CHEMICALS • PROCESS MANUFACTURING

Modernizing High-Risk Process Control — Without Replacing Core PLCs.

How a major chemical manufacturer modernized an aging detergent production tower, eliminating alarm floods and operational blind spots — without hardware replacement or production downtime.

Unified Visibility
Intelligent Alarms
Improved Response
0%
Hardware Replacement

Operating Blind in a High-Risk Process

Operating a Detergent Tower requires continuous, precise control over temperature, pressure, flow rates, and chemical reactions. However, this facility relied on an aging PLC/SCADA setup that introduced serious risks.

  • Fragmented Process Visibility

    Critical parameters spread across outdated HMIs prevented real-time context.

  • Alarm Floods

    Unprioritized alarms generated noise, slowing operator response.

  • Tribal Knowledge

    Operators relied on experience rather than data-driven insights.

LEGACY SYSTEM STATUS
Log #4921
[ALARM] HIGH TEMP ZONE 4 (Ack?)
[ALARM] PRESSURE DROP PUMP B
[ALARM] FLOW RATE MISMATCH
... 42 more alarms suppressed ...
OPERATOR NOTE: "Running blind on Tower B. Checking gauges manually."
THE SOLUTION

Intelligent Automation Overlay

Alarm Rationalization

Replaced noise with intelligent management. Operators now receive clear, prioritized alerts and early warnings for process instability.

Centralized Visualization

Replaced fragmented HMIs with a unified SCADA interface. Supervisors gained a single real-time view of the entire tower.

Brownfield Integration

Integrated directly with legacy PLCs. Process data extracted and contextualized without installing new sensors.

Before vs. After HORUS

Metric Before HORUS After HORUS Impact
Process Visibility Fragmented, Manual Unified Real-Time View Eliminated blind spots
Alarm Handling Noisy & Unprioritized Clear & Prioritized Faster operator response
Process Stability Reactive Adjustments Stable & Monitored Reduced abnormal events
Control Architecture Rigid Legacy System Modern Overlay Ready for future upgrades
// Technical Implementation

Technical Spotlight

Control-Layer Modernization

Enhanced visualization and logic support implemented without altering core PLC programs.

Alarm Rationalization

Structured alarm handling aligned with safe operating practices for process industries.

Anomaly Detection

Early detection of performance degradation in pumps and heat exchangers.

Digital Twin–Ready

A structured process data model now enables future simulation and optimization initiatives.

CTA_PROMPT.SYS
"MODERN SAFETY STANDARDS. LEGACY HARDWARE. ZERO COMPROMISE."

Ready to modernize your control system?

Achieve improved safety, higher process stability, and full operational visibility — without CapEx-heavy upgrades.