PlantPAX- Modern DCS with Virtualization
PlantPAX- Modern DCS with Virtualization. The client is pioneered water treatment in India and is today the country’s premier company in water and environment management, with a strong international presence. They have state-of-the-art units spread across five states of India and in UAE. The unit where the project was implemented is a fully automated, integrated unit for manufacture of cation and anion exchange resins for water & waste water treatment as well as non-water specialty applications. The manufacturing unit already had a good level of automation and thus the connectivity of control system each plant area was one of the most important criteria for client. The Project was a requirement of control system for a new expansion in the cation plant which primarily was to get connected with the existing control system. The plant had mix of multiple make DCS including emersons. In general the DCS vendors have a lot proprietary controls and limitation which at times become challenging for a client to afford and sustain in a longer run and this case was no different. Also the connectivity of Electrical parts was a key parameter for evaluation. The Solution pitched was amalgamation of Rocwkell’s Plant PAX , a modern DCS and Thin manager technology. The Solution enabled the client to view and control the Emerson DCS without any process intervention and without compromising on the cybersecurity aspects. The virtualization technique diminished the dependency on the proprietary communication and saved client from paying exaggerated costs licenses and additional hardware and eventually reduced the overall cost of ownership without any implication on production and quality. Challenges: Supply of new modern DCS with latest functionalities. Integration with with Electrical systems. Backward integration and Scalability expectations. Dealing with proprietary communication protocols with limited facility. Huge Dependency on the DCS vendors for any modification and changes. Virtualization of existing DCS using latest technology. Handling critical batch process. Solutions: Solution built by amalgamation of DCS with Thin Manager technology. Scalability and modular architectures to match exact requirements Virtualization of existing DCS without any process intervention. Premier Integration functionalities for electrical portion. Results: Reduced TCO with Virtualization support Better reliability Reduced dependency on proprietary system. User interface as per ISA 101 Flexibility to customer for any modifications/ changes in any system. System compliant with IEC 62443 cybersecurity standards Latest Case Studies PlantPAX- Modern DCS with Virtualization February 19, 2024 ISA 88 Batch Solution using… February 19, 2024 Basic Needs Of Cyber-Security in… February 19, 2024 Reach Us Your name Your email Subject Your message (optional) NEED HELP? Don’t hesitate to contact us for more information about company or service Contact Us
ISA 88 Batch Solution using Virtualization Technology
ISA 88 Batch Solution using Virtualization Technology As a leading global polyurethanes manufacturer, the company has a strong presence in the market, with multiple established plants in India and plans for further expansion. The manufac- turing facilities utilize multiple reactors to produce a diverse range of products, making the entire process complex yet critical to our operations. To meet the challenges of optimizing hardware complexity & ensuring ISA 88 batch compliance, we sought a solution that could streamline operations and enhance efficiency. The requirement involved 2 key aspects: firstly, the optimization of hardware maintenance through virtualization technology, and secondly, the implementation of batch process compliance using the RA LBSM solution. The proposed solution was a controller-based batch solution aligned with the ISA 88 standard. This approach involved a thorough analysis of the entire process, which was then segmented into physical, process, and procedural models. Leveraging the RA phase manager, we simplified execution and achieved compliance with industry standards. By implementing the LBSM solution, we empowered our client with flexible recipe manage- ment, equipment sequencing, & reduced manual intervention. This led to a significant reduction in batch cycle times, improved equipment utilization, and enhanced batch reporting and visual-ization capabilities. Challenges: Complex demand patterns from market Manual Operation lead to long batch cycle times Product change overtime is huge. Less safety in terms of operation of plant. ISA 88 Batch compliance solution. Isolated production environ- ment from enterprise level Solutions: ISA 88 approach followed for Batch process. Batch process management func- tionality using LBSM technology. Phase manager solution for Equip- ment independent approach ( As per S 88). Using Virtualization technology reduces downtime due to hard- ware failure. Batch reporting and user manage- ment. Results: Reduced Batch Cycle Time. Increased Uptime of plant. Better and optimised utilisation of Equipment. Reduced batch changeover time. Better reporting and visualization. Latest Case Studies PlantPAX- Modern DCS with Virtualization February 19, 2024 ISA 88 Batch Solution using… February 19, 2024 Basic Needs Of Cyber-Security in… February 19, 2024 Reach Us Your name Your email Subject Your message (optional) NEED HELP? Don’t hesitate to contact us for more information about company or service Contact Us
Basic Needs Of Cyber-Security in Manufacturing
Basic Needs Of Cyber-Security in Manufacturing As a leading Agrochemical manufacturer with over 15 global manufacturing units, their organi- zation operates with a significant OT install base, generating a large volume of data. Hence securing the IT/OT network is crucial, especially with aggressive expansion plans. To address these challenges, our initial focus was on evaluating existing architectures and install bases for security vulnerabilities. Traditional security approaches often fall short in mitigating newer threats, compounded by the complexity of ageing infrastructure with proprietary net- works. Breaking the system into zones and defining necessary conduits was essential. Implementing basic cybersecurity measures has been instrumental in safeguarding operations. This approach provides comprehensive digital protection against potential threats, ensuring uninterrupted productivity and preventing the need for workstation replacements. For businesses seeking robust IT security solutions, a comprehensive package is essential. Our security suite includes firewall, anti-virus, anti-spam, wireless security, and online content filtra-tion, offering a layered security approach. With a wide range of cybersecurity services, we are committed to providing diverse features and solutions tailored to ensure optimum security across your business. Challenges: Dealing with traditional security approaches & old infrastructure Data vulnerability due to absence of OT Infrastructure security. IT/OT bridging & IDMZ creation Bifurcating the system into different zones and SL Secure Connectivity between Data Historian and Business Systems IEC 62443 was mandatory Solutions: Implemented needs of Cyber-Security at OT level. Removed irrelevant data, threats, and unwanted services. Windows & OT software security patch update with antivirus to detect latest threats & malware. Restructured user management and credentials as per needs. Secured Connectivity between Manufacturing and Business Systems by converting unmanaged network into well managed network top of OT security appliance. Results: A secure and Robust IT and OT network. Maximum uptime, reliability and quality. Protect private and confidential data. Compliance with IEC 63443 Standard. Reduced support cost and easy to maintain. Latest Case Studies PlantPAX- Modern DCS with Virtualization February 19, 2024 ISA 88 Batch Solution using… February 19, 2024 Basic Needs Of Cyber-Security in… February 19, 2024 Reach Us Your name Your email Subject Your message (optional) NEED HELP? Don’t hesitate to contact us for more information about company or service Contact Us