Chemical Process Control Systems

Asset Performance and Regulatory Compliance for the Chemical Industry

Profitability, Flexibility, and Compliance

As global demand for chemical products grows, the chemical industry faces new business challenges. Chemical producers are responding to customer demands with quality products and competitive prices. These producers are faced with volatility in the cost of feedstock, a complex regulatory environment, and an aging infrastructure. There is a shrinking pool of knowledgeable and skilled workers. We can help you extract the maximum value from your assets and maintain regulatory compliance.

We can help you reduce your energy consumption, upgrade legacy systems, or make better use of the data you generate. We have the process control, information equipment, and resources to help you meet your goals. With our wealth of industry knowledge and automation experience, we can help you remain competitive in a dynamic industry.

Solutions for Chemical Automation

Chemical Process Control for Improved Operations

Our modern distributed control technology allows you to gain plant-wide control and insight so you can better optimize operations. The PlantPAx® modern DCS is based on open communication standards and is scalable from small to large complex plants. This openness, flexibility, and scalability provides you with the ability to securely access real-time information throughout your enterprise when and where you need it.

Our PlantPAx Batch solution allows increased insight into equipment and operator performance which typically cause downtime, throughput, and quality issues.

  • Solutions ranging from single unit to enterprise-wide systems
  • Comply with ISA-88 complete with recipe IP protection
  • Automate manual operations to reduce variation
  • Create repeatable and controlled operations that maximize asset utilization
  • Manage recipes and procedures so you can focus on yield, throughput, and quality
  • Procedural models which allow you to improve traceability, reporting, and approval controls

Learn more about PlantPAx Modern DCS

Learn more about Batch Systems Control

DCS Migration Strategy and Implementation

Minimize Downtime and Maximize Operations Success with DCS Migration

Successful DCS migration projects require careful planning and a methodical approach. We have helped our customers migrate from a multitude of legacy DCS, PLC, and single-loop controller systems. Through this experience you can benefit from our migration methodology and solutions which mitigate common migration challenges and address unforeseen risks.

We bring more than 2000 years of combined consulting experience in the chemical industry, and have participated in numerous migration Front-End Engineering and Design (FEED) studies. We can help you select the right technology and build a system which is compliant and stays within your budget and timeline. Services we offer:

  • Control installed base assessment
  • Information and reporting needs
  • Networking and cyber-security reviews
  • BPCS, SIS, and AC&O application audits
  • Electrical, instrumentation, and control assessments
  • Motor control and drive integration review
  • Project justification and cost estimating

Protect Personnel, Processes, and the Environment

Are Your Safety Instrumented Systems up to Current Standards?

Most chemical processes present hazards that have the potential to adversely affect people, assets, the environment, and your market perception. Safety instrumented systems (SIS) can reduce your risk. Whether you are facing an expansion or a new process, or upgrades to existing SIS, ESD, BMS, or TMC, we can help. We have experienced and functional safety certified engineers who deploy safety system technology, both in process and machine applications. The technologies that we deploy are scalable from small to large, simplex to triplicated, and capable of up to SIL 3. We provide full lifecycle services to support you in design, build, operation, and maintenance of your process safety solutions.

What Our Customers are Saying

We are continuing to realise the many benefits that the new automated system is providing. It has met all of our key requirements by allowing us to reduce labour costs, while also improving quality control and safety. In addition, the solution has established a low base cost to run the plant over time which helps to improve our productivity and competitiveness.

Geoff Biscaya, Rigid Containers GM at VIP Packaging

How We Help Our Customers

Across the world and in all types of chemical plants, we help customers reduce costs, minimize downtime, and improve operations. Whether you seek to modernize your operations, optimize your energy consumption, or enhance your process control, we can help.

How May We Help You?

Rockwell Automation and our partners offer exceptional industry knowledge to help design, implement, and support your automation investment.