforms and technologies.
In addition to on-going professional training, HTSE engineers and IT professionals possess an average decade-plus of field experience.
In the world of process automation and machine control, the state-of-the-art changes continuously. The winning formula for keeping up is platform training plus related experience. We institute continuing employee education and training programs. This ensures our staff is not only experienced in the support of legacy systems, but also knowledgeable and skilled in the design and deployment of emerging control platforms and technologies.
In addition to on-going professional training, HTSE engineers and IT professionals possess an average decade-plus of field experience.
