"Process Automation is a core strength of GrayMatter. We can go into any chemical, life sciences or water/wastewater facility, figure out the processes and document them, develop P&IDs, Functional Description Specification (FDS) and control strategies to come up with an appropriate solution to meet or exceed client requirements."
Design Engineering
Implementation
Testing & Startup
Design Engineering
Identify the time, materials and personnel needed to complete a project. Develop full schematics commissioning documents, checklists for equipment and controls and communication plan with key stakeholders.
- PLC Mapping & Programming
- Control Panel Modernization
- Alarm Structure Optimization
- Develop C&I system architecture, hardware, software, and applications
- Develop P&IDs
- Design Process Control Logic
- Develop detailed specifications and drawings
- Develop procedures for Maintenance of Plant Operations (MOPO) during construction
- SCADA Design/Master Planning
- HMI Screens - ISA 101
- Radio Telemetry Design
CONTROL PANEL DESIGN
- Control Panel Design (custom built from UL-listed industrial control panel shop in the U.S. and Canada)
- Control Panel Build
– UL, cUL - Control Panel QCC
– Point-to-point (conductivity)
– Power Up (test for DOA components) - Program Download
–Setup & Test communications - Factory Acceptance Test (FAT) with GrayMatter or Customer Personnel
Implementation
Translate initial planning into action. Ensure data tags flow from devices to control systems and reporting and visualization tools for plant-floor operators and project leaders.
- SCADA/HMI/MES systems
– Product Agnostic Approach
– System Integration (PLCs, MES, DCS, ERP)
– Remote Monitoring and Control Implementation
– Legacy System Migration
– ANSI/ISA-Compliant Dashboards
– ISA101 Standard Application
– Customized HMI & Style Guide Development
– Alarm & Notification Management - Process and Batching Automation
– Unique PhantomTrac Solution to meet all Process Batching requirements - Machine Control
– Full-scale electrical design and automation of Material Handling Systems
– Electrical design and automation of high-precision cutting systems
– Experienced in all levels of automation in machine environments, including full development, enhancements, and remediation of existing systems - DCS/PLC-based distributed process controls
- Field devices, sensors, and instrumentation
- Industrial networking to connect shop floor PLCs with SCADA workstations
- Bridging process networks with business networks
- Telemetry over radio, leased lines, CDMA/GSM, and POTs
- Motion Applications
– Vast experience in Motion applications from simple, single axis servo systems, to multi-axis multi-machine systems - Reporting
- Validation
- Serialization
Testing & Startup
Calibrate in a passive, controlled environment and finalize go-live plans with operations and quality assurance personnel.
- Rigorous UL-listed standards, acceptance testing, panel shop, on-site control engineers
- Factory tests, calibrations, and loop checkout
- DCS/PLC programming/configuration testing
- Develop procedures for system startup
- Troubleshoot Control Logic
- Fine tune C&I loops
- Interface with plant operations, system availability and acceptance testing
What a Project Timeline Looks Like
01 Receive Customer Request for Proposal
02Create & Submit Proposal
03Receive Purchase Order
04Perform 30, 60, 90 Design Reviews
– Process Description
– Electrical Design (including CAD) of entire system including control panels
– PLC & HMI Design
– Vision Design
– SCADA Design
05Create Issued-for-Construction Packages
– Scope of Work
– Electrical Drawings06Create Validation Documentation
– Change Request
– Specification Documents
– Testing Protocols07Program PLC/HMI/Vision/SCADA
08Support Installation
09Perform Start-up/Debug/Commissioning
10Execute Validation
11Turnover Final Deliverables to Customer
ABB
Auvesy-MDT
AVEVA
AWS
CISA
Cisco
Cognex PSI
CSIA
Dell PartnerDirect
Ethical Hacker
Fortinet
GE Digital Trainer
GE Digital SI
Honeywell
Ignition
Microsoft
Mitsubishi Electric
OEE Downtime
PlantPAx
Rajant KMP
Rockwell Automation
Schneider Electric
Splunk
Stratus
Systech
Tenable
ThinManager
TwinThread
VMWare
VTScada
Industries
Food & Beverage
From soft drinks and fruit juices to infant formulas, cereals and candy, GrayMatter has the requisite controls knowledge and experience in the manufacturing and packaging of food and beverage products.
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Packaging lines
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Process control
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Batching control systems
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HVAC controls
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Process manufacturing
Life Sciences
GrayMatter provides automation solutions to some of the world’s largest life sciences companies – We have knowledge in the automation and validation of pharmaceutical process and packaging line control systems and a thorough understanding of regulatory compliance requirements.
Diversified Materials
GrayMatter helps manufacturing companies maximize throughput, lower operational costs and minimize the cost of re-engineering to accommodate changes as their facilities grow.
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Controls design
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PLC, DCS, and HMI application development
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Industrial IT network design & deployment
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Data acquisition, reporting and presentation
Process
GrayMatter provides automation and project support services for process manufacturers. We have extensive experience in the control of chemical manufacturing processes and equipment using robust DCS and PLC control technologies and associated operator interfaces.
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Pressure, temperature & flow control
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Batching & Continuous control systems
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Fired equipment
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Reactor control
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SIL - Safety Instrumented Systems
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Process manufacturing
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Utilities, Water systems
Critical Infrastructure
GrayMatter has deep industry knowledge and experience working with the critical infrastructure and utility sectors.
- Evaluating/documenting of complex processes: identifying customer requirements
- SCADA/HMI/MES systems
- DCS/PLC-based distributed process controls
- Field devices, sensors, and instrumentation
- Telemetry over radio, leased lines, CDMA/GSM, and POTs
Start a Project
Ready to start a new automation and controls project? Let's talk.