CHEMICAL PROCESS AUTOMATION & CONTROL SYSTEMS
PLC, HMI, SCADA, batch, blending, reactor, transfer, utility, and process-control solutions for chemical facilities.
CONTROL SYSTEMS FOR THE COMPLETE CHEMICAL PROCESS
Industrial Systems Integrators designs, programs, manufactures, installs, and supports automation, electrical, instrumentation, and industrial network systems for batch and continuous chemical operations.
We integrate raw-material receiving, tanks, pumps, valves, reactors, mixers, dosing equipment, heating and cooling systems, packaging equipment, PLCs, HMIs, SCADA systems, and production data. Whether the project involves one process skid or a plantwide modernization, ISI builds control systems operators and maintenance teams can understand, troubleshoot, and operate reliably.
CHEMICAL AUTOMATION CAPABILITIES
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BATCH & RECIPE CONTROL
Automate ingredient additions, equipment sequencing, mixing, heating, cooling, hold times, discharge, and batch records.
CONTINUOUS PROCESS CONTROL
Coordinate flow, level, pressure, temperature, analytical measurements, pumps, valves, and process loops.
REACTOR & MIXING SYSTEMS
Control reactors, agitators, recirculation systems, jackets, feed sequences, vacuum, venting, and product discharge.
CHEMICAL FEED & DOSING
Integrate metering pumps, scales, flowmeters, chemical injection skids, calibration values, and dosing verification.
TANK FARM & TRANSFER
Manage tank levels, transfer routes, pumps, valve lineups, loading, unloading, recirculation, and inventory data.
SCADA, HISTORIANS & REPORTING
Collect alarms, events, trends, batch information, setpoint changes, material usage, and production data.
POWER AND UTILITY FACILITIES WE SUPPORT
- Combined-cycle power plants
- Simple-cycle generation facilities
- Cogeneration facilities
- Combined heat and power systems
- Industrial steam plants
- Boiler houses
- Distributed-generation facilities
- Renewable-generation sites
- Utility substations
- Electrical switchyards
- Industrial power-distribution systems
- Generator and backup-power systems
- Central utility plants
- Remote utility sites
- Water-treatment support systems
- Fuel-gas systems
- Plantwide motor systems
- Battery and energy-storage interfaces
CHEMICAL FACILITIES WE SUPPORT
- Specialty chemical manufacturing
- Chemical blending facilities
- Resin and polymer production
- Coatings, adhesives, and sealants
- Industrial cleaning products
- Water-treatment chemical manufacturing
- Bulk-liquid storage and terminals
- Solvent-handling systems
- Packaged chemical production
- Pilot plants and process-development facilities
- Biofuel and renewable chemical operations
- Industrial utility and support systems
HMI and SCADA displays provide operators with equipment status, process values, operating modes, alarms, trends, and sequence information.
BATCH, RECIPE & FORMULA CONTROL
ISI develops batch-control systems that guide materials through repeatable production sequences while giving operators clear visibility into every active step.
Systems can include:
- Recipe and formula management
- Raw-material verification
- Weighed and metered additions
- Ingredient sequencing
- Equipment permissives and interlocks
- Agitator and mixer control
- Heating and cooling stages
- Timed reactions and hold periods
- Operator prompts and confirmations
- Automatic and manual operating modes
- Batch identification and tracking
- Deviation alarms
- Sequence status displays
- Fault recovery procedures
- Electronic batch records
- Production and material reports
REACTOR & MIXING CONTROL SYSTEMS
We integrate the equipment and instruments surrounding reactors, blending tanks, mixers, and process vessels into coordinated control systems.
Typical control points include:
- Vessel level, temperature, and pressure
- Agitator speed and motor load
- Heating and cooling jackets
- Steam, hot-water, thermal-oil, and chilled-water valves
- Material feed sequencing
- Recirculation pumps and flow control
- Vacuum and vent systems
- Weighing and load-cell systems
- Addition verification
- Discharge pumps and valves
- Process permissives and interlocks
- High and low process alarms
- Trends, setpoints, and operator adjustments
- Cleaning, flushing, and changeover sequences
CHEMICAL FEED, METERING & DOSING
Accurate material addition depends on coordinated instrumentation, pumping, verification, and control logic. ISI integrates chemical-feed equipment into new and existing production systems.
Solutions can include:
- Metering and chemical-injection pumps
- Mass- and volume-based additions
- Flow-paced dosing
- Scale and load-cell batching
- Flowmeter totalization
- Pump run and fault feedback
- Low-tank-level protection
- Flow and pressure verification
- Calibration factors
- Lead and standby pump control
- Leak-detection inputs
- Containment alarms
- Local and remote operating modes
- Addition totals and production reporting
TANK FARM & BULK TRANSFER AUTOMATION
ISI develops controls for storing, routing, transferring, loading, and unloading liquid materials throughout chemical facilities.
Typical functions include:
- Tank level and temperature monitoring
- High and high-high level alarms
- Source and destination confirmation
- Transfer-pump sequencing
- Automated valve lineups
- Transfer-route permissives
- Recirculation control
- Loading and unloading stations
- Material routing
- Inventory measurements
- Pump protection
- Transfer totals
- Alarm and event history
- Operator transfer screens
- Interface with packaged equipment and loading systems
HEATING, COOLING, STEAM & COMBUSTION CONTROLS
Chemical production frequently depends on tightly coordinated process utilities. ISI integrates utility equipment with the production control system to provide clear operating status, alarms, trends, and process permissives.
Systems can include:
- Steam and condensate controls
- Hot-water systems
- Thermal-oil systems
- Chillers and cooling-water loops
- Heat exchangers
- Temperature-control loops
- Pressure and flow controls
- Boilers and process heaters
- Burner and furnace controls
- Fuel-gas monitoring
- Purge and flame-status interfaces
- Utility pumps and valves
- Equipment runtime and maintenance data
Burner and combustion work is completed around the manufacturer’s equipment, documented sequence of operation, project requirements, and applicable facility standards.
HMI, SCADA, HISTORIAN & PRODUCTION DATA
Operators need more than a collection of start and stop buttons. ISI develops HMI and SCADA applications that show what the process is doing, why equipment is not running, and where attention is required.
Capabilities include:
- Process overview screens
- Equipment faceplates
- Batch and sequence displays
- Recipe selection and editing
- Alarm summaries and histories
- Live and historical trends
- Setpoint and operator-change tracking
- Motor, pump, and valve status
- Tank and material dashboards
- Batch reports
- Material-consumption reporting
- Production totals
- Equipment runtime data
- Historian integration
- Database connectivity
- MES and ERP data exchange
- Remote monitoring where permitted
CHEMICAL CONTROL SYSTEM MODERNIZATION
Chemical plants often contain a mixture of current equipment, obsolete controls, undocumented modifications, and isolated package systems. ISI can modernize the controls while keeping the operating process and shutdown schedule in view.
Modernization projects can include:
- Obsolete PLC replacement
- HMI and SCADA migration
- DCS and PLC integration
- Remote I/O replacement
- VFD and motor-control upgrades
- MCC modifications
- Control-panel replacement
- Industrial network upgrades
- Instrument replacement
- Packaged-equipment integration
- Drawing and documentation updates
- PLC, HMI, and drive backups
- Phased installation and cutover planning
- Startup and production support
Equipment and installation requirements are developed around documented area classifications, process information, owner standards, and project specifications.
SYSTEMS & EQUIPMENT WE INTEGRATE
- PLCs and remote I/O
- HMI and SCADA systems
- Historians and reporting systems
- DCS interfaces
- Recipe and batch-management systems
- VFDs, soft starters, and motor controls
- MCCs and control panels
- Industrial Ethernet networks
- Reactors, mixers, and agitators
- Process and storage tanks
- Pumps, valves, and transfer systems
- Metering and chemical-injection skids
- Load cells and weighing systems
- Flow, level, pressure, and temperature instruments
- pH, conductivity, and analytical instruments
- Heat exchangers, chillers, boilers, and process heaters
- Burners and combustion equipment
- Filters, separators, and recirculation systems
- Loading, unloading, filling, and packaging equipment
BUILT FOR CHEMICAL OPERATIONS
REPEATABLE PROCESS SEQUENCES
REPEATABLE PROCESS SEQUENCES
REPEATABLE PROCESS SEQUENCES
Coordinate additions, mixing, temperature control, transfers, and discharge using documented operating sequences.
CLEAR OPERATOR INFORMATION
REPEATABLE PROCESS SEQUENCES
REPEATABLE PROCESS SEQUENCES
Show process conditions, active steps, permissives, interlocks, faults, and recovery information from one operating interface.
PRODUCTION TRACEABILITY
MAINTAINABLE SYSTEM DESIGN
MAINTAINABLE SYSTEM DESIGN
Record batches, alarms, material additions, setpoint changes, process values, and production results.
MAINTAINABLE SYSTEM DESIGN
MAINTAINABLE SYSTEM DESIGN
MAINTAINABLE SYSTEM DESIGN
Use organized programming, documented control panels, standardized HMI objects, backups, and expandable system architecture.
FROM PROCESS REVIEW TO PRODUCTION
1. PROCESS & EQUIPMENT REVIEW
1. PROCESS & EQUIPMENT REVIEW
1. PROCESS & EQUIPMENT REVIEW
We review process flow, equipment, instruments, operating sequences, existing controls, documentation, and production requirements.
2. CONTROLS ENGINEERING
1. PROCESS & EQUIPMENT REVIEW
1. PROCESS & EQUIPMENT REVIEW
We develop the control architecture, I/O requirements, panel designs, network plan, software structure, and sequence of operation.
3. PROGRAMMING & INTEGRATION
3. PROGRAMMING & INTEGRATION
3. PROGRAMMING & INTEGRATION
ISI programs the PLC, HMI, SCADA, drives, instruments, reports, and equipment interfaces required for the process.
4. TESTING & STARTUP
3. PROGRAMMING & INTEGRATION
3. PROGRAMMING & INTEGRATION
We test the system, verify sequences and interlocks, support commissioning, train operators, and address startup issues.
COMMON CHEMICAL AUTOMATION PROJECTS
- Batch-control systems
- Recipe and formula management
- Reactor and mixer controls
- Chemical-feed and dosing systems
- Tank-farm automation
- Bulk-material transfer controls
- Pump and valve sequencing
- Heating and cooling controls
- Boiler, burner, and furnace controls
- PLC and HMI modernization
- SCADA expansion
- Historian and batch reporting
- DCS and PLC integration
- MCC and VFD upgrades
- Industrial network upgrades
- Control-panel replacement
- Instrument integration
- Shutdown and startup support
- Process troubleshooting
- Production-data integration
CHEMICAL PROCESS AUTOMATION FAQ
Yes. ISI develops controls for batch production, continuous processing, utility systems, material handling, and facilities that combine multiple operating methods.
Yes. Recipe management can control material targets, processing steps, setpoints, timing, and equipment selection. Batch records can capture actual additions, process values, alarms, operator activity, and production results.
Yes. ISI can integrate PLC-controlled skids, package equipment, HMIs, historians, and industrial networks with an existing DCS when the required communication and system access are available.
ISI develops equipment and control-system requirements around the documented area classification, owner standards, and project specifications. Equipment selection and installation methods are coordinated with the project’s electrical and safety requirements.
Many upgrades can be divided into planned phases. The appropriate approach depends on the existing architecture, production schedule, available shutdown windows, and the risks associated with each cutover.
Yes. ISI can provide control panels, PLC panels, remote-I/O panels, VFD panels, network enclosures, and other assemblies required for the project.
Yes. ISI supports system testing, commissioning, startup, production ramp-up, process troubleshooting, software changes, and controls-related maintenance.
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INDUSTRIAL ANALYTICS
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Turn alarms, batches, process values, material usage, and equipment data into useful production information.