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Improve Chemical Operator Effectiveness with a Modern DCS

An information-enabled DCS helps workers turn data into actionable results.

Even with more information and greater automation, it’s still true today that successful chemical production depends on workers. But when you need to replace retiring seasoned staff with newer talent, how do you keep the same level of performance? Providing the right tools that empower workers to continually improve is a huge advantage of a data-enabled modern DCS.

A modern DCS is information enabled and connects all aspects of your chemical operations, including both automated and manual tasks. By giving operators clear, actionable information and avoiding non-essential data that can distract them, a modern DCS helps guide them through problems in real time.

This improves process visibility, decision-making and safety. As a result, you can have greater confidence that your new operators can soon become some of your best workers.

A Look Into a Modern DCS

A modern DCS uses a high-performance human machine interface, which provides critical information and guides operators to the right decisions during production and maintenance. This involves using a combination of proven situational-awareness techniques and graphic screen designs that enhance an operator’s focus and response time.

Strengthen Your Workforce

These capabilities can benefit experienced workers just as much as they do new workers, especially if information is limited in your operation. In fact, when one chemical company replaced the control system across its plants with a modern DCS, it improved information gathering and financial reporting.

The company decided to implement the PlantPAx® DCS from Rockwell Automation. The new information-enabled system displayed real-time data, helping operators make better and more timely decisions. Additionally, the new system transformed data collection, data aggregation and reporting so insights could be shared on demand with business management for better decision-making and financial reporting.

As a result, the $16 million project paid for itself in just nine months, and the modern DCS will be used in four other projects within the company.

Reduce Downtime and Alarm Issues

Chemical operations are flooded with data from intelligent devices, which are designed to smooth operations and reduce downtime. However, this is only achievable if the raw data can be turned into actionable information.

A modern DCS can help. It turns diagnostic and performance data into actionable information that operators use to see if an equipment or production unit is nearing failure.

One chemical company needed to expand a unit to meet increasing market demand and chose to update its entire production unit to a modern DCS. The older control system was operating inefficiently, resulting in unplanned downtime.

The modern DCS delivers historical and real-time production data to plant operators in a clear, understandable format for easier analysis. Now, when an issue occurs, downtime is significantly reduced. Operators can easily pinpoint the issue using captured production and equipment performance data. As a result, the chemical company reduced ongoing downtime instances by 50%.

A modern DCS also helps reduce distracting, nuisance alarms and makes remaining alarms actionable. As a result, when alarms do occur, operators are guided by the DCS to immediately know what they need to do and how urgently they need to perform these actions. This helps cut troubleshooting time, costs and downtime.

The Choice is Yours

Whether you’re building a new chemical processing plant or replacing an existing control system, a modern DCS provides many benefits. It helps fill the knowledge gap for newer workers and offers actionable insights. It helps improve productivity and decision-making and helps make your overall business more successful.


Chris King
Chris King
PlantPAx Migration Business Development Manager, Rockwell Automation
Chris King
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