Process control where precision prevents disasters.
DCS, PLC, SCADA, and safety instrumented systems for chemical plants, petrochemical facilities, and specialty manufacturers. Engineered for continuous and batch processes where the margin for error is fractions of a percent.
Three things putting chemical plants a step behind safe.
Aging DCS, no spares
Twenty-year-old controllers, failing I/O cards, and vendor support that ended a decade ago. Operators tune by memory because the original control strategy was never documented. A full plant shutdown for migration costs millions, so nothing changes until something fails.
Undocumented safety systems
Interlock logic has been modified incrementally over the years. Setpoints adjusted, trip devices replaced, requirements specs never updated. The SIS still works, but nobody can prove it meets SIL — and a regulator who asks will find the gaps fast.
Batch variability
Reactor temperature is hand-controlled by operators adjusting steam and cooling valves on instinct. Product quality drifts between batches and shifts. Off-spec material gets reworked or disposed of as hazardous waste, and one thermal excursion is all it takes to trigger a safety review.
Three systems we build for every chemical operation.
Fewer process surprises,
more stable operations.
Results from recent reactor control, DCS migration, and SIS remediation projects in chemical and petrochemical facilities. Specific projects scoped on request.
Got a process that needs control your current system can't hold?
Straight answers.
Yes. SIL assessment, safety requirements specification, SIF design, and safety PLC programming on Triconex, HIMA, Allen-Bradley GuardLogix, and Siemens F-PLCs. Proof test procedure development and safety system lifecycle documentation. Process control and safety instrumented systems are designed by the same team — not handed off to a separate practice.
Yes. We execute phased DCS migrations — Honeywell TDC to Experion, Bailey to ABB, Fisher Provox to DeltaV, Allen-Bradley PLC-5 to ControlLogix — migrating one process unit at a time during planned maintenance windows. Hot cutover planning for critical process loops and updated alarm management strategies built into every migration.
Panel design includes appropriate hazardous area ratings and purge systems. Explosion-proof enclosures, intrinsically safe circuit design, and motor control specified for Class I Division 1/2 and Zone 1/2 environments. Our electrical scope accounts for the area classification requirements that govern chemical facility installations — from engineering through fabrication.
Honeywell Experion, Emerson DeltaV, Schneider M580, Allen-Bradley ControlLogix, and Siemens S7-1500 for control. Ignition, FactoryTalk, AVEVA System Platform, and DCS-native operator stations for supervisory. OSIsoft PI, AVEVA Historian, and Ignition Tag Historian for process data capture.
Yes. We review SIL assessments, document the as-built SIS configuration, identify gaps between the safety requirements specification and the implemented logic, and remediate the discrepancies. The deliverable is a fully documented safety system with current SIL verification calculations, updated proof test procedures, and a lifecycle management framework for ongoing compliance.
Yes. Commissioning documentation meets the site's management-of-change and quality requirements. I/O verification, loop checking, valve stroke testing, safety system proof testing, and process tuning are documented in formats your PSM program and regulatory audits require.
Ready to talk about your plant?
Whether it's a reactor control upgrade, a safety system audit, or a full DCS migration — tell us about the project.