The Challenge
In a high-volume chemical blending facility, outdated controls were holding operations back. The existing Emerson DeltaV system was out of support, leaving operators dependent on mostly manual processes and exposing production to risks of downtime, inefficiency, and costly errors.
The client needed more than a simple replacement. They wanted a new semi-automated batch control system that could streamline transfers, validate recipes in real time, and automate critical blending and purge steps — all while preparing the operation for future expandability into full recipe management and reporting.
Why We Were Chosen
Our engineering team was selected because of our ability to deliver end-to-end automation upgrades: control designs, field device specification, electrical integration, and PLC / HMI programming. The client valued our proven track record in migrating from legacy platforms to Allen-Bradley FactoryTalk architecture while limiting production interference. We didn’t just bring technical expertise — we brought an understanding of how to align control system performance with production goals.
The Solution
Engineering Approach
We designed and implemented a semi-automatic batch control solution centered on Allen-Bradley ControlLogix PLCs with FactoryTalk View SE. Key elements included:
- Semi-automatic transfer controls to move product from Tank Farms with automated validation of source quantities and available destination space.
- Automated sequencing to transition from one product transfer to the next with minimal operator intervention.
- Upgraded field devices, including four new Endress+Hauser Coriolis mass flow meters and 29 new valve actuators (including one added specifically for automated line purging).
- Integration of pump and mixer motor control on four blend tanks, ensuring tighter coordination of process steps.
- A new electrical control enclosure, mounted adjacent to the legacy DeltaV cabinet, ensuring seamless integration while enabling stepwise migration.
Deployment and Verification
- Factory Acceptance Testing at our facility validated system performance before on-site installation, reducing commissioning risk.
- PanelView HMIs were located next to the existing DeltaV HMIs, giving operators an intuitive, side-by-side transition path.
- The system architecture used thin clients.
- On-site I/O checkout and startup support ensured that every valve, pump, and meter was verified in the field before production ramp-up.
What Worked – and What Didn’t
- Worked well: The introduction of automated purge sequences and blending timers significantly reduced operator workload and ensured repeatable quality. Flow validation minimized the risk of batch errors.
Challenges: Early testing showed some operators preferred manual overrides for flexibility. By involving them in FAT and commissioning, we struck a balance between automation and manual control, building trust and adoption.