Chemical industry
Chemical industry automation.
Chemical production needs control that is stable, traceable and never goes down. We supply control and visualisation systems for process lines, instrumentation and control, and a production data historian that keeps working even when a server fails.
Process data must always be available.
Chemical industry automation rests on three things: precise process control, safety and a complete record of what happened in production. Continuous processes run for months without a break, and when something goes wrong the process engineer needs to see trends from the last few hours as well as from years back. A gap in data collection is not just an inconvenience. In an audit or a complaint, it is a hole in the evidence.
Our engineering team has delivered a complete control and visualisation system for a line producing specialist films for the electrical industry, automation of tyre production units and control of wastewater treatment plants. For a chemical manufacturer we designed and deployed a high-availability process data historian with redundant collection interfaces and a duplicated archive. We migrated five years of historical data from the old platform and, after three months of parallel running, switched to the new system without any interruption to production. The whole project was carried out in close cooperation with the customer's in-house IT team.
We design the architecture so that servers can be updated during operation without data loss and so that your IT team can manage it themselves. We work with both Rockwell and Siemens control systems and collect data from a range of PLCs and HMIs through standard industrial interfaces. The delivery includes administrator training, so you can handle routine administration, adding measurement points and reports without outside help.
Typical solutions for chemical production.
Production automation in the chemical industry
Control systems for continuous and batch processes, with interlocks, protections and sequences tailored to the process.
Instrumentation and control
Sensors, actuators and control loops for temperature, pressure, flow and level. Controller tuning and adaptive control.
High-availability data historian
Redundant collection interfaces and a duplicated archive. Data remains available when the main server fails, and servers can be maintained while running.
Operator workstations
Clear control room screens, prioritised alarms, trends and reports that process engineers can open without IT help.
Wastewater treatment plants
Control and visualisation of wastewater treatment plants, including pumps, dosing and remote monitoring.
Redundant process networks
Separately routed fibre optic paths and duplicated nodes, so a single cable fault does not stop control system communication.
What we deliver to chemical plants.
Control, data and the electrical scope, with a focus on availability and safety.
- Process analysis and design of the control and data collection architecture
- Instrumentation and control design, including control loop and batch process diagrams
- Control panels, installation, commissioning and inspections
- PLC and operator workstation programming
- Historian, reporting and historical data migration
- Redundant process and fibre optic networks
- Training for administrators and process engineers
- 24/7 service and remote access
Technologies in our chemical projects
How we switch to a new system without downtime.
Analysis and testing
We map the data sources and the availability and security requirements, then verify the architecture on a test rig.
Installation alongside the old system
We install the new system in parallel with the existing one. Production runs undisturbed.
History migration
We migrate the historical data to the new platform and verify that it is complete.
Parallel running and switchover
Both systems run side by side until you confirm they match. Only then do we shut down the old platform.
Related services.
Production data collection
Historisation of data from PLCs and meters, high-availability historian, visualisation, reporting and remote monitoring.
Instrumentation and control
Turnkey I&C and process control systems: sensors, actuators, control loops, panels and the control system.
PLC programming
PLC control systems, HMI operator panels and SCADA for Siemens, Rockwell, ABB, Omron and Schneider.
Frequently asked questions.
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What does chemical industry automation involve?
Control of process lines and batch processes, instrumentation and control, operator workstations, data collection and historians, and the associated electrical scope. We deliver the complete control system as well as its individual layers.
What does a high-availability historian mean?
Both data collection and the archive are duplicated. If the main server fails, data continues to be collected and users can still access it. Servers can be updated while running without losing records.
Can historical data be migrated from the old system?
Yes. We design the conversion, migrate the data and verify that it is complete. The new system then runs in parallel with the old one until you confirm the data matches, and only then is the original platform shut down.
Does production have to stop for the modernisation?
Not necessarily. We install the new data collection and visualisation alongside the running system. Changes to the control are planned for shutdowns and verified in advance on a test rig.
How much does a historian or new control system cost?
It depends on the number of measurement points, the redundancy requirements, the number of data sources and the scope of the history migration. For control, the number of control loops and the work on field instrumentation are decisive. We give a fixed price after the technical concept.
Do you work with both Rockwell and Siemens?
Yes. We have long experience with Rockwell Automation, ControlLogix, FactoryTalk View and FactoryTalk Historian, as well as with Siemens SIMATIC and WinCC. We can also collect data from other PLCs and HMIs.
Tell us about your process.
The type of process, your current control system and what you need to improve, whether control, data availability or reporting, is enough. We will get back to you within 24 hours with a free consultation.